25/03/2024 17:25:14

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.
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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Removal

This procedure is for vehicles built after April 24, 2019. For vehicles built through April 24, 2019, see Mount - Front Drive Unit - RH (1st Generation) (Remove and Replace).
  1. Verify there is no abnormal tire wear per Courtesy Inspection
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    Note
    SC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment
  2. Set up A/C machine and perform hose flush
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    Note
    Touch time only
  3. Open all four doors
  4. Lower all four windows
  5. Raise and support vehicle
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    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
  6. Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3
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    Note
    1x 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
  7. Unlock vehicle Gateway
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    Note
    After 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
  8. Select ‘Actions’ tab and search for ‘PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain
  9. Select Action 'Start' , Fluid Fill Target 'Refrigerant' and press 'Run'
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    Note
    Check the Routine's Notes before pressing Run, Verify successfully ''Passed'
  10. Wait to see that the routine 'Passed' successfully
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    Note
    Now the system is ready for Fill / Drain
  11. Install steering wheel lock to ensure proper placement of the steering wheel
  12. Move RH front seat fully forward
  13. Open hood
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    Note
    Via Controls > Front Trunk
  14. Remove rear underhood apron
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    Note
    8x clips
  15. Remove RH underhood apron
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    Note
    9x clips
  16. Remove LH underhood apron
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    Note
    9x clips
  17. Remove front underhood apron
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    Note
    7x clips
  18. Release drainage hoses from HEPA filter inlet duct
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    Note
    2x hoses
  19. Remove clips securing HEPA filter inlet duct to cowl panel
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    Note
    3x push clips
  20. Remove HEPA filter inlet duct
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    Note
    2x clips on HEPA filter
  21. Remove HEPA filter outlet duct from vehicle
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    Note
    Lift up, pull towards front of vehicle, then rotate clockwise
  22. Remove dust caps from high-side and low-side service ports
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    Note
    2x caps
  23. Connect hoses to vehicle and perform A/C recovery
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    Note
    Touch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports
  24. Disconnect light and release switch connectors and remove underhood storage carpet
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    Note
    2x connectors, Release edge of carpet from underneath underhood storage unit seal
  25. Remove bolts and clips securing underhood storage unit
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    Note
    2x bolts, 10mm, 7 Nm, 2x push clips
  26. Push wiring harness grommet through underhood storage unit and remove underhood storage unit
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    Note
    1x grommet, Lift the underhood storage unit appropriately to access the grommet
  27. Power off vehicle via UI
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    Note
    Via Controls > Safety > Power Off
  28. Disconnect 12V negative terminal and First Responder Loop
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    Note
    1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
  29. Remove 2nd row seat bottom cushion
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    Note
    2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
  30. Remove NVH padding from underneath 2nd row seat cushion
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    Note
    If equipped
  31. Remove bolts securing seat bottom frame
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    Note
    8x bolts, 11mm, 26 Nm
  32. Lift up and support seat bottom frame
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    Note
    8x clips
  33. Remove tamper evident label from charger cover panel
  34. Remove all items from pockets and ensure not wearing metal items
  35. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  36. Put on HV insulating gloves and leather over gloves
  37. Release HV charger access panel cover
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    Note
    11x bolts, T20, 2 Nm, Discard after removal
  38. Release tabs and open both access doors
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    Note
    4x tabs, Make sure to wear proper PPE
  39. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Measure 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
  40. Secure HV charger access panel cover
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    Note
    11x bolts, T20, 2 Nm, Install new patch bolts
  41. Remove HV insulating gloves
  42. Install new warranty label onto charger cover panel
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    Note
    Wipe charger with IPA prior to installation, Allow 1 minute for IPA to dry
  43. Lower seat frame into position and secure harness clips to frame
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    Note
    8x clips
  44. Install and torque bolts securing seat frame to vehicle
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    Note
    8x bolts, 11mm, 26 Nm
  45. Place NVH padding onto seat frame
  46. Install seat bottom cushion
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    Note
    2x clips, 7x connectors if equipped, Replace clips if necessary
  47. Remove A/C lines from vehicle
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    Note
    Press clear lines once lines have been removed
  48. Release chiller assembly from front subframe
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    Note
    3x bolts, 10mm, 5 Nm
  49. Slide battery pump 2 off of the bracket secured to subframe
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    Note
    Slide pump to the right of vehicle for removal
  50. Disconnect steering rack connectors
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    Note
    2x connectors, 2 stage locking connectors, Disengage the red locking tab before disconnecting
  51. Disconnect the logic connectors for the steering rack
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    Note
    2x electrical connectors, 2-way connectors, slide the grey lock out, then depress the lock to disconnect
  52. Release logic connector harness from subframe
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    Note
    1x fir tree clip
  53. Remove the fasteners securing air suspension pump bracket to subframe
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    Note
    2x bolts, 10mm, 5.5 Nm
  54. Secure air suspension pump bracket and chiller assembly to front end carrier
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    Note
    Use bungee cord or something similar to hold assemblies in general position
  55. Remove accessible bolt on RH 3-way valve
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    Note
    1x bolt, T30, 5 Nm, Remaining bolt will be removed at later step
  56. Remove 12V positive terminal cover
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    Note
    2x tabs
  57. Disconnect 12V positive terminal
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    Note
    1x nut, 10mm, 6 Nm
  58. Remove fasteners securing 12V battery bracket to shock tower cross member and the battery beam
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    Note
    2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
  59. Remove 12V battery bracket assembly
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    Note
    2x clips
  60. Remove fastener securing coolant hose to battery beam
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    Note
    1x bolt, T30, 5 Nm
  61. Remove fasteners securing the battery beam to the LH and RH body beams
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    Note
    2x bolts, T30, 3.5 Nm, 1x edge clip
  62. Remove the battery beam
  63. Disconnect coolant reservoir level sensor
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    Note
    1x connector
  64. Disconnect AC compressor logic connector
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    Note
    1x connector
  65. Release ground connection at the A/C compressor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 7 Nm
  66. Remove AC lines from compressor
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    Note
    2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  67. Release ground strap from front drive unit
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    Note
    1x bolt, E10, 6 Nm
  68. Disconnect logic connector from front drive unit
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    Note
    1x connector with lock tab
  69. Remove lug nut covers from LH front wheel
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    Note
    5x covers
  70. Remove lug nut covers from RH front wheel
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    Note
    5x covers
  71. Remove RH front wheel center cap
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    Note
    1x cap
  72. Remove LH front wheel center cap
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    Note
    1x cap
  73. Loosen LH front axle nut
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    Note
    1x nut, 32mm, 245 Nm
  74. Loosen RH front axle nut
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    Note
    1x nut, 32mm, 245 Nm
  75. Loosen RH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  76. Loosen LH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  77. Raise vehicle partially and lower onto locks
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    Note
    Set 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
  78. Remove LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  79. Remove LH tie rod nut and move tie rod end away
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    Note
    1x Nyloc nut, 21mm, 103 Nm, Discard after removal
  80. Remove RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  81. Remove RH tie rod nut and move tie rod end away
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    Note
    1x Nyloc nut, 21mm, 103 Nm, Discard after removal
  82. Remove nuts and bolts securing RH front wheel arch liner
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    Note
    2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
  83. Remove clips securing RH front wheel arch liner
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    Note
    7x push clips
  84. Release clips and remove RH front wheel arch liner from vehicle
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    Note
    3x clips
  85. Raise vehicle fully and lower lift onto locks
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    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
  86. Remove clips securing LH shear plate to wheel fairing
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    Note
    2x push clips
  87. Remove LH shear plate
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    Note
    2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
  88. Remove clips securing RH shear plate to wheel fairing
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    Note
    2x push clips
  89. Remove RH shear plate
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    Note
    2x clips, 1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
  90. Remove bolts securing mid aero shield to vehicle
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    Note
    7x bolts, 10mm, 4 Nm
  91. Remove clips securing mid aero shield to vehicle
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    Note
    7x push clips
  92. Remove mid aero shield from vehicle
  93. Remove front bash plate extrusion
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    Note
    2x bolts, T30, 16 Nm
  94. Remove LH ski side covers
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    Note
    14x push clips, 3x covers
  95. Remove RH ski side covers
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    Note
    14x push clips, 3x covers
  96. Remove four center bolts securing HV battery
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    Note
    4x patch bolts, E12, 38 Nm, Discard after removal
  97. Position battery table beneath vehicle
  98. Lower vehicle to table
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    Note
    Recommend assistance, Align table to vehicle and raise casters to level table if necessary
  99. Remove remaining eight center bolts securing HV battery
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    Note
    8x patch bolts, E12, 38 Nm, Discard after removal
  100. Remove front four HV battery bolts
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    Note
    4x patch bolts, 13mm, 30 Nm, Discard after removal
  101. Remove 21mm bolts securing front of HV battery
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    Note
    2x bolts, 21mm, 115 Nm, Discard after removal
  102. Remove LH rocker bolts
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal
  103. Remove RH rocker bolts
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    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal
  104. Raise vehicle off HV battery
  105. Move battery away from vehicle
  106. Remove all items from pockets and ensure not wearing metal items
  107. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  108. Put on HV insulating gloves and leather over gloves
  109. Verify no high voltage at HV rapid mate
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  110. Install HV and LV Rapid Mate covers
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    Note
    2x covers, If covers not available then use masking tape to protect Rapid Mate from debris
  111. Remove HV insulating gloves
  112. Remove clips securing front aero shield to vehicle
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    Note
    10x push clips
  113. Remove bolts securing front aero shield to vehicle and remove
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    Note
    12x bolts, 10mm, 4 Nm
  114. Remove skid bar from front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 10 Nm
  115. Remove the bolts securing the bash plate stamping and skid plate to the front subframe skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  116. Remove skid plate from front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  117. Remove nut and bolt securing RH front air spring module to front lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Use pry bar to release tension from air spring module to control arm
  118. Remove nut and bolt securing LH front air spring module to front lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm
  119. Remove the fasteners securing the LH front lower aft link to the subframe and move the aft link aside
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    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
  120. Remove the fasteners securing the LH front lower fore link to the subframe and move the fore link aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
  121. Remove the fasteners securing the RH front lower aft link to the subframe and move the aft link aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
  122. Remove the fasteners securing the RH front lower fore link to the subframe and move the fore link aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Index the location of the eccentric with a paint marker
  123. Remove LH stabar nut from the stabar and move LH stabar end link away from the bar
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    Note
    1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
  124. Remove RH stabar nut from the stabar and move RH stabar end link away from the bar
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    Note
    1x nyloc nut, 15mm, 70 Nm, Counter hold stud with 5mm hex socket and use wrench to remove nut, Discard after removal
  125. Remove the bolt securing the lower i-shaft to the steering gear and slide the i-shaft up away from the steering gear
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 30 Nm
  126. Remove forward bolt securing RH 3-way valve to subframe bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolts, T30, 5 Nm
  127. Remove the LH stay bar
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 11 Nm
  128. Remove the RH stay bar
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 11 Nm
  129. Remove nuts holding ABS pump to subframe and release from rubber grommet
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    Note
    2x nuts, 10mm, 9 Nm, 1 rubber grommet
  130. Position coolant drain container under the front of the vehicle to catch vehicle coolant
  131. Disconnect FDU inlet hose and plug both openings
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    Note
    1x hose clip, 1x fir tree clip
  132. Disconnect the hose from the battery coolant heater to coolant pump 2 at the rear of the subframe and plug the ends
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    Note
    1x hose clamp, 3x fir tree clips, Make sure to remove hose from between steering rack and subframe
  133. Move coolant drain container below right side of FDU
  134. Disconnect coolant hose from radiator inlet and plug the open connections
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    Note
    1x hose clip, 1x fir tree clip
  135. Remove coolant drain container from underneath vehicle
  136. Remove the fasteners securing the FJB to FDU HV harness to the FJB
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    Note
    4x bolts, T30, 7 Nm, Discard bolts after removal
  137. Disconnect AC HV cable from front junction box
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    Note
    1x connector, 2 stage locking connectors
  138. Position the powertrain table with the Model S/Model X subframe adapter installed under the front of the vehicle
  139. Connect shop air supply to the powertrain table
  140. Raise the powertrain table and subframe fixture into position
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    Note
    Ensure the pins are installed into the correct positions on the fixture, Ensure the pins engage the subframe so it is properly supported
  141. Remove the bolts that secure the front subframe to the bumper carrier
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    Note
    4x patch bolts, 10mm, 7.5 Nm, Discard after removal
  142. Remove the fastener connecting the LH stabar mount to the body through the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 80 Nm
  143. Remove the fastener connecting the RH stabar mount to the body through the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 80 Nm
  144. Remove the LH rear bolt securing the front subframe to the body
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    Note
    1x bolt, 18mm, 115 Nm
  145. Remove the RH rear bolt securing the front subframe to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 115 Nm
  146. Lower the front subframe, and move the assembly from under the vehicle
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    Note
    The 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
  147. Lower vehicle partially and set lift onto locks
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  148. Remove LH front axle nut and washer
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm, Discard after removal
  149. Install hub puller onto the LH front brake rotor
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    Note
    5x lug nuts, 21mm, Hand tight
  150. Use hub puller to free LH halfshaft from hub splines
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    Note
    Counter hold hub adapter
  151. Remove hub puller from LH hub assembly
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    Note
    5x lug nuts, Hand tight
  152. Remove LH halfshaft from LH hub assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust hub puller if further clearance is needed to free shaft from knuckle
  153. Install the axle removal tool around the inner joint of the LH front halfshaft
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a wire tie to hold the axle removal tool in place
  154. Remove LH front halfshaft from the drive unit and remove from the vehicle
  155. Remove axle nut and washer securing RH drive axle to hub assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm
  156. Install the hub puller onto the RH front brake rotor
    Informational PurposesAn informational icon, calling your attention
    Note
    5x lug nuts, 21mm, Hand tight
  157. Use hub puller to free RH halfshaft from hub splines
    Informational PurposesAn informational icon, calling your attention
    Note
    Counter hold hub adapter
  158. Remove hub puller from RH hub assembly
  159. Remove RH halfshaft from RH hub assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust hub puller if further clearance is needed to free shaft from knuckle
  160. Install the axle removal tool around the inner joint of the RH front halfshaft
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a wire tie to hold the axle removal tool in place
  161. Remove RH front halfshaft from the drive unit and remove from the vehicle
  162. Position transmission jack fixture under drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure FDU strap
  163. Remove bolts from LH FDU mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E14, 65 Nm
  164. Remove bolts securing RH FDU mount to body
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    Note
    2x bolts, EP20, 120 Nm
  165. Lower front drive unit with jack out of vehicle
  166. 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

  1. 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.
  2. Fully tighten the bolts (x4) that attach the RH side mount onto the front drive unit.
    60 Nm (44.2 lbs-ft) +50 degrees
  3. Raise the FDU into the vehicle
  4. Loosely install bolts securing LH FDU mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E14, 65 Nm
  5. Raise the FDU until the front fastener securing RH FDU mount to the body can be installed
    Informational PurposesAn informational icon, calling your attention
    Note
    Visually inspect holes are aligned
  6. Loosely install the front fastener securing the RH FDU mount to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP20, 120 Nm, Torque at later step
  7. Install bolt securing rear of RH FDU mount
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP20, 120 Nm
  8. Torque bolt securing front of RH FDU mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP20, 120 Nm
  9. Fully secure bolts securing LH FDU mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E14, 65 Nm
  10. Lower the FDU stand and underhoist stand away from the FDU
  11. Install LH front halfshaft into the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    Position 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.
  12. Apply Molykote M-77 to outboard side of LH front halfshaft
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary, Apply no more than 1 gram to axle only
  13. Install LH front halfshaft into hub and bearing assembly and secure nut and washer hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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.
  14. Install RH front halfshaft into the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    Position 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.
  15. Apply Molykote M-77 to outboard side of RH halfshaft
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary, Apply no more than 1 gram to axle only
  16. Install RH halfshaft into hub and bearing assembly and secure nut and washer hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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.
  17. Position the subframe assembly under the vehicle for installation
  18. Raise the subframe into position to be installed
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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
  19. Install the RH rear bolt securing the front subframe to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 115 Nm
  20. Install the LH rear bolt securing the front subframe to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 115 Nm
  21. Install the fastener connecting the RH stabar mount to the body through the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 80 Nm
  22. Install the fastener connecting the LH stabar mount to the body through the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 80 Nm
  23. Install the bolts that secure the front subframe to the bumper carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 10mm, 7.5 Nm, Install new bolts
  24. Lower the powertrain table and remove it from under the vehicle
  25. Disconnect shop air supply from the powertrain table
  26. Connect AC HV cable to front junction box
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage red locking tab
  27. Install the fasteners securing the FJB to FDU HV harness to the FJB
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, T30, 7 Nm, Install new patch bolts
  28. Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
  29. Remove the plugs and connect FDU inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clip, 1x fir tree clip
  30. Remove the plugs and connect the hose from the battery coolant heater to coolant pump 2 at the rear of the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clamp, 3x fir tree clips, Make sure to route hose in between steering rack and subframe
  31. Remove plugs and install FDU outlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clamp, 1x fir tree clip
  32. Remove coolant drain container from underneath vehicle
  33. Slide the lower i-shaft onto the steering gear and install the fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 30 Nm
  34. Install nut securing RH stabar end link to stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
  35. Install nut securing LH stabar end link to stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket
  36. Move the RH front fore link into the subframe and install the fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
  37. Move the RH front lower aft link into position and install the fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  38. Move the LH front fore link into the subframe and install the fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm, Leave fastener hand tight, will be torqued during alignment, Properly align the paint marks
  39. Move the LH front lower aft link into position and install the fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  40. Install nut and bolt securing LH front air spring module to front lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Torque at later step
  41. Install nut and bolt securing RH front air spring module to front lower aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm
  42. Install skid bar to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 10 Nm
  43. Install skid plate to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  44. Install bash plate lower stamping
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  45. Install ABS pump to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 9 Nm
  46. Install LH stay bar
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 11 Nm
  47. Install RH stay bar
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 11 Nm
  48. Remove HV and LV Rapid Mate covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  49. Position HV battery underneath vehicle
  50. Lower vehicle onto HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Before 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
  51. Install front bolts for HV battery with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
  52. Install 21mm bolts at front of HV battery with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
  53. Install outer center bolts with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
  54. Install LH rocker bolts with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
  55. Install RH rocker bolts with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
  56. Torque rocker HV battery bolts on both sides
    Informational PurposesAn informational icon, calling your attention
    Note
    16x patch bolts, 13mm, 55 Nm
  57. Torque remaining HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm
  58. Raise vehicle and remove battery table
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  59. Install inner center HV battery bolts with power tool
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts
  60. Torque the inner center HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x patch bolts, E12, 38 Nm
  61. Install LH ski side covers
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, 3x covers
  62. Install RH ski side covers
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, 3x covers
  63. Install front lower bash plate extrusion
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, T30, 16 Nm
  64. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  65. Install nut securing LH front tie rod end to LH front knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 21mm, 103 Nm, Install new nut
  66. Install nut securing RH front tie rod end to RH front knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 21mm, 103 Nm, Install new nut
  67. Install LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  68. Position RH front wheelhouse liner onto vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Route HEPA drain hose properly and secure clips
  69. Install nuts and bolts securing RH front wheelhouse liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 4 Nm, 3x bolts, 10mm, 4 Nm
  70. Install clips securing RH wheelhouse liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  71. Install RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  72. Lower vehicle until tires are touching ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  73. Torque LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  74. Torque RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  75. Install RH front lug nut covers
    Informational PurposesAn informational icon, calling your attention
    Note
    5x covers
  76. Install LH front lug nut covers
    Informational PurposesAn informational icon, calling your attention
    Note
    5x covers
  77. Torque LH front axle nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm
  78. Torque RH front axle nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm, 1x washer
  79. Install RH front wheel center cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Verify emblem is aligned with valve stem
  80. Install LH front wheel center cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Verify emblem is aligned with valve stem
  81. Secure the ground connection at the A/C compressor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 7 Nm
  82. Connect the AC compressor logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  83. Connect coolant reservoir level sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  84. Install both AC lines to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 10 Nm, Install new O-rings
  85. Secure FDU logic connector harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  86. Connect FDU logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Red locking tab
  87. Install FDU ground strap to FDU assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E10, 6 Nm
  88. Install 12V battery beam
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 3.5 Nm, 1x edge clip
  89. Secure coolant reservoir hose to 12V battery beam
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 5 Nm
  90. Position 12V battery bracket assembly onto battery beam for installation
  91. Install fasteners securing 12V battery bracket to shock tower cross member and the battery beam
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
  92. Connect 12V positive terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm
  93. Install 12V positive terminal cover
  94. Install remaining fastener securing RH 3-way valve to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 5 Nm
  95. Release air suspension pump bracket and chiller assembly from front end carrier
  96. Install the fasteners securing air suspension pump bracket to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5.5 Nm
  97. Secure chiller assembly to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 5 Nm
  98. Connect the logic connectors for the steering rack
    Informational PurposesAn informational icon, calling your attention
    Note
    2x electrical connectors, 2-way connectors, Engage the grey lock after the connector is fully seated
  99. Install logic connector harness clip to subframe assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  100. Connect steering rack connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, 2 stage locking connectors, Ensure the locking tab is engaged after an audible click is heard when connecting
  101. Slide battery pump 2 onto bracket secured to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Line up cut out with bracket and slide pump to the left of vehicle
  102. Connect First Responder Loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x nut, 10mm, 5 Nm, Connect First Responder Loop first
  103. Remove steering wheel holder from vehicle
  104. Connect hoses to vehicle and perform A/C vacuum and leak test
    Informational PurposesAn informational icon, calling your attention
    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
  105. Push wiring harness through underhood storage unit and seat grommet
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rubber grommet
  106. Feed harness grommet through underhood storage unit and install underhood storage unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x grommet, Lift the underhood storage unit appropriately to access the grommet
  107. Install bolts and clips securing underhood storage unit
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 7 Nm, 2x push clips
  108. Install underhood storage carpet and reconnect light and release switch connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure edges of carpet underneath underhood storage unit seal
  109. Install front underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  110. Install HEPA filter outlet duct
  111. Overlap time for A/C vacuum and leak test
  112. Perform A/C refrigerant refill
    Informational PurposesAn informational icon, calling your attention
    Note
    Green check mark approves, Red X declines, Run time only
  113. Select Action 'Stop' , Fluid Fill Target 'Refrigerant' and press 'Run'
    Informational PurposesAn informational icon, calling your attention
    Note
    This stops the fluid Fill/ Drain routine and returns the Thermal system to normal operation
  114. Disconnect AC machine hoses from service ports
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connections, High side (red), low side (blue), Turn knob counter clockwise until fully open, Pull back on AC line lock to release from port
  115. Install dust caps onto high-side and low-side service ports
    Informational PurposesAn informational icon, calling your attention
    Note
    2x caps
  116. Install HEPA filter inlet duct
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, One on each side
  117. Install clips securing HEPA filter inlet duct to cowl panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  118. Secure drainage hoses to HEPA filter inlet duct
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hoses
  119. Install LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips
  120. Install RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips
  121. Test A/C functions in vehicle to ensure cabin cooling functions as designed
  122. Perform A/C hose flush
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only. No overlap from this since the machine is disconnected from the vehicle.
  123. Remove coolant reservoir cap
  124. Start Fluid Fill/Drain in Toolbox 3
    Informational PurposesAn informational icon, calling your attention
    Note
    Go 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'
  125. Fill the reservoir to the "MAX" line with the specified coolant while the "Fluid Drain and Fill" routine is running.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully monitor the coolant level while the routine is running, adding coolant as required
  126. Stop Fluid Fill/Drain in Toolbox 3
    Informational PurposesAn informational icon, calling your attention
    Note
    Go 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'
  127. Start coolant air purge in Toolbox 3
    Informational PurposesAn informational icon, calling your attention
    Note
    In 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'
  128. Fill the reservoir to the "MAX" line with the specified coolant while the system is purging
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully monitor the coolant level while the routine is running, adding coolant as required
  129. Install coolant reservoir cap
  130. Perform Thermal test in Toolbox 3
    Informational PurposesAn informational icon, calling your attention
    Note
    In 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
  131. Exit Service Mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Service Mode > Exit Service Mode
  132. Disconnect Toolbox from vehicle and install cubby under MCU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby
  133. Move RH front seat to original position
  134. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  135. Close hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  136. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
  137. Close all four doors
  138. Verify turn and slip plates are locked
  139. Position vehicle onto 4-post lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Set ride height to standard, Position wheel chocks to keep vehicle from rolling
  140. Raise the alignment rack and lower onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  141. Torque LH air spring module nut and bolt to LH aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 140 Nm
  142. Remove existing paint mark from LH air spring module bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking
  143. Mark LH air spring module bolt to show component has been torqued
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a high visibility paint pen when marking components
  144. Torque RH air spring module nut and bolt to RH aft link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 22mm, 140 Nm
  145. Remove the existing paint mark from RH air spring module
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking
  146. Mark the RH air spring module bolt to show the component has been torqued
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a high visibility paint pen when marking components
  147. Install front aero shield into position and hand tighten center bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 4 Nm
  148. Install clips securing aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    10x push clips
  149. Install and tighten bolts securing aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    12x bolts, 10mm, 4 Nm
  150. Place mid aero shield for installation
  151. Install bolts securing mid aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 4 Nm
  152. Install clips securing mid aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x push clips
  153. Install screws and nut securing RH shear plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
  154. Install clips securing RH shear plate to wheel fairing
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  155. Install screws and nut securing LH shear plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Install new nut
  156. Install push clips securing LH shear plate to wheel fairing
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  157. Lower 4-post lift fully
  158. Remove wheel chocks
  159. Raise all four windows
  160. Remove vehicle from 4-post lift
  161. Review wheel alignment requirements and add correction code as needed