Harness - Lower Dash (RWD) (Remove and Replace)

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

Set up AC machine

Note

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

Open all four doors

Lower all four windows

Open liftgate

Remove cover from outer LH sun visor mount

Note

Take care not to damage the sun visor mounting cover

Remove LH sun visor

Note

1x screw, T20, 2.8 Nm, 1x tab, 1x connector if equipped with lighted visors

Remove LH sun visor center support

Note

1x screw, T15, 2.5 Nm, Release cover and remove screw

Remove rear view mirror lower cover

Note

4x tabs, Pull down at an angle to release the tabs

Disconnect rear view mirror connector

Note

1x connector

Remove rear view mirror

Note

Rotate mirror counterclockwise to release

Remove rear view mirror upper cover

Note

4x clips

Remove cover from outer RH sun visor mount

Note

Take care not to damage the sun visor mounting cover

Remove RH sun visor

Note

1x screw, T20, 2.8 Nm, 1x tab, 1x connector if equipped with lighted visors

Remove RH sun visor center support

Note

1x screw, T15, 2.5 Nm, Release cover and remove screw

Fully lower and extend steering column

Remove LH IP side cover

Note

4x clips, 1x connector

Remove LH middle A-pillar trim

Note

2x clips

Remove LH lower IP trim

Note

1x screw, T20, 2 Nm, 9x clips

Remove LH lower A-pillar trim

Note

4x clips, Number of clips securing trim may vary depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim

Remove RH IP side cover

Note

4x clips, 1x connector

Remove RH middle A-pillar trim

Remove RH instrument panel lower assembly

Note

13x clips

Remove glove box lower trim

Note

6x clips

Remove glove box from IP carrier

Note

6x screws, T20, 2.3 Nm, 3x connectors

Remove RH footwell cover

Note

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

Remove RH lower A-pillar trim

Note

4x clips, The number of clips securing the trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim

Move LH front seat backward

Move RH front seat backward

Open hood

Note

Via Controls > Front Trunk

Remove rear underhood apron

Note

8x clips

Remove RH underhood apron

Note

9x clips

Remove LH underhood apron

Note

9x clips, (*Use this step for Model S Refresh procedures)

Release primary and secondary drain tubes from cabin intake duct assembly

Note

2x hoses

Release cabin intake duct assembly from cowl panel

Note

3x push clips

Remove cabin intake duct assembly

Note

2x tabs, one on each side

Remove HEPA filter outlet duct

Note

Lift up, Pull towards front of vehicle, Then rotate clockwise

Remove caps from low side and high side refrigerant service ports

Note

2x caps

Connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3

Note

1x connector, 2x clips, Newer models will access connector below MCU with cubby removed, Older models will access port at LH side of IP with end cap removedOpen Toolbox 3 website and establish connection to vehicle, 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

Note

After vehicle has been put into "Service Mode", hold down the brake pedal, while holding down brake 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 5400" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information

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

Connect A/C machine hoses to refrigerant service ports in vehicle

Note

Blue hose to the low-side port, Red hose to the high-side port, Use the coupler for this refrigerant type, Do not mix R-134a and R-1234yf fittings, After the couplers are seated open both hose valves

Perform refrigerant system recovery

Note

Note or print the amount of refrigerant and oil recovered, If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart toolbox article 353700

Position wheel chocks at LH rear wheel

Place vehicle into "Tow Mode"

Note

Via Controls > ''Service''

Power off vehicle from center display

Note

Via Controls > Safety > Power Off

Disconnect 12V battery negative terminal and First Responder Loop

Note

1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components

Remove LH shock tower cover

Note

4x push clips

Remove RH shock tower cover

Note

4x push clips

Remove LH side wiper arm

Note

1x nut, 17mm, 31 Nm

Remove RH side wiper arm

Note

1x nut, 17mm, 31 Nm

Release cowl screen from body

Note

4x push clips

Release cowl screen from windshield

Note

The cowl screen sits along the windshield, lift the corners of the cowl and lift the middle of the assembly to full remove the cowl screen from the vehicle

Lift cowl screen past pedestrian protection actuators

Remove cowl screen from vehicle

Note

Carefully flex the cowl screen to clear the hood strut and be sure not to scratch the under hood or fender

Remove wiper motor

Note

3x bolts, 10mm, 6 Nm, 1x connector, 1x clip, Turn the wiper module counter clockwise while removing, Keep your fingers away from any potential pinch points and moving parts while connecting and installing the wiper module, Do not attempt to test the module until it is fully installed in the vehicle

Remove fuse box cover

Note

2x tabs, Push tabs inwards to release and remove fuse box cover

Remove 12V supply cable to DCDC

Note

1x nyloc nut, 13mm, 12 Nm, 1x clip, Discard nyloc nut

Release clips securing 12V battery supply cable to fuse box and strut tower cross beam

Note

3x clips

Disconnect pyrotechnic fuse connector

Note

1x connector, Gently lift up orange lock tab to release connector

Remove bolts securing fuse box to body

Note

2x bolts, 10mm, 6 Nm

Release fuse box from body

Note

2x tabs, Slide fuse box to RH side to release tabs, then lift

Disconnect remaining connectors from bottom of fuse box

Note

3x connectors, Depress locking tabs on sides of flip-type connector and flip lever on connector to reseal

Remove clip securing harness to LH shock tower brace

Remove LH air suspension reservoir bracket from LH shock brace

Note

2x bolts, 10mm, 6 Nm

Remove LH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Remove AC line bracket bolt on RH shock brace

Note

1x bolt, 10mm, 6 Nm

Remove air reservoir bracket mounting bolts from RH shock brace

Note

2x bolts, 10mm, 6 Nm

Remove RH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Remove screws securing air suspension reservoir to bracket

Note

2x screws, T25, 2.5 Nm

Set air suspension reservoir aside for access

Note

Maneuver below AC line

Remove fasteners securing TXV to evaporator

Note

2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Disconnect A/C hoses and TXV from HVAC unit

Note

Gently pull the lines away from the bulkhead/ HVAC box, be sure to retain the O-rings at the TXV

Open second row cup holder

Remove second row cup holder trim panel

Note

3x tabs, Slide panel straight up to remove

Remove RH center console panel

Note

22x clips, Replace any damaged or missing clips

Remove LH center console panel

Note

22x clips, Replace any damaged or missing clips

Remove rear center console vent

Note

2x connectors, 4x tabs, Pull vent straight out, gently release locking tabs for USB connectors and slide out

Close cup holder

Remove rear panel from console

Note

6x clips, 3x connectors

Remove bolts securing rear of console to body

Note

2x bolts, 10mm, 7 Nm

Remove LH side console closeout panel

Note

6x clips, Pull side panel back and slide closeout panel down behind side panel

Remove bolt securing LH front of console to IP

Note

1x bolt, 10mm, 7 Nm

Remove RH side console closeout panel

Note

6x clips

Disconnect 2 USB connectors and release from console trim

Note

2x connectors, 2x fir tree clips, RH front of console

Release clip securing connector and disconnect 12V harness connector

Note

1x connector, 1x clip, RH front of console, on backside of panel

Open console sliding door

Remove console floor panel

Remove bolts securing middle of console to body

Note

2x bolts, 10mm, 3 Nm

Remove center console from vehicle

Note

Lift rear of console up, pull backwards and lift up and remove from vehicle, Recommend assistance

Remove screw securing LH side of top pad

Note

1x screw, T20, 1 Nm

Remove LH upper A-pillar trim panel

Note

1x screw with washer, 7mm, 2 Nm, 1x connector, 2x locating tabs, 1x clip

Remove lower binnacle cover from IP area of vehicle

Note

4x clips

Remove screws securing top pad at binnacle area

Note

2x screws, T20, 1 Nm

Remove screw securing RH side of top pad

Note

1x screw, T20, 1 Nm

Remove RH upper A-pillar trim panel

Note

1x screw, 7mm, 2 Nm, 1x connector

Disconnect connectors from RH side of DAS ECU

Note

7x connectors, DAS 2.0 has 4x connectors

Remove fasteners securing DAS ECU to cross car beam

Note

4x nuts, 8mm, 5 Nm, Discard after removal

Disconnect connectors from LH side of Autopilot ECU and remove from vehicle

Note

7x connectors

Disconnect passenger airbag connectors

Note

2x connectors, Release locking tab

Remove passenger airbag mounting bolts

Note

2x bolts, 10mm, 10 Nm

Cover aluminum strip on top pad and MCU bezel with tape for protection

Release top pad at leading edge, from drivers outer finisher to inner finisher

Note

8x clips

Release RH side of top pad working from right to left

Note

9x clips, Use caution to not crease aluminum trim when lifting top pad

Release MCU ground strap

Note

1x tab

Release remaining clips, remove top pad from vehicle, and place onto protective surface

Note

6x clips, Recommend assistance

Remove defrost mesh grille assembly

Note

10x clips

Remove screws securing RH IP finisher

Note

2x screws, T20, 2 Nm

Release clips for RH IP finisher and remove from vehicle

Note

4x clips

Release clips securing steering gap hider to IC bezel

Note

2x clips

Remove instrument cluster bezel

Note

4x screws, T20, 2 Nm, Remove screws securing instrument cluster bezel to IP carrier and remove bezel

Remove screws securing LH inner IP finisher with vent to IP carrier

Note

2x screws, T20, 2 Nm, raise top pad with airbag tool if additional access is needed

Release clips securing LH inner IP finisher with vent to IP carrier and remove from vehicle

Note

3x clips

Install screws securing LH inner IP finisher with vent to IP carrier

Note

2x screws, T20, 1 Nm

Remove LH outer IP finisher from IP carrier

Note

2x clips

Release fasteners securing driver's airbag to steering wheel

Note

2x screws, T30, 7 Nm, The screws will remain inside the steering wheel, If required rotate the steering wheel to gain access to screws, Afterwards return steering wheel to straight and center position

Remove driver's airbag

Note

3x connectors, disconnect the airbag and steering wheel controls

Remove steering wheel center bolt

Note

1x patch bolt, 10mm allen, 80 Nm, Discard after removal

Mark steering wheel

Note

Position the wheels straight ahead and mark the steering wheel relative position to the column

Remove steering wheel

Tape clock spring cassette to prevent rotation

Note

Do not rotate the clockspring

Release SCCM from steering column

Note

Rock SCCM back and forth to release from column

Remove SCCM

Note

1x connector, Remove black locking tab then depress connector release tab to release connector, Locking tab is one time use discard after removal

Remove LH footwell cover

Note

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

Remove LH side knee airbag cover

Note

2x bolts, 10mm, 10 Nm

Disconnect steering column motor connectors

Note

2x connectors

Mark steering column relative position to lower shaft joint

Remove bolt securing lower shaft to steering column

Note

1x bolt, 13mm, 30 Nm

Release steering column from lower shaft

Note

Slide joint down lower shaft

Remove fasteners securing steering column to cross car beam

Note

2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm

Remove steering column from vehicle

Remove fasteners securing instrument cluster to IP carrier

Note

4x screws, T20, 2 Nm

Disconnect electrical connectors from rear of instrument cluster and remove from IP carrier

Note

3x connectors, tilt the IC away from the IP carrier to access connections, Take care not to put excessive strain on the wiring and connectors to the IC (1x chime connector pulls straight out, 1x flip lock type connector, 1x coaxial connector, release tab is on the underside of the connector), After removal place the IC on ESD safe surface

Remove MCU mounting screws

Note

4x screw, T25, 4.5 Nm, Note locations of washers if present

Tilt MCU out from IP carrier at top in order to access connectors

Note

Caution: Do not pull on harnesses as it can damage the connectors

Disconnect all electrical connections from MCU

Note

13x connectors, Gently tilt the top of the MCU/touch screen for access, recommend assistance. All connectors are equipped with locking tabs that must be depressed prior to disconnect, Avoid putting excessive tension on the connectors and wiring harness during removal, (number of connectors may vary depending on vehicle configuration and MCU part number revision)

Release clips securing tweeter harnesses to IP carrier near LH and RH A-pillars

Note

2x clips

Remove clips securing dash harness to IP carrier

Note

2x clips

Remove fasteners securing IP carrier to cross car beam

Note

15x screws, T20, 2 Nm

Pull IP carrier forward for better access for speaker and edge clip removal

Note

Take care to avoid stressing the connectors to the dash speakers and avoid damaging components in the process of moving the IP carrier forward for better access to edge clips and connections

Remove RH side dash speaker

Note

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

Remove center dash speaker

Note

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

Remove LH dash speaker

Note

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

Remove IP carrier from vehicle

Note

Recommend assistance, Lift up air duct from HVAC assembly, 1x center dash speaker tape to duct

Disconnect headliner harness at LH A-pillar and release from vehicle

Note

3x connectors, 1x clip

Remove cross car beam harness connectors at LH lower A-pillar

Note

7x connectors, Only release connectors that run to the harness on the cross car beam

Disconnect cross car beam harness connectors at RH lower A-pillar

Note

7x connectors, Only release connectors that run to the harness on the cross car beam

Remove fasteners securing cross car beam to HVAC assembly

Note

3x bolts, 10mm, 10 Nm

Remove fasteners securing cross car beam to vehicle

Note

7x bolts, 13mm, 27 Nm

Remove cross car beam from vehicle

Note

Recommend assistance, Exercise caution when removing the cross car beam, the brake switch is attached to the cross car beam and is susceptible to failure

Release bottom portion of LH lower C-pillar trim

Note

2x clips,Take care not to damage, Release the lower portion for access, Replace any damaged or missing clips

Remove fasteners securing LH lower B-pillar trim

Note

2x screws, T25, 2 Nm

Remove LH lower B-pillar trim

Note

6x plastic clips to body, 2x metal clips to upper B-pillar, Replace any damaged or missing clips, Lift the trim to clear the seat and pre-tensioner

Remove LH upper B-pillar trim and move it aside

Note

2x metal clips, 1x tab, First pull the lower part toward inside the vehicle to release clips, once released pull the trim downwards

Release bottom portion of RH lower C-pillar trim

Note

2x clips, Take care not to damage, Release the lower portion for access, Replace any damaged or missing clips

Remove fasteners securing RH lower B-pillar trim

Note

2x screws, T25, 2 Nm

Remove RH lower B-pillar trim

Note

6x plastic clips to body, 2x metal clips to upper B-pillar, Replace any damaged or missing clips

Remove RH upper B-pillar trim and move it aside

Note

2x metal clips, First pull the lower part toward inside the vehicle to release clips, once released pull the trim downwards

Disconnect thermal controller

Note

4x connectors, 1x edge clip

Remove AC hoses from vehicle

Release vacuum from AC lines

Note

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

Remove fasteners securing TXV to evaporator

Note

2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Disconnect A/C hoses and TXV from HVAC unit

Note

Gently pull the lines away from the bulkhead/ HVAC box, be sure to retain the O-rings at the TXV

Disconnect HVAC blower assembly and RKE connector and release harness clip

Note

2x connectors, 2x edge clips

Remove fasteners securing HVAC assembly to body

Note

5x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm

Release HVAC drain hose from HVAC assembly

Note

1x hose connection, Place a shop towel underneath the drain hose prior to disconnecting

Disconnect sensor from RH lower air duct on HVAC assembly

Note

1x connector

Remove fasteners securing RH lower air duct to HVAC assembly

Note

2x screws, PH2, 1 Nm

Remove RH lower air duct from HVAC assembly

Note

Lower left slide of duct and slide out to the left to release from HVAC assembly

Remove the fasteners securing the HVAC assembly cross brace

Note

2x screws, PH2, 1 Nm

Remove HVAC assembly cross brace

Note

Gently push brace to the left to release from HVAC box on RH side, Pull the brace towards the rear for the vehicle then side out to the right to release from HVAC assembly

Remove fasteners securing PTC heater to HVAC assembly

Note

3x screws, PH2, 1 Nm

Remove PTC heater from HVAC assembly

Note

Slide PTC heater out to the left while taking care not to strain the HV cables, Gently move the PTC heater and HV cables behind the HVAC assembly so it can be removed from the vehicle, Take necessary measures to protect the PTC heater and its cables so it can be easily moved out of the way during main body harness replacement as needed

Remove HVAC assembly from vehicle

Note

Recommend assistance

Remove parcel shelf

Remove LH middle C-pillar trim

Note

1x screw, T25, 3 Nm, 4x clips

Remove LH C-pillar upper trim

Note

4x clips

Remove bolt securing headliner and support strap at LH C-pillar

Note

1x bolt, 8mm, 10 Nm

Remove RH middle C pillar trim

Note

1x screw, T25, 3 Nm

Remove RH upper C-pillar trim

Note

4x clips

Remove bolt securing headliner and support strap at RH C-pillar

Note

1x bolt, 8mm, 10 Nm

Release headliner at front of vehicle

Note

6x clips

Release headliner at LH side of vehicle above B-pillar area

Note

1x clip, Recommend looking at reflection of clip in roof glass and using pick tool to release

Release headliner at RH side of vehicle above B-pillar area

Note

1x clip, Recommend looking at reflection of clip in roof glass and using pick tool to release

Fold 2nd row seatbacks down

Release rear headliner clips and lower headliner.

Note

5x clips, 3x velcro strips, Take care not to damage other components. Recommend Assistance

Disconnect the LH curtain airbag

Note

2x clips, 1x locking airbag connector, Lower the LH rear corner of the headliner for access, Take care not to crease the headliner

Disconnect the impact sensor harness connector on LH B-pillar assembly

Note

1x connector, Depress the locking tab and pull the male side of the connector away from the sensor

Disconnect LH seatbelt pretensioner

Note

2x connectors, Release locking tab

Release harness clips at B pillar

Note

3x clips

Remove LH exterior B-pillar finisher

Note

2x tabs

Remove screws securing LH B-pillar applique

Note

2x bolts, T25, 5 Nm

Release B-pillar seals from applique and body along length of applique

Pry LH applique away from body starting at the bottom

Note

2 strips of double-sided tape securing applique to body

Pull down to release LH applique from upper clips

Note

Use caution as camera harness does not have much slack

Remove LH B-pillar applique

Note

1x connector, Hold LH applique away from body and disconnect camera harness connector, then remove applique

Release the harness clips at the B pillar

Note

5x clips

Disconnect the connector tucked into the B pillar opening

Note

1x connector

Release the harness clips along the LH sill panel

Note

3x clips

Remove the ground bolt at the LH lower A pillar

Note

1x bolt, 10mm, 9 Nm

Remove the fasteners securing the main harness carrier at the LH lower A pillar

Note

2x nuts, 10mm, 5 Nm, Discard after removal

Release the A pillar harness connectors from the main harness connectors on the main harness carrier at the LH lower A pillar

Note

2x connectors, 1x clip

Remove the RH side footwell cover exposing the body control module and sunroof control module

Note

8x bolts, 10mm, 5 Nm, 1x edge clip

Disconnect harness from the sunroof control unit at the LH footwell

Note

2x connectors

Disconnect connectors from BCM and remove

Note

9x connnectors, The BCM may need to be tilted and moved into different postitons in order to access and disconnect all connectors

Remove BCM bracket with BCM and sunroof ECU

Note

The BCM with bracket will need to be moved at different angles to clear the surrounding components

Release the barrel clips securing the main harness in the LH side of the bulkhead

Note

4x barrel clips

Remove rubber protective cover above air suspension ECU

Remove the connectors securing the lower dash harness to the motor bay harness

Note

5x connectors

Disconnect RCM and move connectors aside

Note

2x connectors, Disconnect by pressing on the lock tab while pivoting the catch release, The connector will move toward you, When an audible click is heard, the catch release is fully disengaged, Disconnect the rearward connector first

Disconnect adaptive air suspension ECU

Note

3x connectors

Lift up the harness connectors and remove the air suspension ECU from the vehicle

Disconnect the brake switch and accelerator connector

Note

2x connectors

Remove the clips securing the brake and accelerator harness to the body

Note

2x edge clips, 1x fir tree clip

Disconnect the main harness connectors at the upper A pillar

Note

1x connector, windshield defrost, 1x connector, to headliner harness

Remove the RH A pillar ground connection

Note

1x bolt, 10mm, 9 Nm

Disconnect main harness connectors from the RH A pillar cabin fuse box

Note

5x connectors

Release lower RH A pillar Connector bracket from in cabin fuse box

Note

2x tabs, slide the bracket towards the rear of the vehicle to release

Release the front trunk connectors from the RH lower A pillar connector carrier

Note

5x connectors, Release locking tabs and pull connectors straight out of the carrier, Locking tab to carrier is on the inboard side of the connector carrier

Remove the main harness from the vehicle

Note

Take care not to damage surrounding components while removing the harness from the vehicle, This is a good time to compare to the new harness provided to ensure parts received are compatible with the vehicle

Place new main (lower dash) harness in vehicle and lay harness out to its general installation orientation inside the vehicle

Note

Recommend assistance, Take care not to damage any connectors while routing harness and moving around inside the vehicle

Install the front harness connectors into the connector carrier at the lower RH A pillar

Note

5x connectors, Ensure connectors are fully seated and lock into the connector carrier

Secure RH Lower A pillar connector carrier bracket to cabin fuse box

Note

2x tabs, Slide carrier on to tabs, Confirm the carrier is secured to the cabin fuse box

Reconnect all main harness connections at the in cabin fuse box

Note

5x connectors

Secure main harness RH A pillar ground

Note

1x bolt, 10mm, 9 Nm

Secure connections at RH Upper A pillar

Note

1x connector, to headliner harness, 1x connector, to windshield defrost, 2x clips

Connect brake switch and accelerator pedal

Note

2x connector, Ensure locking tab is disengaged prior to making connection and then engaged after fully seating connector

Secure the clips securing the brake and accelerator harness to the body

Note

2x edge clip, 1x fir tree clip

Secure main harness clips at the LH side of the bulkhead

Note

2x square clips, 2x barrel clips

Re-secure connections at PSRCM

Note

2x connectors, Engage connector then flip locking tab to fully seat connector

Lift up the Harness connectors and place the air suspension ECU into the vehicle

Note

1x control module

Connect air suspension ECU

Note

3x connectors

Connect 5 connectors securing the lower dash harness to the motor bay harness

Note

5x connectors

Install rubber protective cover above the Air suspension ECU

Place the BCM and and sunroof ECU into the BCM bracket then place the assembly into the vehicle for installation

Note

The BCM with bracket will need to be moved at different angles to clear the surrounding components

Secure connectors to BCM

Note

9x connnectors, The BCM may need to be tilted and moved into different postitons in order to access and connect all connectors

Connect harness to sunroof control unit at the LH footwell

Note

2x connectors

Install RH side footwell cover

Note

8x bolts, 10mm, 5 Nm, 1x edge clip

Place HVAC assembly back into vehicle for installation

Note

Recommend assistance, Move all loose harness connections out of the way to prevent damage while re-installing the HVAC assembly in the vehicle

Route PTC heater to HVAC assembly for installation and slide into HVAC assembly

Install fasteners securing PTC heater to HVAC assembly

Note

3x screws, PH2, 1 Nm

Position HVAC assembly cross brace for installation to HVAC assembly

Install fasteners securing HVAC assembly cross brace to HVAC assembly

Note

2x screws, PH2, 1 Nm

Position HVAC assembly RH lower air duct for installation

Install fasteners securing RH lower air duct to HVAC assembly

Note

2x screws, PH2, 1 Nm

Connect sensor for RH lower air duct on HVAC assembly

Note

1x connector

Move HVAC assembly into position for installation and secure drain hose

Note

1x hose connection

Install fasteners securing HVAC assembly to body

Note

5x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm

Connect HVAC blower assembly and RKE, and secure harness clip

Note

2x connectors, 2x edge clips

Connect thermal controller

Note

4x connectors, 1x edge clip

Connect A/C Lines with TXV to evaporator at bulkhead

Note

2x bolts, T30, 6 Nm, Install new O-rings prior to installation

Place air suspension reservoir into position

Loosely install air suspension reservoir brackets

Note

2x screws, T25, 2.5 Nm

Install LH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Install air suspension reservoir bracket mounting fasteners to LH shock brace

Note

2x bolts, 10mm, 6 Nm

Clip wire harness to LH shock brace

Note

1x fir tree clip

Install RH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Install air suspension reservoir bracket mounting fasteners to RH shock brace

Note

2x bolts, 10mm, 6 Nm

Install AC line bracket bolt on RH shock brace

Note

1x bolt, 10mm, 6 Nm

Secure air suspension reservoir brackets

Note

2x screws, T25, 2.5 Nm

Position fuse box onto body

Note

2x tabs, Slide the fuse box to LH to attach the tabs into crossbar

Install bolts securing fuse box to body

Note

2x bolts, 10mm, 6 Nm

Reconnect pyrotechnic fuse connector

Note

1x connector, Be sure to secure locking clip

Secure clips holding 12V battery supply cable to fuse box and strut tower beam

Note

3x clips

Install DCDC 12V supply cable to fuse box

Note

1x nyloc nut, 13mm, 12 Nm, Install new nyloc nut

Install fuse box cover

Note

2x clips

Install wiper motor

Note

3x bolts, 10mm, 6 Nm, 1x connector, 1x clip, Turn wiper module clockwise while installing, Keep your fingers away from any potential pinch points and moving parts while connecting and installing the wiper module, Do not attempt to test the module until it is fully installed in the vehicle

Position cowl screen into vehicle

Note

Carefully flex the cowl screen to clear the hood strut and be sure not to scratch the under hood or fender

Install LH side wiper arm

Note

1x nut, 17mm, 31 Nm

Install RH side wiper arm

Note

1x nut, 17mm, 31 Nm

Install cowl screen to windshield

Note

The cowl assembly sits along the windshield, line up the corners of the cowl up along where a A-pillars meet with the fenders and seat the cowl screen assembly properly in the groves around the windshield

Install cowl screen to body

Note

4x push clips

Install LH shock tower cover

Note

4x push clips

Install RH shock tower cover

Note

4x push clips

Install wiper arms

Note

2x nuts, 17mm, 31 Nm, Line up wipers to reference marks on windshield

Connect A pillar harness connectors to main harness connectors at LH lower A pillar harness carrier

Note

2x connectors, 1x clip

Install the fasteners securing the LH lower A pillar main harness connector carrier to the LH lower A pillar

Note

2x nuts, 10mm, 5 Nm, Install new nyloc nuts

Secure the main harness ground to the LH Lower A pillar

Note

1x bolt, 10mm, 9 Nm

Install the harness clips along the LH front sill panel

Note

3x clips

Connect the main harness to the pyrotechnic at the LH seatbelt pretensioner

Note

1x connector

Connect the main harness to the harness inside the LH B pillar

Note

1x connector, 1x clip, after securing connector tuck harness inside of B pillar and secure with harness clip

Route the B pillar camera portion of the harness inside the B pillar

Note

1x connector

Clean LH B-pillar area with IPA wipe and allow to dry

Note

Remove any remaining adhesive

Install new double sided tape to the LH B-pillar applique

Note

2x strips, Remove any remaining residue before adhering tape to applique

Peel backing from double sided tape on LH B-pillar applique

Connect camera and install LH side applique

Note

1x connector, Slide applique up into clips and secure

Reinstall screws securing LH side applique

Note

2x screws, T25, 5 Nm

Reinstall cover over bottom of LH B-pillar applique

Note

2x tabs, Make sure all clips are fully seated

Secure main harness clips at LH lower portion of B pillar

Note

3x clips

Connect LH lap belt pre tensioner pyrotechnic

Note

1x connector

Connect LH B pillar impact sensor

Note

1x connector, secure locking tab

Route the curtain airbag portion of the main harness up the C-pillar and behind the headliner and connect curtain airbag

Note

1x connector, 1x fir tree clip, 1x edge clip, Ensure harness is routed behind the deployment path of the curtain airbag

Install LH upper B-pillar trim

Note

2x metal clips, Ensure locating tab at top of B-pillar is aligned to the opening in the body, Replace any broken or missing clips prior to installation

Install LH lower B-pillar trim

Note

6x plastic clips, 2x metal clips, Replace any broken or missing clips prior to installation

Install fasteners securing LH lower B-pillar trim

Note

2x screws, T25, 2 Nm

Install RH upper B-pillar trim

Note

2x metal clips, Ensure locating tab at top of B-pillar is aligned to the opening in the body, Replace any broken or missing clips prior to installation

Install RH lower B-pillar trim

Note

6x plastic clips, 2x metal clips, Replace any broken or missing clips prior to installation

Install fasteners securing RH lower B-pillar trim

Note

2x screws, T25, 2 Nm

Position cross car beam into vehicle for installation

Note

Recommend assistance, Exercise caution when installing the cross car beam, the brake switch is attached to the cross car beam and is susceptible to failure, Take care not to damage any surrounding components while placing the cross car beam into the vehicle

Install fasteners securing cross car beam to HVAC assembly

Note

3x bolts, 10mm, 10 Nm

Install fasteners securing cross car beam to vehicle

Note

7x bolts, 13mm, 27 Nm

Connect headliner harness at LH A-pillar

Note

3x connectors, 1x clip

Connect cross car beam harness connectors at LH lower A-pillar

Note

7x connectors, (2x coaxial brown and white at tuner)(2x coaxial blue)(1x coaxial purple)(2x connectors gray), Connectors at tuner are routed through amp and tuner bracket

Connect cross car beam harness to main harness connectors at RH lower A-pillar

Note

7x connectors

Install IP carrier into vehicle

Note

Recommend assistance

Install center dash speaker

Note

2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers

Install RH dash speaker

Note

2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers

Install LH dash speaker

Note

2x screws, T20, 2 Nm, 1x connector, Pull the IP carrier forward for better access for speakers

Install fasteners securing IP carrier to cross car beam

Note

15x screws, T20, 2 Nm,

Secure harness clips to IP carrier

Note

2x clips

Place steering column into vehicle for installation

Install fasteners securing steering column to cross car beam

Note

2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm

Connect harness connectors for steering column motors

Note

2x connectors

Connect steering column to lower steering shaft joint

Note

Slide joint up onto lower shaft, Ensure that the previously indexed paint marks align between the lower steering column and shaft joint

Install bolt securing lower shaft to steering column

Note

1x bolt, 13mm, 30 Nm

Install LH side knee airbag cover

Note

2x bolts, 10mm, 10 Nm

Install LH footwell cover

Note

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

Position SCCM to steering column

Note

1x connector, Install new retaining clip

Install SCCM onto steering column

Note

Gently jiggle the SCCM while pressing it onto the column if needed

Remove tape previously applied to clock spring

Note

Do not rotate the clockspring

Position steering wheel to column

Note

Ensure the position of the steering wheel matches the index marks previously made on the column and the wheel

Secure steering wheel

Note

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

Position driver's airbag

Note

3x connectors

Install driver's airbag

Torque driver's airbag fasteners

Note

2x screws, T30, 7 Nm

Connect Instrument cluster and place IC into position for installation

Note

3x connectors, 2x alignment dowels

Install fasteners that secure instrument cluster to IP carrier

Note

4x screws, T20, 2 Nm

Position MCU into vehicle for installation

Connect harness connectors to MCU

Note

17x connectors, Number of connectors may vary depending on vehicle configuration and MCU part number revision

Install bolts securing MCU to IP carrier

Note

4x screws, T25, 4.5 Nm

Install RH IP finisher assembly and fasteners

Note

2x screws, T20, 2 Nm, 6x clips

Position LH inner IP finisher in vehicle and secure clips

Note

3x clips

Install LH outer IP finisher trim assembly

Note

2x clips, 3x screws, T20, 2.3 Nm, Ensure vent ducting is properly aligned to vent during installation

Install IC bezel and fasteners to IP carrier

Note

4x screws, T20, 2 Nm

Install IC bezel and fasteners to IP carrier

Note

4x screws, T20, 2 Nm

Install clips securing steering column gap hider to IC bezel

Note

2x clips, Replace any damaged or missing clips prior to installation

Install LH lower IP trim

Note

1x screw, T20, 2 Nm, 9x clips, Replace any damaged or missing clips prior to installation

Install defrost mesh grille to IP carrier

Note

10x clips, Replace any damaged or missing clips prior to installation

Set top pad in place and connect ground strap

Note

1x tab, Recommend assistance

Install passenger airbag connectors

Note

2x connectors, Engage locking tabs

Install passenger airbag connectors

Note

2x connectors, Engage locking tabs

Remove protective tape from aluminum trim

Fully seat top pad

Note

23x clips, Make sure all clips are aligned and securely fastened

Install airbag mounting bolts

Note

2x bolts, 10mm, 10 Nm

Position DAS ECU for installation and secure LH side ECU connectors

Note

7x connectors, DAS 2.5 has 6x connectors

Connect RH side DAS ECU connectors

Note

7x connectors, DAS 2.0 has 4x connectors, Connector "A" must be plugged in before connector "B" when reinstalling DAS ECU, If equipped with DAS ECU

Install fasteners securing Autopilot ECU

Note

4x nuts, 8mm, 5 Nm, Install new nuts

Place center console into vehicle

Note

Recommend assistance

Connect 2 USB connectors of console

Note

3x connectors, 1x clip

Install bolts securing center console to vehicle

Note

6x bolts, 10mm, 7 Nm, 1x screw,

Install rubber floor mat at base of console

Reinstall cup holder inserts

Note

If equipped

Install RH center console closeout extension

Note

12x clips

Install LH console closeout extension

Note

12x clips

Secure the center console side trim panels LH & RH

Note

22x clips per side

Install RH footwell cover

Note

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

Connect USB module at rear console panel

Note

3x connectors

Install center console back panel

Note

6x clips

Open rear cup holder

Install second row cup holder trim panel

Note

3x tabs, slide panel straight downwards to install

Close rear cup holder

Install USB ports into rear air outlet

Install center console rear air outlet

Note

2x USB connections, 4x tabs

Connect First Responder Loop and 12V battery negative terminal

Note

1x connector, 1x nut, 10mm, 5 Nm, Connect First Responder Loop first

Remove vehicle from Tow Mode

Remove wheel chocks from LH rear wheel

Reconnect AC hoses to vehicle

Perform system vacuum and refrigerant refill

Note

Select 20 mins of Vacuum, Recharge refrigerant to car's specs, add oil quantity as needed, select both HP and LP for charging

Remove AC hoses from vehicle

Install caps onto AC ports

Note

2x caps

Move LH front seat backward

Move LH front seat forward

Move LH front seat to original position

Install LH lower A-pillar trim

Note

4x clips, Number of clips securing A-pillar sill trim may vary depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim

Install LH middle A-pillar trim

Install LH IP side cover

Note

4x clips, 1x connector

Move RH front seat backward

Move RH front seat forward

Move RH front seat to original position

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

Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:

Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain

via Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain

via Toolbox:(link)

Run ODIN routine PROC_THC_X_THERMAL-TESTvia Service Mode:Thermal ➜ Actions ➜ Thermal Testvia Toolbox:(link)

Install RH lower A-pillar trim

Note

4x clips, The number of clips securing the a pillar sill trim varies depending on vehicle production date, Replace any damaged or missing clips prior to re-installing sill trim