Harness - HVAC Assembly (Remove and Replace)

This procedure requires refrigerant evacuation and recharge, please add specific evacuation and recharge correction code as needed

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18200102,18033302,18033305,18200122**Always use this Step ID**

Set up AC machine

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Touch time only, Connect to power, Turn power switch on

Open LH front door

Lower LH front window

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link)

Access Thermal System routines using UI

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Select Service mode > Thermal

Run ODIN routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTvia Toolbox: (link)

Raise and support vehicle

Open hood

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Press "Open" button on touchscreen to release latch, Lift lid manually

Remove rear apron

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12x clips, Only store rear apron visible face upwards

Remove cabin intake upper duct assembly

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3x clips, Some configurations may come with 4x clips

Remove closeout panel from frunk assembly

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4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab closeout panel from bottom then pull it upward to release clips, Disconnect switch

Remove bolts securing frunk assembly

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7x bolts, 10mm, 5 Nm

Remove frunk assembly from vehicle

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12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles

Remove RH wiper arm nut cover

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1x cover

Disconnect washer hose from RH wiper arm

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2x clips, 1x hose, Disconnect Y-tube fitting and release washer hose clips

Remove nut securing RH wiper arm to wiper module

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1x nut, 15mm, 25 Nm

Remove RH wiper arm and hose assembly from vehicle

Remove LH wiper arm nut cover

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1x cover

Disconnect washer hose from LH wiper arm

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2x clips, 1x hose, Disconnect Y-tube fitting and release washer hose clips

Remove nut securing LH wiper arm to wiper module

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1x nut, 15mm, 25 Nm

Remove LH wiper arm and hose assembly from vehicle

Flip LH shock tower cover

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1x push clip, Remove the clip and flip the cover following the arrow.

Flip RH shock tower cover

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1x push clip , Remove the clip and flip the cover following the arrow.

Release cowl screen from windshield and remove from vehicle

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2x push clips, 6x clips

Remove fresh air intake assembly

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2x studs, Lift cowl as needed

Remove bolts securing wiper module

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3x bolts, 10mm, 7 Nm

Disconnect wiper module harness

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1x connector, Do NOT place limbs within the linkage movement area as wiper arms will automatically transition to parking mode

Remove wiper module from vehicle

Release harness clip from LH side of washer tank inlet

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1x clip

Remove LH front wheel center cap

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1x cap

Loosen LH front wheel

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5x nuts, 21mm, 175 Nm

Raise vehicle partially and lower lift onto locks

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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

Remove LH front wheel

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5x nuts, 21mm, 175 Nm

Partially remove LH front wheel liner

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6x clips, 1x bolt, 10mm, 5 Nm, Newer vehicles may be equipped with 2x push clips securing lower portion of liner to body

Remove lower bolt securing washer tank to vehicle

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1x bolt, 10mm, 3 Nm

Partially install LH front wheel liner

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2x clips, Partially install LH front wheel liner, Wheel liner will be removed again later, Install 2 clips to secure LH front wheel liner

Install LH front wheel

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5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool, Torque at later step

Lower vehicle until tires are touching ground

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Remove upper bolt securing washer tank to vehicle

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1x bolt, 10mm, 3 Nm

Disconnect washer pump and level sensor connectors

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2x connectors

Remove washer tank from vehicle

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2x connectors，Keep washer tank upright to keep contents from spilling

Remove vehicle from lift

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

Run ODIN routine PROC_EPB_X_SERVICE-MODE-STARTvia Toolbox: (link)

Push vehicle away from lift

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Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed

Open all four doors

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

Lower all four windows

Remove caps from low side and high side A/C ports

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2x caps

Connect AC hoses to vehicle

Perform refrigerant system recovery

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Note or print the amount of refrigerant and oil recovered, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart https://toolbox.teslamotors.com/articles/353700

Move LH front seat forward

Remove console lower rear panel

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5x clips, Insert the plastic trim tool with a 90 degree bend at the bottom of the cover and pull straight out to release

Remove rear bolts securing center console to vehicle

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2x bolts, 10mm, 7 Nm

Move LH front seat backward

Remove LH front floor mat

Remove LH console side panel carpet

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10x clips, 1x tab, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips, replace any damaged clips

Remove LH front exterior bolts from center console

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2x bolts, 10mm, 7 Nm

Move RH front seat forward

Remove RH rear exterior bolt from center console

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Delete step

Move RH front seat backward and seat back downward

Remove RH front floor mat

Remove RH console side panel carpet

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

Remove RH front exterior bolts from center console

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2x bolts, 10mm, 7 Nm

Power off vehicle from center display

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Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

Disconnect 12V negative terminal

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1x nut, 10mm, 6 Nm, Ensure vehicle is in park, Climate control system is off, and vehicle is not charging before disconnecting 12V

Disconnect first responder loop

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1x connector, Release locking tab

Remove AC hoses from vehicle

Release vacuum from AC lines

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2x Schrader valves, Carefully depress the schrader valves to release vacuum from AC lines

Disconnect harness from rear of center console

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1x connector

Disconnect USB harness at RH of center console

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1x connector

Remove center console from vehicle

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Recommend assistance, Tilt rear of console upward, pull assembly towards rear of vehicle, then tilt front of console upward and remove through passenger side

Remove LH IP end cap

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3x clips

Remove LH mid A-pillar assembly

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

Remove LH air wave bezel cap from main decor assembly

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2x clips, Newer vehicles are equipped with solid bezel.

Remove LH upper A-pillar trim

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3x clips, Pull inside of the upper portion of upper A-pillar, Remove 3x tether hooks by twisting and pulling away from housing, Then pull upper A-pillar upward to remove

Remove clip for LH lower A-pillar trim

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1x push clip

Remove LH lower A-pillar trim

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2x clips, 3 guide tabs, Pull rear of lower A-pillar upward to release clip then pull outward to release front tabs from carpet

Release LH footwell cover

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

Remove LH footwell cover

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

Release driver knee air bag from vehicle

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1x push clip, 2x screws, T20, 2 Nm, 4x patch bolts, T30, 8 Nm, Newer vehicles have 4x patch bolts, E10, Discard after removal, Support the knee air bag while lowering, The connector / harness length is very short

Remove driver knee air bag from vehicle

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1x connector, Release locking tabs, Then release squib from air bag, Support air bag while disconnecting, Connector release may vary

Remove LH footwell duct from HVAC module

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1x push clip

Remove RH IP end cap

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3x clips

Remove RH mid A-pillar assembly

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

Remove RH air wave bezel cap from main decor assembly

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2x clips, Newer vehicles are equipped with solid bezel.

Remove RH upper A-pillar trim

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3x clips, Pull inside of the upper portion of upper A-pillar, Remove 3x tether hooks by twisting and pulling away from housing, Then pull upper A-pillar upward to remove

Remove clip from RH lower A-pillar trim

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1x push clip

Remove RH lower A-pillar trim

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1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull backward to release front tabs from carpet

Release RH footwell assembly from IP

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4x push clips

Remove RH footwell assembly

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2x connectors

Remove bolts securing passenger knee air bag onto vehicle

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4x patch bolts, T30, 8 Nm, Discard after removal, 2x screws, T20, 2 Nm, 1x push clip, Newer vehicles have 4x E10 patch bolts

Remove passenger knee air bag from vehicle

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1x connector, Release locking tab, Connector release may vary

Remove main decor assembly

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15x clips, Entire decor does not need to come off for glove box removal, If you lift RH side of decor then you will have access to 3x torx screws securing top of glove box, Replace securing clips as needed

Disconnect glove box USB cable from car computer

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1x connector, Depress latch on top of USB cable to release internal latches, Then release from car computer

Remove screws securing glove box assembly to IP carrier

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6x screws, T20, 2.3 Nm

Remove glove box from IP carrier

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3x clips

Disconnect glove box assembly connectors

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3x electrical connectors

Remove passenger footwell air duct

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1x push clip

Disconnect RH upper duct thermistor from RH IP air wave duct

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1x connector

Remove RH IP air wave duct

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2x push clips

Release driver air bag assembly away from steering wheel

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2x spring clips, 3x datums, Press the spring simultaneously from two access holes to release, Access holes located at 4 and 8 o’clock position, Do not insert tool too far as air bag connector could be damaged

Remove driver air bag assembly

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1x connector

Disconnect steering wheel

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1x connector

Release steering wheel from steering column

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1x patch bolt, 10mm hex, 80 Nm, Discard after removal, Counter hold the steering wheel when breaking bolt loose

Remove steering wheel from steering column

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Mark position of steering wheel

Release steering column upper shroud from lower shroud

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4x clips, Pull upward to release steering column upper shroud from lower shroud

Release lower shroud from steering column

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3x screws, T20, 1.5 Nm

Remove lower screw securing lower shroud to steering column

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1x screw, T20, 1.5 Nm

Remove lower shroud from steering column

Remove SCCM from steering column

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1x bolt, 5mm allen, 9 Nm

Disconnect SCCM assembly connector

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1x connector, Remove retaining clip on the connector, release connector, then remove the remaining broken clip from connector, Discard retaining clip after removal, Originally installed clip is black, Replacement clip is orange

Remove SCCM from steering column

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1x bolt, 5mm allen, 9 Nm

Release IP service panel from IP and disconnect temperature sensor connector

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4x clips, 4x tabs, 1x connector

Remove bolts securing center display to IP carrier

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Vehicle may be equipped with either: 2x patch bolts, T30, 12 Nm or 2x patch bolts, 10mm, 16 Nm, Discard after removal, Slide towards rear of vehicle to remove

Remove bolts securing housing neck to center display and slide away from display

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2x bolts, T30, 3 Nm, Number of fasteners on older vehicles may vary

Remove retaining clip from display connector

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1x clip

Disconnect harness connector from center display

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1x connector

Remove center display from vehicle

Remove center display neck housing from vehicle

Remove screws securing LH side of IP brow finisher

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4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Remove screws securing RH side of IP brow finisher

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4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Remove IP brow finisher from vehicle

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16x clips, Need to lift top pad up slightly to insert trim tool and release clips, Then slide IP brow finisher towards rear of vehicle

Pull RH side of RH air duct out and release from IP

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1x screw, T20, 2.3 Nm

Disconnect harness connector from RH air duct and remove duct

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1x connector

Pull LH side of LH air duct out and release from IP

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1x screw, T20, 2.3 Nm

Disconnect harness connector from LH air duct and remove duct

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1x connector

Release clips securing defroster grill

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8x clips, Replace any damaged clips

Pivot rear edge of defroster grill up and release tabs from IP

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6x tabs

Remove screws securing LH speaker to IP and remove speaker

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3x screws, T20, 2.3 Nm, 1x connector

Remove screws securing center speaker to IP and remove speaker

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1x connector, 3x screws, T20, 2.3 Nm

Remove screws securing center tweeter to IP and remove speaker

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1x connector, 2x screws, T20, 2.3 Nm, Discard tweeter and screws after removal

Remove screws securing RH speaker to IP and remove speaker

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3x screws, T20, 2.3 Nm, 1x connector

Disconnect connectors for passenger air bag assembly

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3x connectors, 2x connectors for regions other than North America, Connector release may vary

Remove bolts securing passenger air bag assembly to cross car beam

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4x patch bolts, T30, 8 Nm, Newer vehicles have 4x E10 patch bolts, Discard after removal

Remove screws securing IP carrier to cross car beam near passenger air bag

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2x screws, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam on lower LH side

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2x screws, T20, 2.3 Nm

Remove screw securing IP carrier to cross car beam on upper LH side

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1x screw, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam at lower center

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2x screws, T20, 2.3 Nm

Remove screws securing IP carrier to cross car beam at upper center

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2x screws, T20, 2.3 Nm

Remove screw securing IP carrier to cross car beam on upper RH side

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1x screw, T20, 2.3 Nm

Remove IP carrier from cross car beam

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Recommend assistance. Be cautious to clear the harness clipped at top center of HVAC assembly, This will also ease removal, Remove IP carrier through passenger front door

Remove screws securing driver air wave duct to cross car beam

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2x scews, T20, 2.3 Nm

Disconnect LH upper duct thermistor from drivers air wave duct

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1x connector

Remove driver air wave duct from HVAC assembly

Remove headliner harness clips on LH lower a-pillar

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2x clips

Disconnect headliner harness connector from LH lower a-pillar

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1x connector

Disconnect the dash connector from the left body controller

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1x connector, Release locking tab and gently pull down to release connector

Disconnect HVAC connector from left body controller

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1x connector

Disconnect IP harness connector from electronic steering column

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1x connector

Release IP harness clip located on blower motor assembly

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1x harness clip

Disconnect blower motor connector

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1x connector

Release clip securing center speaker harness to HVAC assembly

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1x clip

Disconnect connector from restraint control module

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1x connector, Disengage locking tab to release lever

Remove IP harness clips from body

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4x clips

Release IP harness clip next to RH duct thermistor

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1x harness clip

Release IP harness clip next to RH upper mode actuator

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1x harness clip

Release HVAC harness from IP harness holding mount on RH side of IP harness.

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3x harness holding mounts

Disconnect IP harness connectors from car computer

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2x connectors, Non EU vehicles have 3x connectors

Disconnect dash harness connector from right body controller

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1x connector

Release clip from RH side of cross car beam

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1x harness clip

Disconnect IP harness connectors from RH controller area

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3x connectors

Remove LH center display bracket

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2x bolts, T30, 12 Nm

Remove RH center display bracket

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2x bolts, T30, 12 Nm

Remove bleeder duct adapter from HVAC assembly

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4x clips

Remove nuts securing steering column to cross car beam and carefully lower steering column

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4x nuts, 13mm, 15 Nm

Remove bolts securing cross car beam to LH side of bulkhead

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2x bolts, 13mm, 25 Nm

Remove bolt securing LH cross car beam bracket to cross beam

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1x bolt, 13mm, 25 Nm

Remove nut securing LH cross car beam bracket to body

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1x nut, 13mm, 25 Nm

Remove LH cross car beam bracket from vehicle

Remove clips securing LH front main carpet to vehicle

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

Remove bolt securing RH cross car beam bracket to cross beam

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1x bolt, 13mm, 25 Nm

Remove nut securing RH cross car beam bracket to body

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1x nut, 13mm, 25 Nm

Remove RH cross car beam bracket from vehicle

Remove clip securing RH front main carpet to cross car beam

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1 clip

Remove bolts securing cross car beam to HVAC assembly

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4x bolts, 10mm, 5.5 Nm

Remove bolt securing cross car beam to HVAC assembly

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1x bolt, 10mm, 5.5 Nm

Loosen bolt securing cross car beam to upper cowl

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1x bolt, 13mm, 25 Nm

Remove bolts securing LH cross car beam to body

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2x bolts, 15mm, 29 Nm

Remove the bolts securing the RH cross car beam to body

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2x bolts, 15mm, 29 Nm

Remove cross car beam from vehicle

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Recommend assistance, Use caution not to damage the interior

Lift LH front main carpet towards LH front seat

Disconnect HVAC harness connector from right body controller

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1x connector

Remove AC manifold to HVAC line from HVAC assembly

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2x bolts, 13mm, 22 Nm

Remove bolt securing HVAC assembly to RH side of bulkhead

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1x bolt, 10mm, 5.5 Nm, Recommend assistance to support HVAC assembly during removal

Remove main floor duct from HVAC assembly and set aside

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Use a bungee cord as needed to secure floor duct

Remove HVAC assembly from vehicle

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Recommend assistance, Rotate HVAC assembly counter clockwise and remove out of RH front door

Disconnect intake actuator connector

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1x connector

Disconnect upper mode actuator connector

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1x connector

Disconnect RH lower duct thermistor connector

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1x connector

Disconnect lower mode actuator connector

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1x connector

Disconnect RH bleed actuator connector

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1x connector

Disconnect LH bleed actuator connector

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1x connector

Disconnect LH evaporator thermistor connector

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1x connector

Disconnect LH lower duct thermistor connector

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1x connector

Remove bolts securing LH bleed actuator to HVAC assembly

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2x bolts, 6mm, 2.3 Nm

Remove bolts securing RH bleed actuator to HVAC assembly

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2x bolts, 6mm, 2.3 Nm

Release clips on RH side of HVAC assembly

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3x clips

Release HVAC harness from RH holding tabs

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3x holding tabs

Release HVAC harness from upper holding tabs

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2x holding tabs

Release HVAC harness from LH holding tabs and remove HVAC harness from HVAC assembly

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4x holding tabs

Position HVAC harness onto HVAC assembly and connect LH evaporator thermistor

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1x connector

Connect LH lower duct thermistor connector

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1x connector

Install HVAC harness into LH holding tabs

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4x holding tabs

Install HVAC harness into upper holding tabs

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2x holding tabs

Install clips on RH side of HVAC assembly

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3x clips

Install HVAC harness into RH holding tabs

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3x holding tabs

Connect lower mode actuator connector

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1x connector

Connect upper mode actuator connector

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1x connector

Connect intake actuator connector

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1x connector

Connect RH lower duct thermistor connector

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1x connector

Install bolts securing LH bleed actuator to HVAC assembly

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2x bolts, 6mm, 2.3 Nm

Install bolts securing RH bleed actuator to HVAC assembly

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2x bolts, 6mm, 2.3 Nm

Connect RH bleed actuator connector

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1x connector

Connect LH bleed actuator connector

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1x connector

Position HVAC assembly into vehicle for installation

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Recommend assistance, Install HVAC assembly through RH front door, Rotate HVAC assembly clockwise for installation

Install bolt securing HVAC assembly to RH side of bulkhead

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1x bolt, 10mm, 5.5 Nm

Install main floor duct to HVAC assembly

Replace seal washers on supermanifold to HVAC AC line assembly on HVAC side

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5x seal washers, Install new seal washers, Lube seal washers with ND-11 oil

Install supermanifold to HVAC AC line assembly to HVAC assembly

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2x bolts, 13 mm, 22 Nm

Reconnect AC hoses to vehicle

Perform system vacuum and refrigerant refill

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Select 20 mins of Vacuum, Recharge refrigerant to car's specs, select both HP and LP for charging, add oil quantity as needed, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart article 353700

Connect HVAC harness connector to right body controller

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1x connector

Install LH front main carpet into position for installation

Position cross car beam to vehicle for installation

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Recommend assistance, Use caution not to damage the interior

Loosely install bolts securing RH cross car beam to body

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2x bolts, 15mm, 29 Nm, Torque at later step

Loosely install bolts securing LH cross car beam to body

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2x bolts, 15mm, 29 Nm, Torque at later step

Loosely install bolt securing cross car beam to upper cowl

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1x bolt, 13mm, 25 Nm

Loosely install bolt securing cross car beam to HVAC assembly

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1x bolt, 10mm, 5.5 Nm, Torque at later step

Loosely install bolts securing cross car beam to HVAC assembly

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4x bolts, 10mm, 5.5 Nm, Torque at later step

Position RH cross car beam bracket to vehicle for installation

Loosely install nut securing RH cross car beam bracket to body

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1x nut, 13mm, 25 Nm, Torque at later step

Loosely install bolt securing RH cross car beam bracket to cross car beam

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1x bolt, 13mm, 25 Nm, Torque at later step

Position LH cross car beam bracket to vehicle for installation

Loosely Install nut securing LH cross car beam bracket to body

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1x nut, 13mm, 25 Nm, Torque at later step

Loosely install bolt securing cross car beam to LH cross car beam bracket

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1x bolt, 13mm, 25 Nm, Torque at later step

Install bolts securing cross car beam to LH side of bulkhead

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2x bolts, 13mm, 25 Nm

Torque bolt securing cross car beam to upper cowl

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1x bolts, 13mm, 25 Nm

Torque bolt securing cross car beam to HVAC assembly

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1x bolts, 10mm, 5.5 Nm

Torque bolts securing cross car beam to HVAC module

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4x bolts, 10mm, 5.5 Nm

Torque bolts securing the LH cross car beam to body

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2x bolts, 15mm, 29 Nm

Torque bolts securing RH cross car beam to body

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2x bolts, 15mm, 29 Nm

Torque the nut securing the RH cross car beam bracket to body

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1x nut, 13mm, 25 Nm

Torque bolt securing RH cross car beam bracket to cross car beam

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1x bolt, 13mm, 25 Nm

Install clip securing RH front main carpet to cross car beam

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1x clip

Torque nut securing LH cross car beam bracket to vehicle

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1x nut, 13mm, 25 Nm

Torque bolt securing LH cross car beam bracket to cross car beam

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1x bolt, 13mm, 25 Nm

Install clips securing LH front main cabin carpet to vehicle

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

Position steering column for installation

Install nuts securing steering column to cross car beam

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4x nuts, 13mm, 15 Nm

Install bleeder duct adapter to HVAC

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4x clips

Install RH center display bracket

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2x bolts, T30, 12 Nm

Install LH center display bracket

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2x bolts, T30, 12 Nm

Install clip located on RH side of cross car beam

Connect IP harness connectors to RH controller area

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3x connector

Install dash harness connector to right body controller

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1x connector

Connect IP harness connectors to car computer

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2x connectors

Secure HVAC harness to IP harness

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3x harness holders

Install IP harness clip to HVAC assembly next to RH upper mode actuator

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1x clip

Install IP harness clip to HVAC assembly next to RH lower duct thermistor

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1x clip

Install IP harness clips to body

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4x harness clips

Connect IP harness connector to restrain control module

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1x connector, Engage locking tab

Install clip securing center speaker harness to HVAC assembly

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1x clip

Connect blower motor connector

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1x connector

Install blower motor harness clip to HVAC assembly

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1x clip

Connect IP harness connector to electronic steering column

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1x connector

Connect HVAC connector to left body controller

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1x connector

Connect dash connector to left body controller

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1x connector, Fully seat connector and pull release tab into locking position

Install headliner harness clips to lower a-pillar

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2x clips

Connect headliner harness connector

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1x connector

Install driver air wave duct into HVAC assembly

Connect LH upper duct thermistor to driver air wave duct

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1x connector

Install screws securing driver air wave duct to cross car beam

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2x screws, T20, 2.3 Nm

Install IP carrier onto cross car beam

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4x mounting tabs, Recommend assistance, Slide mounting tabs on IP carrier into brackets on vehicle, Be cautious to clear the harness clipped at top center of HVAC assembly, This will also ease installation

Install screw securing IP carrier to cross car beam on upper RH side

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1x screw, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam at upper center

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2x screws, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam at lower center

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2x screws, T20, 2.3 Nm

Install screw securing IP carrier to cross car beam on upper LH side

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1x screw, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam on lower LH side

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2x screws, T20, 2.3 Nm

Install screws securing IP carrier to cross car beam near passenger air bag

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2x screws, T20, 2.3 Nm

Install bolts securing passenger air bag assembly to cross car beam

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4x patch bolts, E10, 8 Nm, Install new patch bolts

Install connectors for passenger air bag

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3x connectors, 2x connectors for regions other than North America

Install RH speaker to IP carrier

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1x connector, 3x screws, T20, 2.3 Nm

Install center tweeter to IP carrier

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1x connector, 2x screws, T20, 2.3 Nm

Install center speaker to IP

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3x screws, T20, 2.3 Nm, 1x connector

Install LH speaker to IP carrier

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3x screws, T20, 2.3 Nm, 1x connector

Position defroster grill and lower tabs into position on IP

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6x tabs

Secure clips securing defroster grill

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8x clips

Position LH air duct into IP and connect harness connector

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1x connector

Install LH air duct into IP

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1x screw, T20, 2.3 Nm

Position RH air duct into IP and connect harness connector

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1x connector

Install RH air duct into IP

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1x screw, T20, 2.3 Nm

Install IP brow finisher into vehicle

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16x clips, Need to lift top pad up slightly to slide IP brow finisher into position

Install screws securing RH side of IP brow finisher

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4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Install screws securing LH side of IP brow finisher

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4x screws, T20, 2.3 Nm, Fastener count may vary, Older production vehicles may have 5x screws

Install RH IP air wave duct

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2x push clips

Connect RH upper duct thermistor to RH IP air wave duct

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1x connector

Install passenger footwell air duct

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1x push clip

Connect glove box assembly connectors

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3x connectors, New puddle lamp harness routing prevent blocking movement of pawls, Make sure harness is routed properly above passenger footwell air duct before connecting

Install glove box into IP carrier

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3x clips

Install screws securing glove box assembly to IP carrier

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6x screws, T20, 2.3 Nm

Connect glove box USB cable to car computer

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1x connector

Install passenger knee air bag onto vehicle

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1x connector, Use caution not to damage connector and harness, Support knee air bag while connecting connector

Install bolts securing passenger knee air bag to vehicle

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4x patch bolts, E10, 8 Nm, Install new patch bolts, 2x screws, T20, 2 Nm, 1x push clip, If vehicle equipped with T30 bolts update to E10

Install RH footwell assembly onto IP

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4x push clips

Position center display neck housing into vehicle

Position center display into vehicle

Connect center display

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1x connector

Install retaining clip to center display connector

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1x clip

Slide down neck housing and install bolts securing neck housing to center display

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2x bolts, T30, 3 Nm, Number of fasteners on older vehicles may vary

Install center display to IP carrier

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2x patch bolts, 10mm, 16 Nm, Install new 10mm patch bolts, Slide towards front of vehicle

Connect temperature sensor connector and install IP service panel into IP

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4x clips, 4x tabs, 1x connector

Install SCCM onto steering column

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1x bolt, 5mm allen, 9 Nm

Install SCCM onto steering column

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1x bolt, 5mm allen, 9 Nm

Connect SCCM assembly connector

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1x connector, Install new orange retaining clip to connector then install SCCM connector, Perform push-pull-push to make sure connector is seated properly

Position lower shroud onto steering column

Install lower screw securing lower shroud to steering column

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1x screw, T20, 1.5 Nm

Install lower shroud to steering column

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3x screws, T20, 1.5 Nm

Install upper shroud onto lower shroud

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4x clips

Position steering wheel to column

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Align the marking and keyed part of steering wheel and column

Secure steering wheel

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1x patch bolt, 10mm hex, 80 Nm, Install new patch bolt

Connect steering wheel

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1x connector

Position driver air bag assembly

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1x connector

Install driver air bag assembly to steering wheel

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3x datums, 2x spring clips, Inspect to make sure lower horn bracket is properly secured to steering wheel before installing driver air bag, make sure that the driver air bag harness doesn’t get caught between the driver air bag and the horn mechanism, verify air bag is fully engaged

Install main decor assembly

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15x clips, 1x center clip

Install LH footwell duct into HVAC module

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1x push clip

Position driver knee airbag

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1x connector, Use caution not to damage the connector/harness, Support the knee air bag while connecting the connector

Install driver knee air bag to vehicle

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4x patch bolts, E10, 8 Nm, Install new patch bolts, 2x screws, T20, 2 Nm, 1x push clip, If vehicle equipped with T30 bolts, update to E10

Position LH footwell cover

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3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector

Install LH footwell cover

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

Install RH upper A-pillar trim

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3x clips, 1x tether, Slide bottom of trim along IP and speaker grill, attach tether to body side, Set clips starting at the bottom and work up, Pull seal over trim

Install RH lower A-pillar trim

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1x clip, 2 guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar

Install clip for RH lower A-pillar trim

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1x clip

Install RH mid A-pillar assembly

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1x clip, 1x tab, Align bottom tab then push on top clip to fully seat mid A-pillar, Make sure seal seat on top of trim

Install RH air wave bezel cap to main decor assembly

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2x clips, Newer vehicles are equipped with solid bezel.

Install RH IP end cap

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3x clips

Install LH upper A-pillar trim

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3x clips, 1x tether, Slide bottom of trim along IP and speaker grill, attach tether to body side, Set clips starting at the bottom and work up, Pull seal over trim

Install LH lower A-pillar trim

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2x clips, 3 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

Install clip for LH lower A-pillar trim

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1x push clip

Install LH mid A pillar assembly

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1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A pillar, Pull seal over trim

Install LH air wave bezel cap to main decor assembly

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2x clips, Newer vehicles are equipped with solid bezel.

Install LH IP end cap

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3x clips

Install center console into vehicle

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Recommend assistance, Tilt front of console downward, Slide assembly towards front of vehicle and tilt rear of console down into place

Connect USB harness at RH of center console

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1x connector

Connect harness from rear of center console

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1x connector

Install RH front exterior bolts to center console

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2x bolts, 10mm, 7 Nm

Install RH console side panel carpet

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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 LH front exterior bolts to center console

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2x bolts, 10mm, 7 Nm

Install LH console side panel carpet

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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

Connect first responder loop

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

Connect 12V negative terminal

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1x nut, 10mm, 6 Nm

Remove AC hoses from vehicle

Install caps onto A/C ports

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2x caps

Run ODIN routine 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

Run ODIN routine TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Toolbox: (link)via Service Mode: Thermal ➜ Refrigerant System ➜ Run Heat Pump Commissioningvia Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioning

Run ODIN routine 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

Run ODIN routine TEST-SELF_VCRIGHT_X_HVAC-PERFORMANCEvia Toolbox: (link)via Service Mode:

Thermal ➜ Actions ➜ Test HVAC Performance
Thermal ➜ HVAC ➜ HVAC Performance Test
Thermal ➜ Actions ➜ Test HVAC Performance

Move RH front seat forward

Install rear exterior bolts to center console

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2x bolts, 10mm, 7 Nm

Move RH front seat to original position

Move LH front seat forward

Install LH rear exterior bolt to center console

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Delete step

Install console lower rear panel

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5x clips

Move LH front seat to original position

Push vehicle onto lift

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

Press and hold park button to release EPB service mode

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Remove wheel chocks if necessary

Raise and support vehicle

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Ensure vehicle is not charging, Remove charging cable if it's plugged in

Install washer tank into position

Connect washer pump and level sensor connectors

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2x connectors

Install upper bolt securing washer tank to vehicle

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1x bolt, 10mm, 3 Nm

Secure harness clip onto LH side of washer tank inlet

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1x clip

Raise vehicle partially and lower lift onto locks

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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

Remove LH front wheel

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5x nuts, 21mm, 175 Nm

Partially release LH front wheel liner

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2x push clips

Install lower bolt securing washer tank to vehicle

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1x bolt, 10mm, 3 Nm

Install LH front wheel liner to vehicle

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6x clips, 1x bolt, 10mm, 5 Nm, Newer vehicles may be equipped with 2x push clips securing lower portion of liner to body

Install LH front wheel

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5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool

Lower vehicle until tires are touching ground

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Raise lift off locks, Then hold lock release lever to keep locks free while vehicle is lowered

Torque LH front wheel

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5x nuts, 21mm, 175 Nm

Install LH front wheel center cap

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1x cap, Verify emblem is aligned with valve stem

Install wiper module to vehicle

Connect wiper module connector

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1x connector, Do NOT place limbs within the linkage movement area as wiper arms will automatically transition to parking mode

Install bolts securing wiper module

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3x bolts, 10mm, 7 Nm

Install fresh air intake assembly

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2x studs, Lift cowl as needed

Install cowl screen assembly

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2x push clips, 6x clips

Install RH shock tower cover

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1x push clip, Flip back the shock tower cover then install clip.

Install LH shock tower cover

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1x push clip, Flip back the shock tower cover then install clip.

Install LH wiper arm and hose assembly onto vehicle

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Washer hose shall be routed over the arm pivot joint not under

Install nut securing LH wiper arm to wiper module

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1x nut, 15mm, 25 Nm, Make sure wiper tip is aligned between two indicators at windshield

Connect washer hose from LH wiper arm to Y-tube fitting and secure washer hose clips

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2x clips, 1x hose

Install LH wiper arm nut cover

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1x cover

Install RH wiper arm and hose assembly onto vehicle

Install nut securing RH wiper arm to wiper module

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1x nut, 15mm, 25 Nm, Make sure wiper tip is aligned between two indicators at corner of windshield

Connect washer hose from RH wiper arm

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2x clips, 1x hose, Connect to Y-tube fitting and secure washer hose clips

Install RH wiper arm nut cover

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1x cover

Install frunk assembly to vehicle

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12x clips, Make sure frunk assembly is fully seated onto clips, Number of clips may vary on older vehicles, Ensure A/C compressor HVIL harness is not pinched between frunk assembly and thermal beam, replace any damaged clips