11/11/2024 07:13:57

Hose - Inverter Inlet - Front Drive Unit (Heat Pump) (Remove and Replace)

Correction code 18303312 3.30 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2023-08-29: Updated EPB Service Mode reference.
  • 2023-03-10: Fixed errors.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Remove bolts securing the LH rocker panel lower cover to body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
  2. Remove clips securing the LH rocker panel lower cover to wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  3. Remove LH rocker panel lower cover
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  4. Remove bolts securing the RH rocker panel lower cover to body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
  5. Remove clips securing the RH rocker panel lower cover to wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  6. Remove RH rocker panel lower cover
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  7. Open all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If vehicle is being powered down, Latch rear doors to prevent accidental closure
  8. Lower all four windows
  9. Open hood
  10. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips
  11. Remove cabin intake upper duct assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Older vehicles may be equipped with 4x clips
  12. Move LH front seat backward
  13. Remove LH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  14. Remove LH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
  15. Remove clip for LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  16. Remove LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
  17. Remove screw and clips securing LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x screw, T20, 2.5 Nm
  18. Remove connectors from LH footwell cover and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles an additional ODII connector will have to be disconnected
  19. Remove LH front floor mat
  20. Remove LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips
  21. Remove clips securing LH front main carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Number of clips on new vehicles may vary
  22. Fold the LH front main cabin carpet aside for access
    Informational PurposesAn informational icon, calling your attention
    Note
    Dead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more
  23. Remove LH front footwell HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  24. Move RH front seat backward
  25. Remove RH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  26. Remove RH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
  27. Remove clip for RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  28. Remove RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
  29. Remove clips securing RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  30. Disconnect RH foot well assembly connectors and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x electrical connectors
  31. Remove RH front floor mat
  32. Remove RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips
  33. Remove clips securing RH front main cabin carpet to footwell area
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, Number of clips may vary on older vehicles
  34. Fold the RH front main cabin carpet aside for access
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Lift the center piece and pull the carpet back
  35. Remove RH front footwell HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  36. Move RH front seat forward
  37. Move LH front seat forward
  38. Remove 2nd row floor mat from vehicle
  39. Remove 2nd row seat cushion and disconnect harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 2x connectors, Both connectors are located on LH side of vehicle, Press tabs to the left and release front edge of seat cushion, Slide seat buckles out from access holes
  40. Fold the 40 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion
  41. Remove RH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1 tab, Pull outward then slightly upward to remove
  42. Remove and discard bolster plastic bracket from RH side
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
  43. Fold the 40 seat into vertical position
  44. Remove the RH rear door sill trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body
  45. Fold the 60 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion
  46. Remove LH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1 tab, Pull outward then slightly upward to remove
  47. Remove and discard bolster plastic bracket from LH side
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
  48. Fold the 60 seat into vertical position
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat protection
  49. Remove the LH rear door sill trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body
  50. Remove clips securing rear main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  51. Remove LH rear HV battery inner bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access
  52. Remove RH rear HV battery inner bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access
  53. Place wheel chocks to keep vehicle from moving
  54. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  55. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  56. Disconnect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
  57. Disconnect first responder loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  58. Remove all items from pockets and ensure not wearing metal items
  59. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to each use
  60. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  61. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5-Lobe, 6 Nm, Discard after removal
  62. Remove ancillary bay probe lid cover from the ancillary bay cover
  63. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  64. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm no visual damage present. Good to reuse seal.
  65. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5-Lobe, 6 Nm, Install new rubber washer bolts
  66. Remove HV cap from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  67. Remove edge support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm, 1x clip
  68. Remove fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  69. Remove bolts securing chargeport busbar to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  70. Lift chargeport busbar connector to remove from HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal
  71. Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm
  72. Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm
  73. Remove 12V cap from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  74. Disconnect HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  75. Remove nut securing DCDC ground busbar to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  76. Remove bolt securing DCDC ground busbar to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 12mm, 20 Nm
  77. Remove DCDC ground busbar
  78. Remove positive 12V output cover from PCS cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  79. Remove nut securing positive 12V output from PCS cable and move cable aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 15 Nm, Discard nut after removal
  80. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure all doors are latched to prevent accidental closure when vehicle is powered down
  81. Push vehicle onto lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
  82. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove body plugs and install M3 lift pad adapters to indicated locations
  83. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects
  84. Remove outer fasteners securing front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm
  85. Remove remaining nuts and remove front aero shield from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  86. Remove the clips securing the front LH and RH wheel liners to the front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  87. Remove bolts securing front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10, 13 Nm
  88. Remove skid plate from HV battery
  89. Remove bolt securing FDU HV harness to the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  90. Disconnect the FDU HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
  91. Remove the FDU HV harness connector from the FDU and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  92. Remove bolt securing FDU ground strap to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  93. Remove FDU ground strap harness clip from FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  94. Disconnect both AC compressor HV harness connectors on HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
  95. Remove push clip securing LH front wheel liner to LH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  96. Remove push clip securing RH front wheel liner to RH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  97. Use bungee strap to pull back LH front wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure to subframe
  98. Use bungee strap to pull back RH front wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure to subframe
  99. Position coolant drain container underneath RH front of HV battery
  100. Disconnect PT return tube from FDU inverter inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Lower hose located on RH front of HV battery, Plug both hose ends
  101. Disconnect PT supply tube and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Upper hose located on RH front of HV battery
  102. Position coolant drain container underneath LH front of HV battery
  103. Disconnect HV battery return tube from HV battery hose
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Located on LH front of HV battery
  104. Position coolant drain container below HV battery front manifold hose
  105. Release HV battery front manifold hose from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  106. Disconnect HV battery front manifold hose and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  107. Remove coolant drain container from underneath vehicle
  108. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    13x bolts, 10mm, 5 Nm
  109. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  110. Release LH side hose clip from rear battery skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  111. Release RH side hose clips from rear battery skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  112. Release clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  113. Remove lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
  114. Remove upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
  115. Remove upper bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  116. Remove HV battery rear skid plate enclosure
  117. Position coolant drain container underneath LH rear of HV battery
  118. Disconnect RDU inverter inlet tube from LH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug HV battery and hose
  119. Position coolant drain container underneath RH rear of HV battery
  120. Disconnect RDU outlet hose from PT return tube and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary
  121. Disconnect PT supply tube from RH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Plug HV battery side and allow coolant hose to fully drain
  122. Remove coolant drain container from underneath vehicle
  123. Remove RDU HV cable bracket from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Number of fasteners may vary
  124. Disconnect RDU HV cable from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
  125. Support front portion of rear subframe
  126. Remove smaller fasteners securing LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  127. Remove smaller fasteners for RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  128. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 128 Nm, Discard at later step
  129. Hand tighten bolt securing RH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 128 Nm
  130. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 128 Nm, Discard at later step
  131. Hand tighten bolt securing LH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 128 Nm
  132. Remove support stand from under vehicle
  133. Place HV battery table into position and lower vehicle to support HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
  134. Remove central bolts securing HV battery center ski cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm
  135. Remove bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  136. Remove bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  137. Remove LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  138. Remove RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  139. Raise vehicle free of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  140. Remove ancillary bay perimeter seal from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard anytime HV battery is removed from vehicle
  141. Remove PT supply tube from RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Upper hose location, Remove plugs from each end of hose and allow coolant to fully drain if discarding

Install

  1. Install PT supply tube to RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Upper hose location
  2. Install ancillary bay perimeter seal onto HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped
  3. Install HV battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay
  4. Lower vehicle onto HV battery and align holes
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
  5. Loosely install RH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  6. Loosely install LH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  7. Remove HV battery front alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods
  8. Install bolts securing RH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  9. Install bolts securing LH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  10. Install central bolts securing HV battery center ski cover hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm, Torque at later step
  11. Open LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  12. Remove HV battery alignment rod from LH rear rear HV battery interior bolt location
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rod
  13. Install LH rear HV battery interior bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary
  14. Close LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  15. Open LH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  16. Install LH front footwell HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  17. Close LH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  18. Open RH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  19. Remove HV battery alignment rod from RH rear HV battery interior bolt location
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rod
  20. Install RH rear HV battery interior bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary
  21. Close RH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  22. Open RH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  23. Install RH front footwell HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  24. Close RH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  25. Lower vehicle onto pack completely
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  26. Torque RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  27. Torque LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  28. Torque bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  29. Torque bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  30. Torque central bolts securing HV battery center ski cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm
  31. Raise vehicle and lower onto locks, then remove battery table from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  32. Support front portion of rear subframe
  33. Remove bolt securing LH side of rear subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  34. Install bolt and shear plate to LH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  35. Install bolts securing LH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  36. Remove bolt securing RH side of rear subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard after removal
  37. Install RH front bolt and shear plate to rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
  38. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  39. Torque bolts securing shear plates to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  40. Torque bolt securing subframe and LH shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm, Mark bolt after torque
  41. Torque bolt securing subframe and RH shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm, Mark bolt after torque
  42. Remove support stand from under vehicle
  43. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
  44. Install RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Number of fasteners may vary
  45. Position coolant drain container underneath RH rear of HV battery
  46. Install PT supply tube to RH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Remove plug from HV battery side, Perform push-pull-push test to make sure hose is fully seated
  47. Remove hose plugs and connect RDU outlet hose to PT return tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary
  48. Position coolant drain container underneath LH rear of HV battery
  49. Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully engaged
  50. Remove coolant drain container from underneath vehicle
  51. Position HV battery rear skid plate enclosure onto HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed
  52. Install upper bolts securing HV battery rear skid plate enclosure hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  53. Install upper nut securing HV battery rear skid plate enclosure hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  54. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  55. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  56. Torque upper nut securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  57. Install clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  58. Install RH side hose clips to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  59. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  60. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  61. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    13x bolts, 10mm, 5 Nm
  62. Position coolant drain container underneath LH front of HV battery
  63. Remove plugs then connect HV battery return tube
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged
  64. Position coolant drain container below HV battery front manifold hose
  65. Remove plugs then connect HV battery front manifold hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged
  66. Secure HV battery front manifold hose to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x barrel clip
  67. Position coolant drain container underneath RH front of HV battery
  68. Remove plug and connect PT supply tube
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x plug, Perform push-pull test to verify hoses are fully engaged
  69. Remove plugs then connect PT return tube
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Perform push-pull-push test to make sure hoses are fully engaged
  70. Release RH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  71. Release LH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  72. Install push clip securing LH front wheel liner to LH front rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  73. Install clip securing RH front wheel liner to RH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  74. Connect both AC compressor HV harness connectors on HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
  75. Install FDU ground strap and bolt to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  76. Install FDU ground strap harness clip to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  77. Install FDU HV harness connector to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
  78. Connect the FDU HV harness connector and lock the release lever
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
  79. Install bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  80. Install front skid plate onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Slide tabs onto front of HV battery
  81. Install the bolts securing the front skid plate to the HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10, 13 Nm
  82. Install the clips securing the front LH and RH wheel liners to the front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  83. Position the front aero shield to vehicle and install nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  84. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm
  85. Lower vehicle fully and move rack arms away from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove M3 lift adapters from body and install body plugs
  86. Push vehicle away from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
  87. Open all four doors
  88. Install positive 12V output from PCS cable and torque nut securing it
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque, Make sure rubber boot is not pinched between cable terminal and pass through
  89. Install positive 12V output cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  90. Install DCDC ground busbar
  91. Install bolt securing DCDC ground busbar to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 12mm, 20 Nm
  92. Install nut securing DCDC ground busbar to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
  93. Remove logic cap and connect the HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
  94. Install 12V cap to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  95. Install bolts securing RH inner ancillary bay rail to the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm
  96. Install bolts securing LH inner ancillary bay rail to the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm
  97. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  98. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector
  99. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  100. Position chargeport busbar connector to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs, Recommend assistance, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
  101. Install bolts securing charge port busbar HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  102. Install edge support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm, 1x clip
  103. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to each use
  104. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  105. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step
  106. Remove HV insulating gloves
  107. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  108. Install HV cap to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  109. Torque LH rear HV battery interior bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary
  110. Torque RH rear HV battery interior bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary
  111. Install clips and secure Velcro holding rear main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  112. Install the LH rear door sill trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Align the guiding tab to slot, Then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim. Newer vehicles may not be equipped with metal bracket and a foam insert will be present the bottom of trim piece
  113. Install RH rear door sill trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Align the guiding tab to slot, then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim
  114. Remove coolant bottle cap
  115. Place empty coolant container into front storage area
  116. Fill container with at least 15L of coolant
  117. Place filled coolant container into front storage area
  118. Install refill tool cap onto coolant bottle assembly
  119. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  120. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully engaged
  121. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  122. Position overflow hose into empty container
  123. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  124. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes to approximately (-27 to -24 inHg or -70 to -60 cmHg). Vacuum should not drop after the valves are closed
  125. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  126. Once the gauge reads zero, close the refill valve
  127. Disconnect shop air supply from coolant refill tool
  128. Remove coolant refill hose from coolant container
  129. Remove coolant overflow hose from coolant container
  130. Remove vacuum refill hose from refill cap on coolant bottle
  131. Remove refill tool cap from coolant bottle assembly
  132. Remove coolant refill tool from vehicle
  133. Remove both coolant containers from inside underhood area
  134. Connect first responder loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer
  135. Connect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm
  136. Press and hold park button to release EPB service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove wheel chocks if necessary
  137. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete
  138. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
  139. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  140. Install coolant bottle cap
  141. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete.
  142. Install cabin intake upper duct assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Older vehicles may be equipped with 4x clips
  143. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, If present untuck cut loop label and make sure it is still visible after apron is installed, Later builds may not have label
  144. Close hood
  145. Fold the 60 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion if necessary
  146. Install new bolster plastic bracket to LH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Install new bolster bracket
  147. Install LH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push inward to install
  148. Fold the 60 seat into vertical position
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection
  149. Fold the 40 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion if necessary
  150. Install new bolster plastic bracket to RH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Install new bolster bracket
  151. Install RH side bolster
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push inward to install
  152. Fold the 40 seat into vertical position
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection
  153. Connect 2nd row seat cushion harness and install 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Both connectors are located on LH side of vehicle, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips
  154. Install 2nd row floor mat into vehicle
  155. Move RH front seat backward
  156. Torque RH front footwell HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  157. Fold the RH front main cabin carpet back to original position
    Informational PurposesAn informational icon, calling your attention
    Note
    Move front edge down and slide back section up to ease positioning, Install seat harness into clips
  158. Install clips securing the RH front main cabin carpet to footwell area
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, Number of clips may vary on older vehicles
  159. Install RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
  160. Install RH front floor mat
  161. Install RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar
  162. Install clip for RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  163. Install RH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Make sure the seal seat on top of the trim
  164. Install RH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  165. Move LH front seat backward
  166. Torque LH front footwell HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  167. Fold the LH front main cabin carpet back to original position
    Informational PurposesAn informational icon, calling your attention
    Note
    Move front edge down and slide back section up to ease positioning, Install seat harness into clip
  168. Install clips securing LH front main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, Number of clips on newer vehicles may vary
  169. Install LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
  170. Install LH front floor mat
  171. Install LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim
  172. Install clip for LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  173. Install LH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
  174. Install LH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  175. Move RH front seat to original position
  176. Move LH front seat to original position
  177. Raise all the windows
  178. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Unlatch rear doors before closing
  179. Install RH rocker panel lower cover into position
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  180. Install clips securing the RH rocker panel lower cover to wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  181. Install bolts securing RH rocker panel lower cover to body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary
  182. Install LH rocker panel lower cover into position
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  183. Install clips securing the LH rocker panel lower cover to wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  184. Install bolts securing LH rocker panel lower cover to body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary