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

Remove bolts securing the LH rocker panel lower cover to body

Note

4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary

Remove clips securing the LH rocker panel lower cover to wheel liners

Note

4x push clips

Remove LH rocker panel lower cover

Note

10x clips

Remove bolts securing the RH rocker panel lower cover to body

Note

4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary

Remove clips securing the RH rocker panel lower cover to wheel liners

Note

4x push clips

Remove RH rocker panel lower cover

Note

10x clips

Open all four doors

Note

If vehicle is being powered down, Latch rear doors to prevent accidental closure

Lower all four windows

Open hood

Remove rear apron

Note

12x clips

Remove cabin intake upper duct assembly

Note

3x clips, Older vehicles may be equipped with 4x clips

Move LH front seat backward

Remove LH IP end cap

Note

3x clips

Remove LH mid A-pillar assembly

Note

1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove

Remove clip for LH lower A-pillar trim

Note

1x push clip

Remove LH lower A-pillar trim

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

Remove screw and clips securing LH footwell cover

Note

2x push clips, 1x screw, T20, 2.5 Nm

Remove connectors from LH footwell cover and remove from vehicle

Note

3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles an additional ODII connector will have to be disconnected

Remove LH front floor mat

Remove LH console side panel carpet

Note

12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips

Remove clips securing LH front main carpet to vehicle

Note

3x clips, Number of clips on new vehicles may vary

Fold the LH front main cabin carpet aside for access

Note

Dead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more

Remove LH front footwell HV battery bolts

Note

2x bolts, EP20, 136 Nm

Move RH front seat backward

Remove RH IP end cap

Note

3x clips

Remove RH mid A-pillar assembly

Note

1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove

Remove clip for RH lower A-pillar trim

Note

1x push clip

Remove RH lower A-pillar trim

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

Remove clips securing RH footwell assembly

Note

4x push clips

Disconnect RH foot well assembly connectors and remove from vehicle

Note

2x electrical connectors

Remove RH front floor mat

Remove RH console side panel carpet

Note

12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips

Remove clips securing RH front main cabin carpet to footwell area

Note

3x push clips, Number of clips may vary on older vehicles

Fold the RH front main cabin carpet aside for access

Note

2x clips, Lift the center piece and pull the carpet back

Remove RH front footwell HV battery bolts

Note

2x bolts, EP20, 136 Nm

Move RH front seat forward

Move LH front seat forward

Remove 2nd row floor mat from vehicle

Remove 2nd row seat cushion and disconnect harness

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

Fold the 40 seat in down position

Note

Protect the seat cushion

Remove RH side bolster

Note

1x clip, 1 tab, Pull outward then slightly upward to remove

Remove and discard bolster plastic bracket from RH side

Note

2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal

Fold the 40 seat into vertical position

Remove the RH rear door sill trim panel

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

Fold the 60 seat in down position

Note

Protect the seat cushion

Remove LH side bolster

Note

1x clip, 1 tab, Pull outward then slightly upward to remove

Remove and discard bolster plastic bracket from LH side

Note

2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal

Fold the 60 seat into vertical position

Note

Remove seat protection

Remove the LH rear door sill trim panel

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

Remove clips securing rear main cabin carpet to vehicle

Note

2x push clips

Remove LH rear HV battery inner bolt

Note

1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access

Remove RH rear HV battery inner bolt

Note

1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access

Place wheel chocks to keep vehicle from moving

Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)

Power off vehicle from center display

Note

Via Controls > Safety & Security > Vehicle Power > Power Off

Disconnect 12V negative terminal

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

Disconnect first responder loop

Note

1x connector, Release locking tab

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

Note

Check gloves for damage prior to each use

Put on HV insulating gloves and leather over gloves

Note

Make sure to wear Electrical Protective Gloves any time Hioki tester is used

Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, E10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover from the ancillary bay cover

Verify no high voltage

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

Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note

Confirm no visual damage present. Good to reuse seal.

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, E10 5-Lobe, 6 Nm, Install new rubber washer bolts

Remove HV cap from ancillary bay

Note

1x cap

Remove edge support bracket

Note

2x bolts, 10mm, 10 Nm, 1x clip

Remove fastener securing busbar cover access door

Note

1x bolt, 10mm, 9 Nm

Remove bolts securing chargeport busbar to HV header

Note

2x bolts, 10mm, 9 Nm

Lift chargeport busbar connector to remove from HV header

Note

4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal

Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover

Note

2x bolts, T40, 24 Nm

Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover

Note

2x bolts, T40, 24 Nm

Remove 12V cap from ancillary bay

Note

1x cap

Disconnect HVC logic connector and install logic cap

Note

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Remove nut securing DCDC ground busbar to HV battery

Note

1x nyloc nut, 13mm, 9 Nm, Discard nut after removal

Remove bolt securing DCDC ground busbar to body

Note

1x bolt, 12mm, 20 Nm

Remove DCDC ground busbar

Remove positive 12V output cover from PCS cable

Note

1x cover

Remove nut securing positive 12V output from PCS cable and move cable aside

Note

1x nyloc nut, 13mm, 15 Nm, Discard nut after removal

Close all four doors

Note

Make sure all doors are latched to prevent accidental closure when vehicle is powered down

Push vehicle onto lift

Note

Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed

Raise and support vehicle

Note

Remove body plugs and install M3 lift pad adapters to indicated locations

Raise vehicle fully and lower lift onto locks

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

Remove outer fasteners securing front aero shield

Note

9x bolts, 10mm, 5 Nm

Remove remaining nuts and remove front aero shield from vehicle

Note

2x nuts, 15mm, 5 Nm

Remove the clips securing the front LH and RH wheel liners to the front skid plate

Note

2x push clips

Remove bolts securing front skid plate

Note

4x bolts, E10, 13 Nm

Remove skid plate from HV battery

Remove bolt securing FDU HV harness to the FDU

Note

1x bolt, 10mm, 10 Nm

Disconnect the FDU HV harness connector

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

Remove the FDU HV harness connector from the FDU and move aside

Note

1x connector

Remove bolt securing FDU ground strap to HV battery

Note

1x bolt, 10mm, 10 Nm

Remove FDU ground strap harness clip from FDU

Note

1x clip

Disconnect both AC compressor HV harness connectors on HV battery

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

Remove push clip securing LH front wheel liner to LH rocker panel

Note

1x push clip

Remove push clip securing RH front wheel liner to RH rocker panel

Note

1x push clip

Use bungee strap to pull back LH front wheel liner

Note

Secure to subframe

Use bungee strap to pull back RH front wheel liner

Note

Secure to subframe

Position coolant drain container underneath RH front of HV battery

Disconnect PT return tube from FDU inverter inlet hose

Note

2x clips, 2x plugs, Lower hose located on RH front of HV battery, Plug both hose ends

Disconnect PT supply tube and plug both hose ends

Note

2x clips, 2x plugs, Upper hose located on RH front of HV battery

Position coolant drain container underneath LH front of HV battery

Disconnect HV battery return tube from HV battery hose

Note

2x clips, 2x plugs, Located on LH front of HV battery

Position coolant drain container below HV battery front manifold hose

Release HV battery front manifold hose from body

Note

1x clip

Disconnect HV battery front manifold hose and plug both hose ends

Note

1x spring clip, 2x plugs

Remove coolant drain container from underneath vehicle

Remove mid aero shield

Note

13x bolts, 10mm, 5 Nm

Release clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Release LH side hose clip from rear battery skid plate enclosure

Note

2x clips, Clip quantity may vary on older vehicles

Release RH side hose clips from rear battery skid plate enclosure

Note

2x fir tree clips

Release clips securing coolant hoses to RH shear plate

Note

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count

Remove upper nut securing HV battery rear skid plate enclosure

Note

1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles

Remove upper bolts securing HV battery rear skid plate enclosure

Note

4x bolts, 13mm, 35 Nm

Remove HV battery rear skid plate enclosure

Position coolant drain container underneath LH rear of HV battery

Disconnect RDU inverter inlet tube from LH rear of HV battery

Note

1x spring clip, 2x plugs, Plug HV battery and hose

Position coolant drain container underneath RH rear of HV battery

Disconnect RDU outlet hose from PT return tube and plug both hose ends

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

Disconnect PT supply tube from RH rear of HV battery

Note

1x spring clip, 1x plug, Plug HV battery side and allow coolant hose to fully drain

Remove coolant drain container from underneath vehicle

Remove RDU HV cable bracket from HV battery

Note

1x nut, 10mm, 10 Nm, Number of fasteners may vary

Disconnect RDU HV cable from HV battery

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

Support front portion of rear subframe

Remove smaller fasteners securing LH shear plate

Note

2x bolts, 13mm, 35 Nm

Remove smaller fasteners for RH shear plate

Note

2x bolts, 13mm, 35 Nm

Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 128 Nm, Discard at later step

Hand tighten bolt securing RH side of subframe to body

Note

1x bolt, 21mm, 128 Nm

Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 128 Nm, Discard at later step

Hand tighten bolt securing LH side of subframe to body

Note

1x bolt, 21mm, 128 Nm

Remove support stand from under vehicle

Place HV battery table into position and lower vehicle to support HV battery

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

Remove central bolts securing HV battery center ski cover

Note

4x bolts, EP14, 34 Nm

Remove bolts securing RH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove bolts securing LH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove LH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Remove RH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Raise vehicle free of HV battery

Note

Recommend assistance

Remove ancillary bay perimeter seal from HV battery pack

Note

Discard anytime HV battery is removed from vehicle

Remove PT supply tube from RH side of HV battery

Note

5x clips, Upper hose location, Remove plugs from each end of hose and allow coolant to fully drain if discarding

Install PT supply tube to RH side of HV battery

Note

5x clips, Upper hose location

Install ancillary bay perimeter seal onto HV battery pack

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

Install HV battery alignment rods

Note

2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay

Lower vehicle onto HV battery and align holes

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)

Loosely install RH bolts securing HV battery to vehicle hand tight

Note

8x bolts, 13mm, 35 Nm

Loosely install LH bolts securing HV battery to vehicle hand tight

Note

8x bolts, 13mm, 35 Nm

Remove HV battery front alignment rods

Note

2x rods

Install bolts securing RH front support bracket to vehicle hand tight

Note

4x bolts, 16mm, 110 Nm, Torque at later step

Install bolts securing LH front support bracket to vehicle hand tight

Note

4x bolts, 16mm, 110 Nm, Torque at later step

Install central bolts securing HV battery center ski cover hand tight

Note

4x bolts, EP14, 34 Nm, Torque at later step

Open LH rear door

Note

Use caution while working around this area not to damage any components

Remove HV battery alignment rod from LH rear rear HV battery interior bolt location

Note

1x rod

Install LH rear HV battery interior bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary

Close LH rear door

Note

Do not latch

Open LH front door

Note

Use caution while working around this area not to damage any components

Install LH front footwell HV battery bolts hand tight

Note

2x bolts, EP20, 136 Nm, Torque at later step

Close LH front door

Note

Do not latch

Open RH rear door

Note

Use caution while working around this area not to damage any components

Remove HV battery alignment rod from RH rear HV battery interior bolt location

Note

1x rod

Install RH rear HV battery interior bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step, Lift up LH rear main carpet for access if necessary

Close RH rear door

Note

Do not latch

Open RH front door

Note

Use caution while working around this area not to damage any components

Install RH front footwell HV battery bolts hand tight

Note

2x bolts, EP20, 136 Nm, Torque at later step

Close RH front door

Note

Do not latch

Lower vehicle onto pack completely

Note

Recommend assistance

Torque RH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Torque LH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Torque bolts securing RH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Torque bolts securing LH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Torque central bolts securing HV battery center ski cover

Note

4x bolts, EP14, 34 Nm

Raise vehicle and lower onto locks, then remove battery table from under vehicle

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

Support front portion of rear subframe

Remove bolt securing LH side of rear subframe to body

Note

1x bolt, 21mm, 130 Nm, Discard after removal

Install bolt and shear plate to LH side of rear subframe hand tight

Note

1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step

Install bolts securing LH shear plate to HV battery hand tight

Note

2x bolts, 13mm, 35 Nm

Remove bolt securing RH side of rear subframe to body

Note

1x bolt, 21mm, 130 Nm, Discard after removal

Install RH front bolt and shear plate to rear subframe hand tight

Note

1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step

Install bolts securing RH shear plate to HV battery hand tight

Note

2x bolts, 13mm, 35 Nm

Torque bolts securing shear plates to vehicle

Note

4x bolts, 13mm, 35 Nm

Torque bolt securing subframe and LH shear plate to body

Note

1x front bolt, 21mm, 130 Nm, Mark bolt after torque

Torque bolt securing subframe and RH shear plate to body

Note

1x front bolt, 21mm, 130 Nm, Mark bolt after torque

Remove support stand from under vehicle

Connect RDU HV cable to HV battery

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

Install RDU HV cable bracket to HV battery

Note

1x nut, 10mm, 10 Nm, Number of fasteners may vary

Position coolant drain container underneath RH rear of HV battery

Install PT supply tube to RH rear of HV battery

Note

1x spring clip, 1x plug, Remove plug from HV battery side, Perform push-pull-push test to make sure hose is fully seated

Remove hose plugs and connect RDU outlet hose to PT return tube

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

Position coolant drain container underneath LH rear of HV battery

Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery

Note

1x spring clip, Perform push-pull-push test to make sure hose is fully engaged

Remove coolant drain container from underneath vehicle

Position HV battery rear skid plate enclosure onto HV battery for installation

Note

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note

4x bolts, 13mm, 35 Nm, Torque at later step

Install upper nut securing HV battery rear skid plate enclosure hand tight

Note

1x nut, 10mm, 13 Nm, Torque at later step

Install lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts

Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note

4x bolts, 13mm, 35 Nm

Torque upper nut securing HV battery rear skid plate enclosure

Note

1x nut, 10mm, 13 Nm

Install clips securing coolant hoses to RH shear plate

Note

2x fir tree clips

Install RH side hose clips to HV battery rear skid plate enclosure

Note

2x fir tree clips

Install LH side hose clip to HV battery rear skid plate enclosure

Note

2x clips, Clip quantity may vary on older vehicles

Install clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note

13x bolts, 10mm, 5 Nm

Position coolant drain container underneath LH front of HV battery

Remove plugs then connect HV battery return tube

Note

2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged

Position coolant drain container below HV battery front manifold hose

Remove plugs then connect HV battery front manifold hose

Note

1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged

Secure HV battery front manifold hose to body

Note

1x barrel clip

Position coolant drain container underneath RH front of HV battery

Remove plug and connect PT supply tube

Note

2x clips, 1x plug, Perform push-pull test to verify hoses are fully engaged

Remove plugs then connect PT return tube

Note

2x clips, 2x plugs, Perform push-pull-push test to make sure hoses are fully engaged

Release RH front wheel liner from bungee strap

Note

Remove strap from vehicle

Release LH front wheel liner from bungee strap

Note

Remove strap from vehicle

Install push clip securing LH front wheel liner to LH front rocker panel

Note

1x push clip

Install clip securing RH front wheel liner to RH rocker panel

Note

1x push clip

Connect both AC compressor HV harness connectors on HV battery

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

Install FDU ground strap and bolt to HV battery

Note

1x bolt, 10mm, 10 Nm

Install FDU ground strap harness clip to FDU

Note

1x clip

Install FDU HV harness connector to FDU

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

Connect the FDU HV harness connector and lock the release lever

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

Install bolt securing FDU HV harness to FDU

Note

1x bolt, 10mm, 10 Nm

Install front skid plate onto HV battery

Note

2x tabs, Slide tabs onto front of HV battery

Install the bolts securing the front skid plate to the HV battery

Note

4x bolts, E10, 13 Nm

Install the clips securing the front LH and RH wheel liners to the front skid plate

Note

2x push clips

Position the front aero shield to vehicle and install nuts

Note

2x nuts, 15mm, 5 Nm

Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note

9x bolts, 10mm, 5 Nm

Lower vehicle fully and move rack arms away from vehicle

Note

Remove M3 lift adapters from body and install body plugs

Push vehicle away from lift

Note

Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed

Open all four doors

Install positive 12V output from PCS cable and torque nut securing it

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

Install positive 12V output cover

Note

1x cover

Install DCDC ground busbar

Install bolt securing DCDC ground busbar to body

Note

1x bolt, 12mm, 20 Nm

Install nut securing DCDC ground busbar to HV battery

Note

1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut

Remove logic cap and connect the HVC logic connector

Note

1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

Install 12V cap to ancillary bay

Note

1x cap

Install bolts securing RH inner ancillary bay rail to the ancillary bay cover

Note

2x bolts, T40, 24 Nm

Install bolts securing LH inner ancillary bay rail to the ancillary bay cover

Note

2x bolts, T40, 24 Nm

Clean busbar HV connector contact surface of residual Penetrox

Note

Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

Clean HV connector contact surface of residual Penetrox

Note

Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector

Apply Penetrox onto HV connector joints

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

Position chargeport busbar connector to HV header

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

Install bolts securing charge port busbar HV header

Note

2x bolts, 10mm, 9 Nm

Install edge support bracket

Note

2x bolts, 10mm, 10 Nm, 1x clip

Inspect HV insulating gloves

Note

Check gloves for damage prior to each use

Put on HV insulating gloves and leather over gloves

Note

Make sure to wear Electrical Protective Gloves any time Hioki tester is used

Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

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

Remove HV insulating gloves

Install fastener securing busbar cover access door

Note

1x bolt, 10mm, 9 Nm

Install HV cap to ancillary bay

Note

1x cap

Torque LH rear HV battery interior bolt

Note

1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary

Torque RH rear HV battery interior bolt

Note

1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary

Install clips and secure Velcro holding rear main cabin carpet to vehicle

Note

2x push clips

Install the LH rear door sill trim panel

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

Install RH rear door sill trim panel

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

Remove coolant bottle cap

Place empty coolant container into front storage area

Fill container with at least 15L of coolant

Place filled coolant container into front storage area

Install refill tool cap onto coolant bottle assembly

Setup coolant refill tool

Note

Verify all valves on refill tool are in the closed position, See image for clarity

Install vacuum refill hose into refill cap on coolant bottle

Note

Perform push-pull-push test to verify hose is fully engaged

Place refill hose inside filled coolant container

Note

Make sure hose end is fully submerged into coolant

Position overflow hose into empty container

Connect shop air supply to coolant refill tool

Note

If not already done, Verify refill valve is set to off

Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note

Gauge stabilizes to approximately (-27 to -24 inHg or -70 to -60 cmHg). Vacuum should not drop after the valves are closed

Slowly open the refill valve to allow coolant to be drawn into the system

Note

Make sure hose end of refill hose is fully submerged during entire process

Once the gauge reads zero, close the refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Remove vacuum refill hose from refill cap on coolant bottle

Remove refill tool cap from coolant bottle assembly

Remove coolant refill tool from vehicle

Remove both coolant containers from inside underhood area

Connect first responder loop

Note

1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer

Connect 12V negative terminal

Note

1x nut, 10mm, 6 Nm

Press and hold park button to release EPB service mode

Note

Remove wheel chocks if necessary

Connect to vehicle using Toolbox 3.0

Note

Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)

Select ‘Actions/Autodiag’ and search for ‘Thermal’

Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete

Note

Select ‘X’ at top right of window to close once complete

Select ‘Actions/Autodiag’ tab and search for ‘ Purge'

Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE ’, click ‘Run’, and allow routine to complete

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

Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle

Inspect coolant level and top off as necessary

Note

Ensure that the fluid level is at the Max line

Install coolant bottle cap

Select ‘TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCE’, click ‘Run’, and allow routine to complete

Note

Select ‘X’ at top right of window to close once complete.

Remove the HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle.

Install cabin intake upper duct assembly

Note

3x clips, Older vehicles may be equipped with 4x clips

Install rear apron

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

Close hood

Fold the 60 seat in down position

Note

Protect the seat cushion if necessary

Install new bolster plastic bracket to LH side bolster

Note

2x tabs, Install new bolster bracket

Install LH side bolster

Note

1x clip, 1x tab, Align the bottom tab then push inward to install

Fold the 60 seat into vertical position

Note

Remove seat cushion protection

Fold the 40 seat in down position

Note

Protect the seat cushion if necessary

Install new bolster plastic bracket to RH side bolster

Note

2x tabs, Install new bolster bracket

Install RH side bolster

Note

1x clip, 1x tab, Align the bottom tab then push inward to install

Fold the 40 seat into vertical position

Note

Remove seat cushion protection

Connect 2nd row seat cushion harness and install 2nd row seat cushion

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

Install 2nd row floor mat into vehicle

Move RH front seat backward

Torque RH front footwell HV battery bolts

Note

2x bolts, EP20, 136 Nm

Fold the RH front main cabin carpet back to original position

Note

Move front edge down and slide back section up to ease positioning, Install seat harness into clips

Install clips securing the RH front main cabin carpet to footwell area

Note

4x push clips, Number of clips may vary on older vehicles

Install RH console side panel carpet

Note

1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear

Install RH front floor mat

Install RH lower A-pillar trim

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

Install clip for RH lower A-pillar trim

Note

1x push clip

Install RH mid A-pillar assembly

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

Install RH IP end cap

Note

3x clips

Move LH front seat backward

Torque LH front footwell HV battery bolts

Note

2x bolts, EP20, 136 Nm

Fold the LH front main cabin carpet back to original position

Note

Move front edge down and slide back section up to ease positioning, Install seat harness into clip

Install clips securing LH front main cabin carpet to vehicle

Note

3x push clips, Number of clips on newer vehicles may vary

Install LH console side panel carpet

Note

1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear

Install LH front floor mat

Install LH lower A-pillar trim

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