Mount - Front Drive Unit - RH (2nd Generation) (Remove and Replace)
Correction code 39012422 6.9 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 to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See to make sure wearing proper PPE when performing the below procedure.
- 2023-09-19: Updated torque value for RH side mount bolts.
Removal
-
Verify there is no abnormal tire wear
per Courtesy Inspection
NoteSC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment
-
Set up A/C machine and perform hose
flush
NoteTouch time only
-
Open all four doors
-
Lower all four windows
-
Raise and support vehicle
NotePrepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
-
Remove cubby under MCU and connect
laptop to vehicle with a tethered Ethernet connection via Toolbox 3
Note1x connector, 2x clips, Remove cubby under MCU and connect laptop to vehicle, Open Toolbox 3 website and establish connection to 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), Local connection will enable service mode plus on display
-
Unlock vehicle Gateway
NoteAfter vehicle has been put into "Service Mode", hold down the brake pedal, while holding down break pedal simultaneously hold the turn signal stalk fully up for at least 10 seconds, "GTW UNLOCKING" should pop up on the instrument cluster right below the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 899" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 15 minutes, follow steps on Toolbox article #5582900 for any additional information
-
Select ‘Actions’ tab and search for
‘PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain’
-
Select Action 'Start' , Fluid Fill
Target 'Refrigerant' and press 'Run'
NoteCheck the Routine's Notes before pressing Run, Verify successfully ''Passed'
-
Wait to see that the routine 'Passed'
successfully
NoteNow the system is ready for Fill / Drain
-
Install steering wheel lock to ensure
proper placement of the steering wheel
-
Move RH front seat fully forward
-
Open hood
NoteVia Controls > Front Trunk
-
Remove rear underhood apron
Note8x clips
-
Remove RH underhood apron
Note9x clips
-
Remove LH underhood apron
Note9x clips
-
Remove front underhood apron
Note7x clips
-
Release drainage hoses from HEPA
filter inlet duct
Note2x hoses
-
Remove clips securing HEPA filter
inlet duct to cowl panel
Note3x push clips
-
Remove HEPA filter inlet duct
Note2x clips on HEPA filter
-
Remove HEPA filter outlet duct from
vehicle
NoteLift up, pull towards front of vehicle, then rotate clockwise
-
Remove dust caps from high-side and
low-side service ports
Note2x caps
-
Connect hoses to vehicle and perform
A/C recovery
NoteTouch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports
-
Disconnect light and release switch
connectors and remove underhood storage carpet
Note2x connectors, Release edge of carpet from underneath underhood storage unit seal
-
Remove bolts and clips securing
underhood storage unit
Note2x bolts, 10mm, 7 Nm, 2x push clips
-
Push wiring harness grommet through
underhood storage unit and remove underhood storage unit
Note1x grommet, Lift the underhood storage unit appropriately to access the grommet
-
Power off vehicle via UI
NoteVia Controls > Safety > Power Off
-
Disconnect 12V negative terminal and
First Responder Loop
Note1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
-
Remove 2nd row seat bottom
cushion
Note2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
-
Remove NVH padding from underneath 2nd
row seat cushion
NoteIf equipped
-
Remove bolts securing seat bottom
frame
Note8x bolts, 11mm, 26 Nm
-
Lift up and support seat bottom
frame
Note8x clips
-
Remove tamper evident label from
charger cover panel
- Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves
-
Release HV charger access panel cover
Note11x bolts, T20, 2 Nm, Discard after removal
-
Release tabs and open both access
doors
Note4x tabs, Make sure to wear proper PPE
-
Verify no high voltage
NoteMeasure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, Verify you are using a proper ground and not a coated surface, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work escalate a toolbox session for assistance
-
Secure HV charger access panel
cover
Note11x bolts, T20, 2 Nm, Install new patch bolts
-
Remove HV insulating gloves
-
Install new warranty label onto
charger cover panel
NoteWipe charger with IPA prior to installation, Allow 1 minute for IPA to dry
-
Lower seat frame into position and
secure harness clips to frame
Note8x clips
-
Install and torque bolts securing seat
frame to vehicle
Note8x bolts, 11mm, 26 Nm
-
Place NVH padding onto seat
frame
-
Install seat bottom cushion
Note2x clips, 7x connectors if equipped, Replace clips if necessary
-
Remove A/C lines from vehicle
NotePress clear lines once lines have been removed
-
Release chiller assembly from front
subframe
Note3x bolts, 10mm, 5 Nm
-
Slide battery pump 2 off of the
bracket secured to subframe
NoteSlide pump to the right of vehicle for removal
-
Disconnect steering rack connectors
Note2x connectors, 2 stage locking connectors, Disengage the red locking tab before disconnecting
-
Disconnect the logic connectors for
the steering rack
Note2x electrical connectors, 2-way connectors, slide the grey lock out, then depress the lock to disconnect
-
Release logic connector harness from
subframe
Note1x fir tree clip
-
Remove the fasteners securing air
suspension pump bracket to subframe
Note2x bolts, 10mm, 5.5 Nm
-
Secure air suspension pump bracket and
chiller assembly to front end carrier
NoteUse bungee cord or something similar to hold assemblies in general position
-
Remove accessible bolt on RH 3-way
valve
Note1x bolt, T30, 5 Nm, Remaining bolt will be removed at later step
-
Remove 12V positive terminal
cover
Note2x tabs
-
Disconnect 12V positive terminal
Note1x nut, 10mm, 6 Nm
-
Remove fasteners securing 12V battery
bracket to shock tower cross member and the battery beam
Note2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
-
Remove 12V battery bracket
assembly
Note2x clips
-
Remove fastener securing coolant hose
to battery beam
Note1x bolt, T30, 5 Nm
-
Remove fasteners securing the battery
beam to the LH and RH body beams
Note2x bolts, T30, 3.5 Nm, 1x edge clip
-
Remove the battery beam
-
Disconnect coolant reservoir level
sensor
Note1x connector
-
Disconnect AC compressor logic
connector
Note1x connector
-
Release ground connection at the A/C
compressor mount bracket
Note1x bolt, T25, 7 Nm
-
Remove AC lines from compressor
Note2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Release ground strap from front drive
unit
Note1x bolt, E10, 6 Nm
-
Disconnect logic connector from front
drive unit
Note1x connector with lock tab
-
Remove lug nut covers from LH front
wheel
Note5x covers
-
Remove lug nut covers from RH front
wheel
Note5x covers
-
Remove RH front wheel center cap
Note1x cap
-
Remove LH front wheel center cap
Note1x cap
-
Loosen LH front axle nut
Note1x nut, 32mm, 245 Nm
-
Loosen RH front axle nut
Note1x nut, 32mm, 245 Nm
-
Loosen RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Loosen LH front wheel
Note5x nuts, 21mm, 175 Nm
-
Raise vehicle partially and lower onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
-
Remove LH front wheel
Note5x nuts, 21mm, 175 Nm
-
Remove LH tie rod nut and move tie rod
end away
Note1x Nyloc nut, 21mm, 103 Nm, Discard after removal
-
Remove RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Remove RH tie rod nut and move tie rod
end away
Note1x Nyloc nut, 21mm, 103 Nm, Discard after removal
-
Remove nuts and bolts securing RH
front wheel arch liner
Note2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
-
Remove clips securing RH front wheel
arch liner
Note7x push clips
-
Release clips and remove RH front
wheel arch liner from vehicle
Note3x clips
-
Raise vehicle fully and lower lift
onto locks
NoteSet 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 clips securing LH shear plate
to wheel fairing
Note2x push clips
-
Remove LH shear plate
Note2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
-
Remove clips securing RH shear plate
to wheel fairing
Note2x push clips
-
Remove RH shear plate
Note2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
-
Remove bolts securing mid aero shield
to vehicle
Note7x bolts, 10mm, 4 Nm
-
Remove clips securing mid aero shield
to vehicle
Note7x push clips
-
Remove mid aero shield from
vehicle
-
Remove front bash plate
extrusion
Note2x bolts, T30, 16 Nm
-
Remove LH ski side covers
Note14x push clips, 3x covers
-
Remove RH ski side covers
Note14x push clips, 3x covers
-
Remove four center bolts securing HV
battery
Note4x patch bolts, E12, 38 Nm, Discard after removal
-
Position battery table beneath
vehicle
-
Lower vehicle to table
NoteRecommend assistance, Align table to vehicle and raise casters to level table if necessary
-
Remove remaining eight center bolts
securing HV battery
Note8x patch bolts, E12, 38 Nm, Discard after removal
-
Remove front four HV battery
bolts
Note4x patch bolts, 13mm, 30 Nm, Discard after removal
-
Remove 21mm bolts securing front of HV
battery
Note2x bolts, 21mm, 115 Nm, Discard after removal
-
Remove LH rocker bolts
Note8x patch bolts, 13mm, 55 Nm, Discard after removal
-
Remove RH rocker bolts
Note8x patch bolts, 13mm, 55 Nm, Discard after removal
-
Raise vehicle off HV battery
-
Move battery away from vehicle
- Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves
-
Verify no high voltage at HV rapid
mate
NoteMake 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
-
Install HV and LV Rapid Mate
covers
Note2x covers, If covers not available then use masking tape to protect Rapid Mate from debris
- Remove HV insulating gloves
-
Remove clips securing front aero
shield to vehicle
Note10x push clips
-
Remove bolts securing front aero
shield to vehicle and remove
Note12x bolts, 10mm, 4 Nm
-
Remove skid bar from front
subframe
Note4x bolts, 10mm, 10 Nm
-
Remove the bolts securing the bash
plate stamping and skid plate to the front subframe skid plate
Note2x bolts, 10mm, 9 Nm
-
Remove skid plate from front
subframe
Note2x bolts, 10mm, 9 Nm
-
Remove nut and bolt securing RH front
air spring module to front lower aft link
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Use pry bar to release tension from air spring module to control arm
-
Remove nut and bolt securing LH front
air spring module to front lower aft link
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm
-
Remove the fasteners securing the LH
front lower aft link to the subframe and move the aft link aside
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
-
Remove the fasteners securing the LH
front lower fore link to the subframe and move the fore link aside
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
-
Remove the fasteners securing the RH
front lower aft link to the subframe and move the aft link aside
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
-
Remove the fasteners securing the RH
front lower fore link to the subframe and move the fore link aside
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
-
Remove LH stabar nut from the stabar
and move LH stabar end link away from the bar
Note1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
-
Remove RH stabar nut from the stabar
and move RH stabar end link away from the bar
Note1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
-
Remove the bolt securing the lower
i-shaft to the steering gear and slide the i-shaft up away from the steering gear
Note1x bolt, 13mm, 30 Nm
-
Remove forward bolt securing RH 3-way
valve to subframe bracket
Note1x bolts, T30, 5 Nm
-
Remove the LH stay bar
Note2x bolts, 10mm, 11 Nm
-
Remove the RH stay bar
Note2x bolts, 10mm, 11 Nm
-
Remove nuts holding ABS pump to
subframe and release from rubber grommet
Note2x nuts, 10mm, 9 Nm, 1 rubber grommet
-
Position coolant drain container under
the front of the vehicle to catch vehicle coolant
-
Disconnect FDU inlet hose and plug
both openings
Note1x hose clip, 1x fir tree clip
-
Disconnect the hose from the battery
coolant heater to coolant pump 2 at the rear of the subframe and plug the ends
Note1x hose clamp, 3x fir tree clips, Make sure to remove hose from between steering rack and subframe
-
Move coolant drain container below
right side of FDU
-
Disconnect coolant hose from radiator
inlet and plug the open connections
Note1x hose clip, 1x fir tree clip
-
Remove coolant drain container from
underneath vehicle
-
Remove the fasteners securing the FJB
to FDU HV harness to the FJB
Note4x bolts, T30, 7 Nm, Discard bolts after removal
-
Disconnect AC HV cable from front
junction box
Note1x connector, 2 stage locking connectors
-
Position the powertrain table with the
Model S/Model X subframe adapter installed under the front of the vehicle
-
Connect shop air supply to the
powertrain table
-
Raise the powertrain table and
subframe fixture into position
NoteEnsure the pins are installed into the correct positions on the fixture, Ensure the pins engage the subframe so it is properly supported
-
Remove the bolts that secure the front
subframe to the bumper carrier
Note4x patch bolts, 10mm, 7.5 Nm, Discard after removal
-
Remove the fastener connecting the LH
stabar mount to the body through the subframe
Note1x bolt, 16mm, 80 Nm
-
Remove the fastener connecting the RH
stabar mount to the body through the subframe
Note1x bolt, 16mm, 80 Nm
-
Remove the LH rear bolt securing the
front subframe to the body
Note1x bolt, 18mm, 115 Nm
-
Remove the RH rear bolt securing the
front subframe to the body
Note1x bolt, 18mm, 115 Nm
-
Lower the front subframe, and move the
assembly from under the vehicle
NoteThe powertrain table will need to be tilted with rear side angled down and front side tilted up as the subframe is clearing front end carrier, Take caution not to damage front end carrier
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Remove LH front axle nut and
washer
Note1x nut, 32mm, 245 Nm, Discard after removal
-
Install hub puller onto the LH front
brake rotor
Note5x lug nuts, 21mm, Hand tight
-
Use hub puller to free LH halfshaft
from hub splines
NoteCounter hold hub adapter
-
Remove hub puller from LH hub
assembly
Note5x lug nuts, Hand tight
-
Remove LH halfshaft from LH hub
assembly
NoteAdjust hub puller if further clearance is needed to free shaft from knuckle
-
Install the axle removal tool around
the inner joint of the LH front halfshaft
NoteUse a wire tie to hold the axle removal tool in place
-
Remove LH front halfshaft from the
drive unit and remove from the vehicle
-
Remove axle nut and washer securing RH
drive axle to hub assembly
Note1x nut, 32mm, 245 Nm
-
Install the hub puller onto the RH
front brake rotor
Note5x lug nuts, 21mm, Hand tight
-
Use hub puller to free RH halfshaft
from hub splines
NoteCounter hold hub adapter
-
Remove hub puller from RH hub
assembly
-
Remove RH halfshaft from RH hub
assembly
NoteAdjust hub puller if further clearance is needed to free shaft from knuckle
-
Install the axle removal tool around
the inner joint of the RH front halfshaft
NoteUse a wire tie to hold the axle removal tool in place
-
Remove RH front halfshaft from the
drive unit and remove from the vehicle
-
Position transmission jack fixture
under drive unit
NoteSecure FDU strap
-
Remove bolts from LH FDU mount to
body
Note2x bolts, E14, 65 Nm
-
Remove bolts securing RH FDU mount to
body
Note2x bolts, EP20, 120 Nm
-
Lower front drive unit with jack out
of vehicle
-
Remove the bolts (x4) that attach the
RH side mount onto the front drive unit, and then remove t he mount from the drive
unit.
Installation
-
Install the RH side mount to the front
drive unit, and then install and hand-tighten the bolts (x4) that attach the mount to
drive unit.
-
Fully tighten the bolts (x4) that
attach the RH side mount onto the front drive unit.
-
Raise the FDU into the vehicle
-
Loosely install bolts securing LH FDU
mount to body
Note2x bolts, E14, 65 Nm
-
Raise the FDU until the front fastener
securing RH FDU mount to the body can be installed
NoteVisually inspect holes are aligned
-
Loosely install the front fastener
securing the RH FDU mount to the body
Note1x bolt, EP20, 120 Nm, Torque at later step
-
Install bolt securing rear of RH FDU
mount
Note1x bolt, EP20, 120 Nm
-
Torque bolt securing front of RH FDU
mount to body
Note1x bolt, EP20, 120 Nm
-
Fully secure bolts securing LH FDU
mount to body
Note2x bolts, E14, 65 Nm
-
Lower the FDU stand and underhoist
stand away from the FDU
-
Install LH front halfshaft into the
FDU
NotePosition C-clip opening at the bottom of axle to ease installation, Ensure the axle is fully seated into the drive unit, Straighten axle and apply pressure to opposite end until an audible click is heard when the C-Clip is fully engaged, If an audible click is not heard adjust shaft position and reinstall. For a visual indicator, inspect axle seal clamp is inline with base of FDU LH side mount bolt.
-
Apply Molykote M-77 to outboard side
of LH front halfshaft
NoteClean if necessary, Apply no more than 1 gram to axle only
-
Install LH front halfshaft into hub
and bearing assembly and secure nut and washer hand tight
Note1x nut, 1x washer, 32mm, 245 Nm, Torque at later step. Use the nut without the washer to pull the shaft through hub, Then remove nut and install the washer and nut. Do not use power tools, The risk of stripping the threads is very high.
-
Install RH front halfshaft into the
FDU
NotePosition C-clip opening at the bottom of axle to ease installation, Ensure the axle is fully seated into the drive unit, Straighten axle and apply pressure to opposite end until an audible click is heard when the C-Clip is fully engaged, If an audible click is not heard adjust shaft position and reinstall.
-
Apply Molykote M-77 to outboard side
of RH halfshaft
NoteClean if necessary, Apply no more than 1 gram to axle only
-
Install RH halfshaft into hub and
bearing assembly and secure nut and washer hand tight
Note1x nut, 1x washer, 32mm, 245 Nm, Torque at later step. Use the nut without the washer to pull the shaft through hub, Then remove nut and install the washer and nut. Do not use power tools, The risk of stripping the threads is very high.
-
Position the subframe assembly under
the vehicle for installation
-
Raise the subframe into position to be
installed
NoteThe powertrain table will need to be tilted with rear side angled down and front side tilted up as the subframe is clearing front end carrier, Take caution not to damage front end carrier
-
Install the RH rear bolt securing the
front subframe to the body
Note1x bolt, 18mm, 115 Nm
-
Install the LH rear bolt securing the
front subframe to the body
Note1x bolt, 18mm, 115 Nm
-
Install the fastener connecting the RH
stabar mount to the body through the subframe
Note1x bolt, 16mm, 80 Nm
-
Install the fastener connecting the LH
stabar mount to the body through the subframe
Note1x bolt, 16mm, 80 Nm
-
Install the bolts that secure the
front subframe to the bumper carrier
Note4x patch bolts, 10mm, 7.5 Nm, Install new bolts
-
Lower the powertrain table and remove
it from under the vehicle
-
Disconnect shop air supply from the
powertrain table
-
Connect AC HV cable to front junction
box
Note1x connector, Engage red locking tab
-
Install the fasteners securing the FJB
to FDU HV harness to the FJB
Note4x bolts, T30, 7 Nm, Install new patch bolts
-
Position coolant drain container under
the LH front corner of the vehicle to catch vehicle coolant
-
Remove the plugs and connect FDU inlet
hose
Note1x hose clip, 1x fir tree clip
-
Remove the plugs and connect the hose
from the battery coolant heater to coolant pump 2 at the rear of the subframe
Note1x hose clamp, 3x fir tree clips, Make sure to route hose in between steering rack and subframe
-
Remove plugs and install FDU outlet
hose
Note1x hose clamp, 1x fir tree clip
-
Remove coolant drain container from
underneath vehicle
-
Slide the lower i-shaft onto the
steering gear and install the fastener
Note1x bolt, 13mm, 30 Nm
-
Install nut securing RH stabar end
link to stabar
Note1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
-
Install nut securing LH stabar end
link to stabar
Note1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
-
Move the RH front fore link into the
subframe and install the fastener
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
-
Move the RH front lower aft link into
position and install the fastener
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Ensure the bolt is installed with the bolt head facing the front of the vehicle
-
Move the LH front fore link into the
subframe and install the fastener
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
-
Move the LH front lower aft link into
position and install the fastener
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Ensure the bolt is installed with the bolt head facing the front of the vehicle
-
Install nut and bolt securing LH front
air spring module to front lower aft link
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Torque at later step
-
Install nut and bolt securing RH front
air spring module to front lower aft link
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm
-
Install skid bar to front
subframe
Note4x bolts, 10mm, 10 Nm
-
Install skid plate to front
subframe
Note2x bolts, 10mm, 9 Nm
-
Install bash plate lower
stamping
Note2x bolts, 10mm, 9 Nm
-
Install ABS pump to subframe
Note2x nuts, 10mm, 9 Nm
-
Install LH stay bar
Note2x bolts, 10mm, 11 Nm
-
Install RH stay bar
Note2x bolts, 10mm, 11 Nm
-
Remove HV and LV Rapid Mate
covers
Note2x covers
-
Position HV battery underneath
vehicle
-
Lower vehicle onto HV battery
pack
NoteBefore lowering fully use assistance to align the pack using the alignment rods and guide via the borescope camera or a flexible inspection mirror checking HV and LV rapid mates
-
Install front bolts for HV battery
with power tool
Note4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
-
Install 21mm bolts at front of HV
battery with power tool
Note2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
-
Install outer center bolts with power
tool
Note8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
-
Install LH rocker bolts with power
tool
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
-
Install RH rocker bolts with power
tool
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
-
Torque rocker HV battery bolts on both
sides
Note16x patch bolts, 13mm, 55 Nm
-
Torque remaining HV battery
bolts
Note8x patch bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm
-
Raise vehicle and remove battery
table
NoteRecommend assistance
-
Install inner center HV battery bolts
with power tool
Note4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts
-
Torque the inner center HV battery
bolts
Note4x patch bolts, E12, 38 Nm
-
Install LH ski side covers
Note14x clips, 3x covers
-
Install RH ski side covers
Note14x clips, 3x covers
-
Install front lower bash plate
extrusion
Note2x patch bolts, T30, 16 Nm
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install nut securing LH front tie rod
end to LH front knuckle
Note1x nyloc nut, 21mm, 103 Nm, Install new nut
-
Install nut securing RH front tie rod
end to RH front knuckle
Note1x nyloc nut, 21mm, 103 Nm, Install new nut
-
Install LH front wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Position RH front wheelhouse liner
onto vehicle
Note3x clips, Route HEPA drain hose properly and secure clips
-
Install nuts and bolts securing RH
front wheelhouse liner to vehicle
Note2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
-
Install clips securing RH wheelhouse
liner to vehicle
Note7x clips
-
Install RH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Lower vehicle until tires are touching
ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Torque LH front wheel
Note5x nuts, 21mm, 175 Nm
-
Torque RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Install RH front lug nut covers
Note5x covers
-
Install LH front lug nut covers
Note5x covers
-
Torque LH front axle nut
Note1x nut, 32mm, 245 Nm
-
Torque RH front axle nut
Note1x nut, 32mm, 245 Nm, 1x washer
-
Install RH front wheel center
cap
Note1x cap, Verify emblem is aligned with valve stem
-
Install LH front wheel center
cap
Note1x cap, Verify emblem is aligned with valve stem
-
Secure the ground connection at the
A/C compressor mount bracket
Note1x bolt, T25, 7 Nm
-
Connect the AC compressor logic
connector
Note1x connector
-
Connect coolant reservoir level sensor
Note1x connector
-
Install both AC lines to
compressor
Note2x nuts, 10mm, 10 Nm, Install new O-rings
-
Secure FDU logic connector harness
clip
Note1x clip
-
Connect FDU logic connector
Note1x connector, Red locking tab
-
Install FDU ground strap to FDU
assembly
Note1x bolt, E10, 6 Nm
-
Install 12V battery beam
Note2x bolts, T30, 3.5 Nm, 1x edge clip
-
Secure coolant reservoir hose to 12V
battery beam
Note1x bolt, T30, 5 Nm
-
Position 12V battery bracket assembly
onto battery beam for installation
-
Install fasteners securing 12V battery
bracket to shock tower cross member and the battery beam
Note2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
-
Connect 12V positive terminal
Note1x nut, 10mm, 6 Nm
-
Install 12V positive terminal
cover
-
Install remaining fastener securing RH
3-way valve to subframe
Note1x bolt, T30, 5 Nm
-
Release air suspension pump bracket
and chiller assembly from front end carrier
-
Install the fasteners securing air
suspension pump bracket to subframe
Note2x bolts, 10mm, 5.5 Nm
-
Secure chiller assembly to
subframe
Note3x bolts, 10mm, 5 Nm
-
Connect the logic connectors for the
steering rack
Note2x electrical connectors, 2-way connectors, Engage the grey lock after the connector is fully seated
-
Install logic connector harness clip
to subframe assembly
Note1x fir tree clip
-
Connect steering rack connectors
Note2x connectors, 2 stage locking connectors, Ensure the locking tab is engaged after an audible click is heard when connecting
-
Slide battery pump 2 onto bracket
secured to front subframe
NoteLine up cut out with bracket and slide pump to the left of vehicle
-
Connect First Responder Loop and 12V
negative terminal
Note1x connector, 1x nut, 10mm, 5 Nm, Connect First Responder Loop first
-
Remove steering wheel holder from
vehicle
-
Connect hoses to vehicle and perform
A/C vacuum and leak test
Note(Touch time only)30 minute vacuum, 10 minute leak test. Ensure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports
-
Push wiring harness through underhood
storage unit and seat grommet
Note1x rubber grommet
-
Feed harness grommet through underhood
storage unit and install underhood storage unit
Note1x grommet, Lift the underhood storage unit appropriately to access the grommet
-
Install bolts and clips securing
underhood storage unit
Note2x bolts, 10mm, 7 Nm, 2x push clips
-
Install underhood storage carpet and
reconnect light and release switch connectors
Note2x connectors, Secure edges of carpet underneath underhood storage unit seal
-
Install front underhood apron
Note7x clips
-
Install HEPA filter outlet duct
- Overlap time for A/C vacuum and leak test
-
Perform A/C refrigerant refill
NoteGreen check mark approves, Red X declines, Run time only
-
Select Action 'Stop' , Fluid Fill
Target 'Refrigerant' and press 'Run'
NoteThis stops the fluid Fill/ Drain routine and returns the Thermal system to normal operation
-
Disconnect AC machine hoses from
service ports
Note2x connections, High side (red), low side (blue), Turn knob counter clockwise until fully open, Pull back on AC line lock to release from port
-
Install dust caps onto high-side and
low-side service ports
Note2x caps
-
Install HEPA filter inlet duct
Note2x tabs, One on each side
-
Install clips securing HEPA filter
inlet duct to cowl panel
Note3x push clips
-
Secure drainage hoses to HEPA filter
inlet duct
Note2x hoses
-
Install LH underhood apron
Note9x clips
-
Install RH underhood apron
Note9x clips
-
Test A/C functions in vehicle to
ensure cabin cooling functions as designed
-
Perform A/C hose flush
NoteTouch time only. No overlap from this since the machine is disconnected from the vehicle.
-
Remove coolant reservoir cap
-
Start Fluid Fill/Drain in Toolbox 3
NoteGo to Actions and search for PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain Click 'Fluid Fill/Drain' Under 'Action' select 'Start' Under 'Fluid Fill Target' select 'Coolant' Click 'RUN'
-
Fill the reservoir to the "MAX" line
with the specified coolant while the "Fluid Drain and Fill" routine is running.
NoteCarefully monitor the coolant level while the routine is running, adding coolant as required
-
Stop Fluid Fill/Drain in Toolbox
3
NoteGo to Actions and search for PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drainclick 'Fluid Fill/Drain'. Under 'Action' select 'Stop' Under 'Fluid Fill Target' select 'Coolant' Click 'RUN'
-
Start coolant air purge in Toolbox 3
NoteIn Toolbox 3 go to Actions and search for Coolant Air Purge click PROC_THC_X_COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Actions - Coolant Air Purge and click 'RUN'
-
Fill the reservoir to the "MAX" line
with the specified coolant while the system is purging
NoteCarefully monitor the coolant level while the routine is running, adding coolant as required
-
Install coolant reservoir cap
-
Perform Thermal test in Toolbox
3
NoteIn Toolbox 3, go to Actions and search for PROC_THC_X_THERMAL-TESTSearch for routine in ToolboxThermal System TestThermal / Actions - Thermal Test then click 'Thermal System Test', check 'Precondition' and click 'RUN' and wait for the results
-
Exit Service Mode
NoteControls > Service Mode > Exit Service Mode
-
Disconnect Toolbox from vehicle and
install cubby under MCU
Note1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby
-
Move RH front seat to original
position
-
Install rear underhood apron
Note8x clips
-
Close hood
NotePress firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
-
Close all four doors
-
Verify turn and slip plates are
locked
-
Position vehicle onto 4-post
lift
NoteSet ride height to standard, Position wheel chocks to keep vehicle from rolling
-
Raise the alignment rack and lower
onto locks
NoteSet 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
-
Torque LH air spring module nut and
bolt to LH aft link
Note1x bolt, 21mm, 1x nut, 22mm, 140 Nm
-
Remove existing paint mark from LH air
spring module bolt
NoteClean the area thoroughly so the new marking is not confused with the previous marking
-
Mark LH air spring module bolt to show
component has been torqued
NoteUse a high visibility paint pen when marking components
-
Torque RH air spring module nut and
bolt to RH aft link
Note1x bolt, 21mm, 1x nut, 22mm, 140 Nm
-
Remove the existing paint mark from RH
air spring module
NoteClean the area thoroughly so the new marking is not confused with the previous marking
-
Mark the RH air spring module bolt to
show the component has been torqued
NoteUse a high visibility paint pen when marking components
-
Install front aero shield into
position and hand tighten center bolts
Note2x bolts, 10mm, 4 Nm
-
Install clips securing aero shield to
vehicle
Note10x push clips
-
Install and tighten bolts securing
aero shield to vehicle
Note12x bolts, 10mm, 4 Nm
-
Place mid aero shield for
installation
-
Install bolts securing mid aero shield
to vehicle
Note7x bolts, 10mm, 4 Nm
-
Install clips securing mid aero shield
to vehicle
Note7x push clips
-
Install screws and nut securing RH
shear plate to vehicle
Note1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
-
Install clips securing RH shear plate
to wheel fairing
Note2x push clips
-
Install screws and nut securing LH
shear plate to vehicle
Note1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
-
Install push clips securing LH shear
plate to wheel fairing
Note2x push clips
-
Lower 4-post lift fully
-
Remove wheel chocks
-
Raise all four windows
-
Remove vehicle from 4-post lift
- Review wheel alignment requirements and add correction code as needed