07/08/2024 06:32:51

DCDC Converter - 2nd Generation (Retrofit)

Correction Code 44200306

  • 2024-08-07: Updated instructions for cable markings.
  • 2024-04-11: Clarified flat-rate billing for this retrofit.
  • 2024-03-07: Added note and photos about 2nd Generation logic harness with 1st Generation DCDC converter.
  • 2023-09-20: Added steps to move the vehicle to a 2-post lift.
  • 2023-06-27: Added Cautions and Tips to prevent swapping of the FJB logic connector (X040) and the DCDC logic connector (X041).
  • 2023-06-07: Revised step 29 of section "Retrofit the Forward Junction Box" to use the existing vehicle ground harness, and added part number to the "parts required" table.

This procedure retrofits a Model S vehicle equipped with a 1st Generation DCDC Converter to have a 2nd Generation DCDC Converter and a 1st Generation Forward Junction Box.

Important: This is a flat-rate retrofit, in that the customer is billed for the service as a phantom part, 1525217-00-A, which is inclusive of all parts consumed and all labor provided for this procedure. When adding the phantom part to the service visit, apply the Customer Pay paytype. When adding the consumed parts and labor to the service visit, apply the Customer Pre-paid paytype.
Informational PurposesAn informational icon, calling your attention
Note
Some vehicles may have a 1st Generation DCDC Converter, yet are built with a 2nd Generation logic harness. For these vehicles, an additional 2nd Generation to 1st Generation logic jumper harness (1030144-00-A) has been pre-installed, and a second connector with an HVIL jumper is taped to the logic harness under the cabin fuse box 1. For the retrofit of these vehicles, remove the 2nd Generation to 1st Generation jumper harness altogether, remove the HVIL jumper from the second connector, and route the second connector to the distribution box. Additionally, a 5A fuse may have been pre-installed into location 26 of the cabin fuse box 1. Refer to Toolbox article 166400 for additional information.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1020566-00-E BATT MAN LIFT TABLE - MDLS
Tesla 1026526-00-C HV Battery Alignment Rods
Tesla 10558696-00-A Wiper Arm Removal Tool
Tesla 1065660-00-A ESD FOAM CONTAINER FOR MEDIA CONTROL UNIT

Parts required for this procedure.

Part Number Description Qty
1008293-00-A Mini Blade fuse 5amp 1
1485782-00-B Retrofit jumper harness 1
1015872-00-A Fasteners for FJB lid and DCDC mounting brackets 13
1028676-00-D DCDC upper bracket 1
1028665-00-B/C DCDC Assy 1
1033107-00-A DCDC lower bracket 1
1038174-00-A M6 Riv nut 5
1004341-00-B DCDC/FJB Mounting fasteners 6
1028843-0* FJB 1
1030582-00-D/E HV Cables 1
1030935-01-C FJB Lid assy 1
1129025-00-A Frunk support bracket fasteners 4
1028540-00-A HOSE (BATT), HEATER TO BATTERY ASSY, MS 1
1028549-00-C HOSE (BATT) BATT TO 4WVLV ASSY, MS 1
1028527-00-B HOSE (BATT), PUMP TO DCDC ASSY, MS 1
1032273-00-B Replacement 12v Positive battery cable 1
1028546-00-B HOSE (BATT), DCDC TO HEATER, MS 1
1028688-00-F BATT HTR BRKT,MDL S 1
1006381-00-A Supporting fasteners for new DCDC bracket 2
1037324-99-A Ground fastener 1
1009513-00-C Washer 1
1009514-00-C Washer 1
1037760-00-A 12v Positive fastener 1
1009510-00-C Washer 1
1009511-00-C Washer 1
1008722-00-A Front battery bolts (13mm) 4
1004383-00-C Side battery bolts (13mm) 16
1009778-00-C Center battery bolts (E12) 12
1037743-00-A Front battery bolts (21mm) 2
2007059-00-B Shear plate nuts (Nyloc) 2
1005897-00-G New underhood extension 1
1016261-00-B Frunk carpet extrusion supports 2
1007325-00-E New frunk carpet (Shorter) 1
1507923-00-A LH frunk support bracket 1
1507924-00-A HH frunk support bracket 1
1487265-00-A HV cable retrofit bracket 1
1028635-00-C Frunk support beam 1
1017532-00-C Ground cable for junction box (or alternative) 1
1118500-00-A M8 Riv nut for FJB ground cable 1
1120017-00-A FJB ground bolt (13mm) 1
1032804-00-A ASY,HARN,20A HV 2P+HVL KEY D,3MMSQ,KET 1
1009210-00-A SCR M6-1X16 HEX W/WSHR SEM ST BK ZNC PAT 4
* Use the part number applicable for your region.
Informational PurposesAn informational icon, calling your attention
Note
These part numbers were current at the time of publication. Use the revisions listed or later, unless otherwise specified in the Parts Catalog.

Preparation

  1. Move the vehicle to a 2-post lift. See Raise Vehicle - 2 Post Lift.
  2. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Install) .
  3. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  4. Remove the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace) .
  5. Remove cowl screen panel. See Panel - Cowl Screen (Remove and Replace) .
  6. Remove the particulate filter. See Filter - Particulate (Remove and Replace) .
  7. Remove the bolts (x2) that attach the particulate filter housing to the body, and then remove the housing from the vehicle.
  8. Remove the RH wrapped panel assembly. See Assembly - Panel - Wrapped - LH (Remove and Replace) .
  9. Remove the center console RH closeout extension assembly. See Assembly - Closeout Extension - LH - Center Console (Remove and Replace) .
  10. Remove the passenger footwell cover assembly. See Assembly - Cover - Footwell - Passenger's (Remove and Replace) .
  11. Remove the bolts (x4) that attach the footwell bracket cover to the body, and then remove the cover from the vehicle.
  12. Remove the glove box. See Glove Box (Remove and Replace) .
  13. Remove the top pad. See Assembly - Top Pad - Instrument Panel (Remove and Install) .
  14. Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
  15. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
  16. Using Toolbox 3:
    1. Select the Actions tab and search for "Fluid fill drain"
    2. Select the ODIN routine PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain, click on the link of the routine, and then select "Fluid Fill/Drain".
    3. Under "Action", select "Start".
    4. In "Fluid Fill Target", select "Coolant".
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Ensure that the charge cable is not connected before continuing to the next step in this procedure.
    5. Click RUN, and allow the routine to complete.
  17. Disconnect 12V power. See Disconnect 12V Power .
  18. Remove the Media Control Unit. See Media Control Unit (Remove and Install) .
  19. Remove the LH and RH shock tower braces. See Shock Tower Brace - LH (Remove and Replace) .
  20. Remove the wiper motor assembly. See Wiper Module (Remove and Replace) .
  21. Remove the front RH wheel. See Wheel Assembly (Remove and Install) .
  22. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  23. Lower the vehicle.
  24. Move a coolant drain to under the chiller.
  25. Disconnect the chiller LH coolant hose from the chiller and allow to drain.
  26. Connect shop compressed air to the cooling system pressure tester.
  27. Adjust the cooling system pressure tester regulator for 5 psi.
  28. Remove the coolant reservoir cap and install the reservoir adapter onto the reservoir.
  29. Insert the cooling system pressure tester hose into the reservoir adapter.
  30. Clamp the chiller LH coolant hose.
  31. Slowly open the valve on the cooling system pressure tester and drain coolant from the chiller.
  32. After coolant flow has slowed to a drip, close the valve.
  33. Remove the clamp from the chiller LH coolant hose, and then clamp the chiller RH coolant hose.
  34. Slowly open the valve on the cooling system pressure tester to drain coolant from the chiller LH coolant hose, and after coolant flow has slowed to a drip, close the valve.
  35. Remove the clamp from the chiller RH coolant hose, and connect the chiller LH coolant hose to the chiller.
  36. Remove the cooling system pressure tester from the reservoir adapter, and then remove the adapter from the reservoir.
  37. Raise the vehicle.
  38. Remove the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install) .
  39. Remove the RH front wheel arch liner louver. See Louver - Wheel Arch Liner - Front - LH (Remove and Replace) .
  40. Remove the RH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace) .
  41. Remove the DCDC converter. See DCDC Converter (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the DCDC converter.

Retrofit the DCDC Converter

  1. Release the clips (x4) that attach the DCDC converter HV harness to wheel well.
  2. Release the clip that attaches the RH rocker coolant hose to the body.
  3. Route the DCDC converter HV harness to the other side of the RH rocker coolant hose.
  4. Release the clip that attaches the DCDC converter HV harness to the 12V battery enclosure.
  5. Lower the vehicle.
  6. Remove the bolts (x6) that attach the HV junction box cover to the HV junction box, and then remove the cover from the box.
    Informational PurposesAn informational icon, calling your attention
    Note
    Parts number for the bolts: 1048910-00-C.
  7. Remove and discard the bolts (x2) that attach the DCDC converter HV harness to the HV junction box, and then remove the harness from the box.
    Informational PurposesAn informational icon, calling your attention
    Note
    Parts number for the bolts: 1006809-00-A.
  8. Fold back the carpet at the RH C-pillar trim to expose the DCDC converter HV harness body grommet.
  9. Use a plastic pry tool to push the DCDC converter HV harness body grommet into the RH rocker.
  10. Move the rest of the DCDC converter HV harness into the RH rocker, and out of the rocker at the front of the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the HV harness.
  11. Release the clip that attaches the coolant hose to the RH subframe brace.
  12. Remove the coolant hose from the battery coolant pump 1.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the coolant hose.
  13. Remove the nuts (x4) that attach the particulate filter rear housing to the body, and remove the housing from the body.
  14. Remove the 12V auxiliary battery. See Battery - Auxiliary - 12V (Remove and Replace) .
  15. Raise the vehicle.
  16. Remove the bolts (x2) that attach the frunk extension support bracket to the body, and then remove the bracket from the vehicle.
  17. Remove the electric battery heater. See Coolant Heater - Electric - Battery - 1st Generation (Remove and Replace) .
  18. Remove the bolts (x4) that attach the electric battery heater bracket onto the electric battery heater, and then remove the bracket from the heater.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the heater bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Parts number for the bolts: 1005817-00-A.
  19. Release the clamp and remove the RapidMate to 4-way valve coolant hose from the RapidMate.
  20. Release the clamp and remove the RapidMate to 4-way valve coolant hose from the 4-way valve.
  21. Release the clips (x4) that attach the RapidMate to 4-way valve coolant hose to the body, and remove the hose from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the coolant hose.
  22. Release the clamp and remove the RapidMate to electric battery heater hose from the RapidMate.
  23. Disconnect the electrical harness from the temperature sensor connector, and then release the clips (x4) that attach the RapidMate to electric battery heater hose to the body, and remove the hose from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the coolant hose.
  24. Remove the coolant drain from under the vehicle.
  25. Lower the vehicle.
  26. Remove the nuts (x4) that attach the bulkhead grommet plate to the bulkhead, and then remove the plate from the bulkhead.
  27. Remove sufficient electrical tape at the bulkhead grommet to permit additional wires.
  28. Route the DCDC converter jumper harness along the original DCDC converter logic harness, from the RH front wheel well to the bulkhead grommet.
  29. Connect the DCDC converter jumper harness to the DCDC converter logic harness.
  30. Tape the DCDC converter jumper harness to DCDC converter logic harness along its length.
    Informational PurposesAn informational icon, calling your attention
    Note
    Work from the connection to the bulkhead grommet.
  31. Slide the red and blue wires of the DCDC converter jumper harness into the grommet, and follow with the rest of the harness, to take up slack.
  32. Move the DCDC converter jumper harness into the vehicle interior.
  33. Inside of the vehicle, route the DCDC converter jumper harness along the interior harness to the thermal controller.
  34. Disconnect connector X052 from the thermal controller connector.
  35. Release the terminal lock on connector X052.
  36. Fully insert the red wire into cavity 12.
  37. Fully insert the blue wire into cavity 2.
  38. Fasten the terminal lock on connector X052, and then perform a push-pull-push test of both wires.
  39. Wrap electrical tape to attach the DCDC converter jumper harness to the thermal controller harness.
  40. Connect connector X052 to the thermal controller connector, and then perform a push-pull-push test of the connector.
  41. Tape the DCDC converter jumper harness to the interior harness along its length.
  42. Apply electrical tape around the bulkhead grommet to protect the harnesses.
  43. Install the bulkhead grommet plate to the bulkhead, and then install the nuts (x4) that attach the plate to the bulkhead (torque 5 Nm).
  44. Release the tabs (x2), and then remove the lid from cabin fuse box 1.
  45. Remove the bolts (x2) that attach the cabin fuse box 1 to the fuse box bracket, and then remove the fuse box from the bracket.
  46. Use a small flat-blade screwdriver to separate the terminal lock plate from the cabin fuse box 1.
  47. Locate the cavity for fuse 26.
  48. Insert the red and white wire of the DCDC converter jumper harness into the cavity for fuse 26.
  49. Press the terminal lock plate into the cabin fuse box 1, and perform a push-pull-push test of the red and white wire.
  50. Install a 5 amp fuse into the location for fuse 26.
  51. Wrap electrical tape to attach the DCDC converter jumper harness to the cabin fuse box 1 harness.
  52. Install the cabin fuse box 1 onto the fuse box bracket, and then install the bolts (x2) that attach the fuse box from the bracket (torque 6 Nm).
  53. Install the lid onto the cabin fuse box 1, and then fasten the tabs to attach the lid to the box.
  54. Remove the body ground terminal nut from the RH front frame rail.
  55. Route the DCDC converter jumper harness ground lead along the vehicle harness to the body ground terminal stud.
  56. Install the nut to attach the DCDC converter jumper harness ground lead to the body ground terminal stud (torque 9 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Parts number for the nut: 1013805-00-A.
  57. Wrap electrical tape to attach the DCDC converter jumper harness ground lead to the vehicle harness.
  58. Install the upper bracket onto the new DCDC converter, and then install the bolts (x4) that attach the bracket to the DCDC converter (torque 3 Nm).
  59. Install the lower bracket onto the new DCDC converter, and then install the bolts (x2) that attach the bracket to the DCDC converter (torque 3 Nm).
  60. Temporarily install the DCDC converter onto the bulkhead, and align the RH DCDC converter upper bracket hole with the LH frunk extension support bracket hole, and install a bolt to attach the DCDC converter to the bulkhead (torque 10 Nm).
  61. Use a paint pen to mark the location of the DCDC converter upper bracket mounting hole and the DCDC converter lower bracket mounting hole.
  62. Remove the bolt that attaches the DCDC converter to the bulkhead, and then remove the DCDC converter from the bulkhead.
  63. Disconnect the electrical harness from the powertrain coolant pump connector.
  64. Release the clips (x5) that attach the electrical harness to the bulkhead, and remove the electrical harness from the bulkhead.
  65. Drill a 3/8 in or 9.5 mm hole at the location just marked for the upper bracket mounting hole.
  66. Use an IPA wipe to clean any debris from the hole, allow at least one minute to dry, and then apply e-coat to any exposed metal.
  67. Use the rivnut setting tool to install a rivnut into the upper bracket mounting hole.
  68. Raise the vehicle.
  69. Drill a 3/8 in or 9.5mm hole at the location just marked for the lower bracket mounting hole.
  70. Use an IPA wipe to clean any debris from the hole, allow at least one minute to dry, and then apply e-coat to any exposed metal.
  71. Use the rivnut setting tool to install a rivnut into the lower bracket mounting hole.
  72. Install the DCDC converter onto the bulkhead, and then install the bolts (x3) that secure the DCDC converter to the bulkhead (torque 10 Nm).
  73. Connect the electrical harness to the powertrain coolant pump connector.
  74. Fasten the clips (x5) that attach the electrical harness to the bulkhead.

Retrofit the Forward Junction Box

  1. Hold the new forward junction box (FJB) against the bulkhead and to the RH side of the HVAC drain tube, and then center the FJB upper mounting hole between the edge of the bulkhead and the brake line.
  2. Use a paint pen to mark the location of the FJB mounting holes (x3).
  3. Drill a 3/8 in or 9.5mm hole at the locations just marked for the FJB mounting holes (x3).
  4. Use IPA wipes to clean any debris from the holes, allow at least one minute to dry, and then apply e-coat to any exposed metal.
  5. Use the rivnut setting tool to install a rivnut into each of the FJB mounting holes (x3).
  6. Install the FJB to the bulkhead, and then install the bolts (x3) that attach the FJB to the bulkhead (torque 8 Nm).
  7. Lower the vehicle.
  8. Position the flat side of the bracket of the HV harness as shown, and perform the following sub-steps to label the positive and negative cables at both ends:
    1. On the harness side going to the FJB (with the large metal sleeves, on the right in the image), mark the shorter cable with a POSITIVE (+) sign.
    2. On the harness side going to the FJB (with the large metal sleeves, on the right in the image), mark the longer cable with a NEGATIVE (-) sign.
    3. Use a multimeter to check continuity from the cable end that was just marked POSITIVE (+) to the other end of the cable. Mark the other end with a POSITIVE (+) sign when continuity is obtained.
    4. Use a multimeter to check continuity from the cable end that was just marked NEGATIVE (-) to the other end of the cable. Mark the other end with a NEGATIVE (-) mark when continuity is obtained.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Reversed polarity will cause destructive damage on HV components. Double check continuity on both cables to ensure correct markings for POSITIVE (+) and NEGATIVE (-).
  9. Wrap tape around the FJB terminals of the new HV harness, so that the terminals are protected, and can pass easier through body openings.
  10. Remove the retaining bracket and cable ties from the other end of the HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the bracket and cable ties.
  11. Bend back the retaining tabs at each terminal eyelet, and then remove the bolts from the eyelets.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the bolts.
  12. Use a 5.5 mm drill and then a 6 mm drill to enlarge the terminal eyelets to 6 mm.
  13. Move the HV harness into the RH rocker, and out of the rocker at the front of the vehicle.
  14. Fully seat the HV harness body grommet into the RH rocker.
  15. Unfold the carpet at the RH C-pillar and cover the HV harness body grommet.
  16. Remove the second screw from the front of the master charger, closest to the HV junction box.
  17. Install the HV bracket onto the master charger, and then install the screw that attaches the bracket to the charger (torque 3 Nm).
  18. Install the HV harness positive cable into the lower mount, and then the HV harness negative cable into the upper mount of the HV bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    REVERSED POLARITY WILL CAUSE DESTRUCTIVE DAMAGES ON SEVERAL HV COMPONENTS. Make sure to install the HV harness POSITIVE cable into the LOWER mount, and then the HV harness NEGATIVE cable into the UPPER mount of the HV bracket.
  19. Install the bolts (x2) that attach the HV harness cable terminal eyelets to the HV junction box (torque 9 Nm).
  20. Install the nuts (x2) and bolts (x2) that secure the HV harness cables in the HV bracket (torque 3 Nm).
  21. Install the HV junction box cover onto the HV junction box, and then install the bolts (x6) that attach the cover to the box (torque 5 Nm).
  22. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Install) .
  23. Route the HV harness to the FJB, and then fasten the clips (x5) that attach the HV harness to the body.
  24. Use a cable tie to attach the DCDC converter jumper harness logic connector to the HV harness, and then remove excess cable tie.
  25. Raise the vehicle.
  26. Release the tabs (x2), and then open the HV cable access door on the FJB.
  27. Install the HV harness into the FJB, and then install the bolts (x2) that attach the HV harness cable terminal eyelets to the FJB (torque 4 Nm).
  28. Close the HV cable access door.
  29. Route the original DCDC converter ground harness around the FJB and to the new DCDC converter.
  30. Install that bolt that attaches the DCDC converter ground harness to the DCDC converter (torque 25 Nm).
  31. Install the bolt that attaches the FJB ground strap to the FJB (torque 4.2 Nm).
  32. Use a paint pen to mark a location on the bulkhead, 40 mm down from the top body seam, and 85 mm from the side body seam.
  33. Drill a 17/32 in or 13.5mm hole at the location just marked for the FJB ground strap rivnut.
  34. Remove the e-coating where the rivnut is to be installed.
  35. Use an IPA wipe to clean any debris from the hole, allow at least one minute to dry.
  36. Use the rivnut setting tool to install a rivnut into the hole.
  37. Install the FJB ground strap to the rivnut, and then install the bolt that attaches the ground strap to the rivnut (torque 9 Nm).
  38. Use a multimeter to measure the resistance between the FJB ground strap and a known good ground point.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is greater than 0.3 ohms, investigate why.
  39. Apply e-coat to the exposed metal around the FJB ground strap rivnut, and allow at least 5 minutes for the e-coat to dry.
  40. Repeat step 39 an additional 2 times, and allow the e-coat to completely dry.

Final Assembly

  1. Install the DCDC converter 12V positive harness onto the DCDC converter, and then install the bolt that attaches the harness to the DCDC converter (torque 13 Nm).
  2. Route the DCDC converter 12V positive harness along the FJB and to the battery fuse box.
  3. Connect the DCDC converter jumper harness to the FJB logic connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Though appearing identical, the FJB logic connector (X040) and the DCDC logic connector (X041) are not interchangeable. Mistakenly swapping the connectors will cause HVIL issues.
    Tip: Use a paint pen to label the FJB logic connector "FJB".
  4. Connect the DCDC converter jumper harness to the DCDC converter logic connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Though appearing identical, the DCDC logic connector (X041) and the FJB logic connector (X040) are not interchangeable. Mistakenly swapping the connectors will cause HVIL issues.
    Tip: Use a paint pen to label the DCDC logic connector "DCDC".
  5. Connect the DCDC converter jumper harness to the electric battery heater connector.
  6. Install the FJB lid onto the FJB, and then install the bolts (x6) that attach the lid to the FJB (torque 4.2 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Shown outside of vehicle for clarity.
  7. Install the RH frunk extension support bracket to the body, and then install the bolts (x2) that attach the support bracket to the body (torque 8 Nm).
  8. Remove and discard the two forward bolts that attach the coolant RapidMate to the body.
  9. Position the LH frunk extension support bracket over the coolant RapidMate, and then install two new forward bolts to attach the support bracket to the coolant RapidMate to the body (torque 8 Nm).
  10. Install the new RapidMate to electric battery heater hose onto the coolant RapidMate, and then fasten the clamp.
  11. Connect the electrical harness to the HV battery inlet temperature sensor.
  12. Lower the vehicle.
  13. Install the 12V auxiliary battery. See Battery - Auxiliary - 12V (Remove and Replace) .
  14. Install particulate filter rear housing to the body, and then install the nuts (x4) that attach the housing to the body (torque 6 Nm).
  15. Route the HV harness over the particulate filter housing, and fasten the clips (x2) that attach the HV harness to the body.
  16. Install a new RapidMate to 4-way valve coolant hose between the coolant RapidMate and the 4-way valve, and then fasten the clamps.
  17. Install a new coolant hose between the battery coolant pump 1 and the DCDC converter lower coolant fitting, and then fasten the clamps.
  18. Install a new electric battery heater bracket onto the electric battery heater, and then install the bolts (x4) that attach the bracket to the heater (torque 9 Nm).
  19. Install a new coolant hose onto the DCDC converter upper coolant fitting, and then fasten the clamp.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shown outside of vehicle for clarity.
  20. Install the electric battery heater into the coolant hose from the DCDC converter upper coolant fitting, and then fasten the clamp.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shown outside of vehicle for clarity.
  21. Install the electric battery heater to the bulkhead, and then install the bolts (x2) that attach the heater to the bulkhead (torque 8 Nm).
  22. Install the RapidMate to electric battery heater hose onto the electric battery heater, and then fasten the clamp.
  23. Connect the DCDC converter jumper harness to the electric battery heater connector, and then fasten the clip that attaches the connector to the electric battery heater bracket.
  24. Connect the electric battery heater HV harness to the FJB connector.
  25. Connect the DCDC converter HV harness to the FJB connector and DCDC converter connector.
  26. Connect the A/C compressor HV harness to the FJB connector.
  27. Connect the PTC heater HV harness to the FJB connector.
  28. Install the frunk extension support beam into the RH and LH frunk extension support brackets.
  29. Fasten the clips (x4) that attach the coolant hose to the frunk extension support beam.
  30. Raise the vehicle.
  31. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  32. Install the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install) .
  33. Install the RH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace) .
  34. Install the RH front wheel arch liner louver. See Louver - Wheel Arch Liner - Front - LH (Remove and Replace) .
  35. Install the front RH wheel. See Wheel Assembly (Remove and Install) .
  36. Lower the vehicle.
  37. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill .
  38. Install the wiper motor assembly. See Wiper Module (Remove and Replace) .
  39. Install the LH and RH shock tower braces. See Shock Tower Brace - LH (Remove and Replace) .
  40. Install the Media Control Unit. See Media Control Unit (Remove and Install) .
  41. Connect 12V power. See Disconnect 12V Power .
  42. Update the vehicle firmware.
  43. Install the top pad. See Assembly - Top Pad - Instrument Panel (Remove and Install) .
  44. Install the glove box. See Glove Box (Remove and Replace) .
  45. Install the footwell bracket cover to the body, and then install the bolts (x4) that attach the cover to the body (torque 5 Nm).
  46. Install the passenger footwell cover assembly. See Assembly - Cover - Footwell - Passenger's (Remove and Replace) .
  47. Install the center console RH closeout extension assembly. See Assembly - Closeout Extension - LH - Center Console (Remove and Replace) .
  48. Install the RH wrapped panel assembly. See Assembly - Panel - Wrapped - LH (Remove and Replace) .
  49. Install the particulate filter housing to the body, and then install the bolts (x2) that attach the housing from the vehicle (torque 1.5 Nm).
  50. Install the particulate filter. See Filter - Particulate (Remove and Replace) .
  51. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace) .
  52. Install the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace) .
  53. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  54. Disconnect the laptop from the vehicle.
  55. Remove the vehicle from the 2-post lift. See Raise Vehicle - 2 Post Lift.