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 Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

1. Ask the customer to remove all personal belongings from the vehicle before proceeding.
   CAUTION

   Debris from the rework will damage items left inside vehicle.
2. Cover all neighboring vehicles.
   CAUTION

   Debris from rework will damage paint on any surrounding vehicles.
3. Spray primer onto the 3 phase header plate. If the plate is already e-coated, skip this step.
   Warning

   Make sure to wear the proper PPE for using aerosol cans.

   Warning

   Do not breathe in fumes.

   CAUTION

   Use a cardboard box to prevent overspray onto other vehicles.

   

4. Open all the doors and lower all the windows.
5. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
6. Position the 2 post lift pads for HV battery removal.

   

   

   

7. Enable Service Mode through the vehicle touchscreen. See Service Mode (Enable and Disable)
8. Unlock the vehicle Gateway. See Gateway (Unlock).
9. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Diagnostics > Thermal to access thermal system routines.
10. Authorize thermal routines by holding the right turn signal, and then pressing the brake pedal for 10 seconds with the key on the phone dock.
11. Touch the Start button next to "Start Thermal Fill Drain (Coolant only)", and allow the routine to complete.
    Note

    A window displaying PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:

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

    will appear.

    Note

    Verify the coolant status is green for "Ready for Fill/Drain".

    Note

    The routine has a 5 hour limit. After 5 hours, the routine must be performed again.

    Note

    Touch the X in the top left of the window to close once the routine is completed.
12. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
13. Open the liftgate.
14. Move the front seats fully forward.
15. Fold the 2nd row seat backs to the down position.
16. Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
17. Apply masking tape to LH and RH racetrack to avoid damage.

    

18. Remove the front trunk load floor. See Trunk Load Floor - Front (Remove and Replace).
19. Remove the trunk gap hider. See Gap Hider - Trunk (5 Seat) (Remove and Replace).
20. Remove the LH and RH trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace)
21. Remove the LH and RH trunk load floor bracket covers. See Cover - Bracket - Trunk Load Floor - LH (Remove and Replace).
22. Remove the LH and RH middle C-pillar trims. See Trim - C-Pillar - Mid - LH (Remove and Replace).
23. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
24. Fold the trunk carpet rearward.
    Note

    Starting from the front, lift the carpet over the harpoon brackets, and then fold the carpet back enough to access the rear seat components.

    

    

25. Remove the 2nd row mid floor panel. See Floor Panel - Mid - 2nd Row (5 Seat) (Remove and Replace).
26. Remove the 2nd row rear floor panel. See Floor Panel - Rear - 2nd Row (5 Seat) (Remove and Replace).
27. Remove the RH 2nd row seat floor support.

    

28. Remove the RH 2nd row seat assembly. See Seat Assembly - 2nd Row - RH (5 Seat) (Remove and Replace).
29. Remove the LH 2nd row floor supports. See Floor Supports - Rear - 2nd Row - LH (Remove and Replace)
30. Remove the LH 2nd row seat assembly. See Seat Assembly - 2nd Row - LH (5 Seat) (Remove and Replace).
31. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
32. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
33. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
34. Lower the vehicle fully.
35. Remove the bolt that secures the charge port busbar connector access door.
    

    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 10 mm socket

    

36. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header.
    

    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 10 mm socket

    

37. Lift the charge port busbar connector to remove the connector from the DC input HV header.

    

38. Remove the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
39. If the vehicle is equipped with a performance rear drive unit, slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit HV harness from the HV battery RH HV header.

    

    

    

40. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
41. Remove the front skid plate. See Skidplate - Front (Remove and Replace).
42. Position a coolant drain collector under the front of the vehicle to catch the vehicle coolant.
43. Release the clip and disconnect the 3 way valve to HV battery hose from the HV battery, and then immediately plug the fittings.

    

44. Release the clip and disconnect the HV battery coolant supply hose from the HV battery, and then immediately plug the fittings.

    

45. Release the clip and disconnect the power conversion system coolant supply hose from the HV battery, and then immediately plug the fittings.

    

    

46. Pull the red locking tab out, and then pull the tab again to disconnect the electrical harness from the HV battery logic connector.

    

47. Pull the red locking tab out, and then disconnect the electrical harness from the HV battery LV connector.

    

48. Move the LH front wheel absorber aside to access the LH sill hose fitting.

    

49. Release the clip and disconnect the power conversion system coolant return to LH sill hose from the LH sill hose, and then immediately plug the fittings.

    

50. Release the clips (x3) that attach the LH sill coolant hose to the body.

    

51. Plaid vehicles only - Place a foldable funnel and absorbent material over the HV harness connectors and under the power conversion system coolant return hose to direct coolant away from the HV battery.

    

    

52. Plaid vehicles only - Release the clip, disconnect the rear drive unit branch of the power conversion system coolant return hose from the coolant return hose, and then immediately plug both fittings.

    

53. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.

    

54. Release the clip that attaches the RH sill coolant hose clip to the HV battery.

    

55. Remove the bolt that attaches the ground strap to the body, and then remove the ground strap from the body.
    

    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 10 mm socket

    

56. Remove coolant drain collector out from underneath the vehicle.
57. Hold down the red locking tab, disengage the release lever, and then release the HV compressor connector from the HV battery.
    CAUTION

    Do not force the release lever up.

    

    

58. Remove the bolt that attaches the front drive unit HV harness to the HV battery.
    

    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 8 mm socket

    

59. Slide the red connector locking tab, open the black release lever, and then disconnect the front drive unit HV harness from the HV battery front drive unit HV header.

    

    

60. First loosen all the bolts with a ratchet, and then use a power tool to remove the center bolts (x4) that attach the HV battery to the vehicle.
    

    35 Nm (25.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • External Torx Plus EP16

    

61. Remove four center bolts securing HV battery with battery powered drill
    Note

    4x bolts, EP16, 35 Nm

    

    

62. Position the battery table underneath the vehicle.

    

63. With the help of an assistant, lower the vehicle to just above the battery table, raise and lower table casters as necessary to level the table to the HV battery, and then lower the vehicle onto the table.

    

64. First loosen all the bolts with a ratchet, and then use a power tool to remove the outer center bolts (x4) that attach the HV battery to the vehicle.
    

    20 Nm (14.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • External Torx Plus EP14

    

    

65. First loosen all the bolts with a ratchet, and then use a power tool to remove the outer bolts (x12) that attach the HV battery to the vehicle.
    

    35 Nm (25.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • External Torx Plus EP16

    

    

    

    

66. First loosen all the bolts with a ratchet, and then use a power tool to remove the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    

    35 Nm (25.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 15 mm socket

    

67. First loosen all the bolts with a ratchet, and then use a power tool to remove the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    

    35 Nm (25.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:

    • 15 mm socket

    

68. Raise the vehicle off of the HV battery.

    

69. With the help of an assistant, move the HV battery and table away from the vehicle.

    

70. Lower the vehicle until the tires are touching the ground.
71. Remove the RH floor support.

    

72. Remove the LH and RH 2nd row mid floor common brackets. See Common Bracket - Mid Floor - 2nd Row - LH (Remove and Replace).
73. Wrap the rear half of cabin across the B-pillars.

    

74. Wrap the rear half of the cabin across the C-pillars.

    

75. Wrap the charge port busbar and LH racetrack.

    

    

76. Cut a cardboard box to fit the rework area.
    Note

    The box needs to fit inside the 2nd row floor panel. The box will act as a shield and prevent debris from spreading.

    

77. Install the cardboard box onto the 2nd row floor panel.

    

78. Position a section of the cardboard over the body harness.
    Note

    The section will guard the harness from the cut-off tool.

    

79. Position the 3 phase header plate onto the 2nd row floor panel.
    Note

    Note the plate placement on the floor panel.

    

    

80. Apply masking tape to the floor panel on the LH and RH side of the 3 phase header plate to mark the position.
    Note

    Do not tape the header plate to the floor panel.

    

81. Remove the 3 phase header plate from the 2nd row floor panel.
82. Apply masking tape 1 inch inward of the 3 phase header plate placement.

    

83. Apply masking tape along the 2nd row floor panel seams.
    Note

    Apply the tape inside the front seam and outside the rear seam.

    CAUTION

    Reference the image closely to avoid cutting into incorrect panel.

    

84. Drill 4 holes into the 2nd row floor panel.
    CAUTION

    Drill inside the templated corners.

    Warning

    Make sure to wear proper PPE for drilling.

    

    

85. Vacuum all debris produced by the drill.

    

86. Connect shop air to the cut-off tool.

    

87. Use the cutting tool to cut a square out of the 2nd row floor panel along the inside of the masking tape template, and then discard the cutout after removal.
    CAUTION

    DO NOT cut the extruded aluminum.

    CAUTION

    Only cut the area inside the taped section.

    Warning

    Make sure to wear proper PPE for cutting.

    Warning

    Do not breathe in fumes.

    

    

    

88. Vacuum all debris produced by the cut-off tool.

    

89. Remove the front tape from 3 phase header plate template.

    

90. Drill 2 holes into the 2nd row floor panel inside and mid-level with rivets.
    Warning

    Make sure to wear proper PPE for drilling.

    CAUTION

    Drill inside and mid-level with the rivets.

    CAUTION

    Do not drill out rivets.

    

    

91. Vacuum all debris produced by the drill.

    

92. Apply masking tape along the drilled holes.

    

93. Cut a rectangle out of the 2nd row floor panel.
    Warning

    Make sure to wear proper PPE for cutting.

    Warning

    Do not breathe in fumes.

    CAUTION

    Only cut inside and mid-level with the rivets. Discard rectangle after removal.

    

    

    

94. Vacuum all debris produced by the cut-off tool.

    

95. Remove the masking tape, position the 3 phase header plate onto the floor panel, reapply masking tape on the outside of the header plate to create a new template, and then remove the header plate from the floor panel.

    

    

    

96. Use a heat gun to heat the NVH material inside the 3 phase header plate template on the floor panel, and then use a scraper to remove the material from the floor panel.

    

    

    

97. Use IPA wipes to clean the 2nd row floor panel mating surface.
    Note

    Allow 1 minute of dry time.

    

98. Prepare a caulking gun and structural adhesive.

    

99. Apply structural adhesive onto the 2nd row floor panel along the inside of the template, and then spread the adhesive evenly with a brush.

    

    

100. Install the 3 phase header plate onto the 2nd row floor panel.
     Note

     Apply equal pressure and ensure the panel and plate are flush.

     

101. Remove the masking tape from the 2nd row floor panel.

     

102. Position cardboard over the 3 phase header plate edges.
     Note

     This will protect sand bag from adhesive squeeze out.

     

103. Position a sand bag onto the 3 phase header plate.
     Note

     Make sure the weight is evenly distributed and holding the plate down.

     Important: Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.

     

104. Raise the vehicle fully and lower lift onto locks.
     Note

     Set the vehicle to comfortable working height. Make sure there is an audible click from the locks on both sides before lowering, otherwise the vehicle may tilt to the side.
105. Apply structural adhesive underneath the 2nd row floor panel, and then spread the adhesive evenly with a brush.
     Warning

     Avoid dripping adhesive onto skin or hair.

     Important: Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.

     

106. Lower vehicle until the tires are touching the ground.
107. Perform a power conversion system coolant drain on the old HV battery. See Power Conversion System Coolant (Drain) (On Table).
108. Perform a platter enclosure coolant drain on the old HV battery. See Platter Enclosure Coolant (Drain) (On Table).
109. Release the clip that attaches the power conversion system coolant return hose to the HV battery.

     

110. Release the clip, and then disconnect the power conversion system coolant return hose from the HV battery.

     

111. Attach the HV battery H-frame to the gantry and raise the H-frame into position.

     

112. Use shackles (x4) to attach the P2 battery sling adapter to the H-frame.
     Note

     Make sure that the shackles are tight, secure, and the sling will not bind or twist when lifting the HV battery.

     

     

     

113. With the help of an assistant, remove the top from the HV battery shipping crate.

     

114. With the help of an assistant, position the gantry over the HV battery shipping crate.

     

115. Lower the H-frame to the new HV battery.

     

116. Install the P2 sling adapter onto the new HV battery.
     1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
     2. Insert the lifting pin into the lifting hole of the HV battery.
     3. Install the collar over the end of the lifting pin, and then release the button.
        CAUTION

        Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.

        

        

        

        

        

     4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
     5. Repeat substeps 42.a through 42.d for the other 5 lifting pins.
117. Lift the new HV battery out of the shipping crate.

     

118. With the help of an assistant, move the gantry away from the HV battery shipping crate and over a battery table.

     

119. Position an unused HV battery table under the gantry.

     

120. Lower the new HV battery onto the battery table.

     

121. Remove the P2 battery sling adapter from the new HV battery.
     1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.

        

     2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
        Note

        The collar will fall free, but is tethered to the lifting pin.

        

     3. Repeat substeps 46.a through 46.b for the other 5 lifting pins.
122. With the help of an assistant, remove HV battery and table from under the gantry.

     

     

123. With the help of an assistant, position the old HV battery and battery table under the gantry.

     

124. Install the P2 sling adapter onto the old HV battery.
     1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
     2. Insert the lifting pin into the lifting hole of the HV battery.
     3. Install the collar over the end of the lifting pin, and then release the button.
        CAUTION

        Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.

        

        

        

        

        

     4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
     5. Repeat substeps 2.a through 2.d for the other 5 lifting pins.
125. Raise the old HV battery off of the battery table.

     

126. Move the HV battery table out from under the gantry.

     

127. With the help of an assistant, position the gantry over the HV battery shipping crate.

     

128. With the help of an assistant, align the old HV battery to the shipping crate, then lower the battery into the crate.

     

129. Remove the P2 battery sling adapter from the old HV battery.
     1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.

        

     2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
        Note

        The collar will fall free, but is tethered to the lifting pin.

        

     3. Repeat substeps 7.a through 7.b for the other 5 lifting pins.
130. Raise the gantry and H-frame from the shipping crate.

     

131. With the help of an assistant, install the top onto the HV battery shipping crate, and return the battery to MRB.

     

132. Return the gantry to position and remove the HV battery H-frame from the gantry.

     

     

133. Important:
     If performing retrofit procedure for vehicles built before August 15, 2022, continue to the next step. If performing retrofit procedure for vehicles built between August 15, 2022 to September 29, 2022, skip to step 136.
134. Use a cut-off tool to cut the bottom of the HV battery pack bolts (x2).
     Warning

     Make sure to wear proper PPE for cutting.

     Warning

     Do not breathe in fumes.

     CAUTION

     Do not cut the top of the bolts. Only remove the bottom of the two bolts shown in image.

     

     

     

     

     

     

135. Spray primer onto the bottom of HV battery pack bolts (x2).
     Warning

     Make sure to wear proper PPE for using aerosol cans. Do not breathe in fumes.

     CAUTION

     Spray away from connectors and ground strap.

     

     

     

     

136. Secure the PCS outlet hose to the HV battery, and then install the spring clip.
     Note

     Perform a push-pull-push test to ensure the hose is fully seated.

     

137. Install the clip that attaches the PCS outlet hose to the HV battery.

     

138. After 24 hours, remove the sand bag from the 3 phase header plate.
     Important: Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.

     

139. Remove the cardboard from the 2nd row floor panel.

     

140. Clean the 2nd row floor panel area.
     Note

     Vacuum all debris from interior components before continuing. Wipe wrap as needed. Allow 1 minute of dry time.
141. Remove the wrap from the vehicle.

     

142. Vacuum the 2nd row interior components.
     Note

     All debris MUST be removed.

     

     

143. Position the RH 2nd row common bracket into the vehicle, and then install the clips (x2) that attach the bracket to the vehicle.

     

144. Position the new 3-phase LH 2nd row common bracket into the vehicle, and then install the clips (x2) that attach the bracket to the vehicle.

     

     

145. Install the RH floor support.
     Note

     Align the floor support with the common bracket.

     

146. Raise the vehicle fully and lower lift onto locks.
147. With the help of an assistant, move the HV battery and table to underneath the vehicle.

     

148. Carefully lower the vehicle onto the HV battery.
     Note

     Verify that the liftpads will not contact the battery, and that hoses and harness are not compressed or damaged while lowering.

     

     

     

149. First hand start, and then use a power tool to install the outer bolts (x12) that attach the HV battery to the vehicle.
     Note

     Final torque is applied in a later step.

     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP16

     

     

     

     

150. First hand start, and then use a power tool to install the outer center bolts (x4) that attach the HV battery to the vehicle.
     Note

     Final torque is applied in a later step.

     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP14

     

     

     

151. First hand start, and then use a power tool to install the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
     Note

     Final torque is applied in a later step.

     Tip: Use of the following tool(s) is recommended:

     • 15 mm socket

     

152. First hand start, and then use a power tool to install the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
     Note

     Final torque is applied in a later step.

     Tip: Use of the following tool(s) is recommended:

     • 15 mm socket

     

153. Tighten the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
     

     35 Nm (25.8 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 15 mm socket

     

154. Tighten the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
     

     35 Nm (25.8 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 15 mm socket

     

155. Tighten the outer bolts (x12) that attach the HV battery to the vehicle.
     

     35 Nm (25.8 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP16

     

     

     

     

156. Tighten the outer center bolts (x4) that attach the HV battery to the vehicle.
     

     20 Nm (14.7 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP14

     

     

157. With assistance, raise the vehicle, and then remove battery table from underneath the vehicle.

     

158. First hand start, use a power tool to install, and after all have been installed, tighten the center bolts (x4) that attach the HV battery to the vehicle.
     

     35 Nm (25.8 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP16

     

159. Secure the clip that attaches the RH sill coolant hose clip to the HV battery.

     

160. Position coolant drain container underneath the LH side sill hose connection.

     

161. Remove the plugs from both fittings and immediately connect the power conversion system coolant return to LH sill hose to the LH sill hose, fasten the clip, and perform a Push-Pull-Push check of the fittings.

     

162. Fully seat the LH front wheel liner absorber.

     

163. Install the clips (x3) that attach the LH sill coolant hose to the body.

     

164. Plaid vehicles only - Place a foldable funnel and absorbent material over the HV harness connectors and under the power conversion system coolant return hose to direct coolant away from the HV battery.

     

165. Plaid vehicles only - Remove the plugs, immediately connect the rear drive unit branch of the power conversion system coolant return hose to the coolant return hose, fasten the clip, and perform a Push-Pull-Push check of the fittings.

     

166. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.

     

167. Install the ground strap to the body, and then install the bolt that attaches the ground strap to the body.
     

     10 Nm (7.4 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 10 mm socket

     

168. Verify that the black release lever of the compressor HV harness connector is in the open position, install the connector square to the HV battery compressor HV header, secure the release lever to the closed position, and then slide the red connector locking tab.

     

169. Remove all items from pockets and make sure not to wear any metal items.
170. Inspect the HV insulating gloves.
     Note

     Refer to service document TN-15-92-003, for information on inspecting HV gloves.
171. Put on the HV insulating gloves and then leather over gloves.
     
172. Remove the bolts (x2) that attach the front drive unit HV header to the HV battery, and then gently separate the header to remove it from the HV battery.
     

     10 Nm (7.4 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP10

     

     

     

     

173. Position the new front drive unit HV header (PN: 1567101-20-A) onto the HV battery, and then install the bolts (x2) that attach the header to the HV battery.
     

     10 Nm (7.4 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • External Torx Plus EP10

     

     

     

174. Remove the bolts (x2) that attach the rear drive unit HV battery LH HV header to the HV battery.
     

     10 Nm (7.4 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • E10 5-lobe socket

     

     

175. Release the tabs (x2) that secure the rear drive unit HV battery LH HV header to the HV battery, and then use a plastic trim tool to gently remove the header from the HV battery.

     

     

     

176. Secure the new rear drive unit HV battery LH HV header (PN: 1567101-10-A) to the HV battery.
     Note

     Verify the header is fully seated.

     

     

     

     

     

177. Install the bolts (x2) that attach the rear drive unit HV battery LH HV header to the HV battery.
     

     10 Nm (7.4 lbs-ft)
     Note

     Tighten the bolts evenly.

     Tip: Use of the following tool(s) is recommended:

     • E10 5-lobe socket

     

178. Repeat step 172 through step 177 for the rear drive unit HV battery RH HV header.
     Note

     Replace the RH HV header with the same new part - PN: 1567101-10-A.
179. Remove the leather glove protectors and the HV insulating gloves.
180. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector square to the HV battery front drive unit header, secure the release lever to the closed position, and then slide the red connector locking tab.

     

     

     

181. Install the bolt that attaches the front drive unit HV harness to the HV battery.
     

     5.5 Nm (4.1 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 8 mm socket

     

182. Connect the power connector to the HV battery, and then secure the locking tab.

     

     

183. Connect the logic connector to the HV battery, and then secure the locking tab.

     

     

184. Position the coolant drain container underneath front of the vehicle.

     

185. Remove the plugs from both fittings and immediately connect the PCS inlet hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.

     

186. Remove the plugs from both fittings and immediately connect the HV battery coolant supply hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.

     

187. Remove the plugs from both fittings and immediately connect the 3 way valve to HV battery hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.

     

188. Remove the coolant drain container from underneath the vehicle.
189. Install the front skid plate. See Skidplate - Front (Remove and Replace).
190. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
191. Remove the gore breathers (x4) from rear breather assembly.
     CAUTION

     Be careful not to damage the breathers during removal.

     Note

     The breathers will be re-used. The breathers are located at the rear of the pack.

     

     

192. Install tapered plugs (x3) into indicated breather holes.
     CAUTION

     Do not push the plugs too far inside.

     

     

     

193. Install the leak test adapter into the fourth breather hole.

     

     

     

     

194. Close both valves on the regulator test tool.
     Note

     Make sure the valves are closed.

     

195. Connect the enclosure leak tester fitting to the leak test adapter.
     Note

     If required, safely secure the leak tester air line in a manner where it will not tug the adapter off.

     

196. Connect the regulator to air supply.

     

197. Turn the RH side regulator valve to the open position.
     Note

     Open the valve closest to the air line by turning the valve knob to the horizontal position.

     

198. Set the regulator to 0.3 psi, and then allow the regulator to stabilize.

     

199. Open the LH side regulator valve to allow air into the HV battery, allow the pressure to stabilize at 0.3 psi, and then close the RH side regulator valve.
     Note

     It will take approximately 60 seconds to reach 0.3 psi.

     

     

     

200. Wait 60 seconds to allow pressure to stabilize.
201. Record the start pressure value.
202. Wait 30 seconds for test.
203. Record the end pressure value.
     Note

     If pressure did not drop more than 0.026 psi, continue to next step, If pressure dropped more than 0.026 psi, then inspect HV battery enclosure for leaks
204. Disconnect the air supply from the leak tester.

     

205. Disconnect the enclosure leak tester fitting from the leak test adapter.
     Note

     Release the leak tester air line if previously secured.

     

     

206. Remove the leak test adapter from the breather hole.

     

     

207. Remove the tapered plugs (x3) from the breather holes.

     

     

     

208. Install the gore breathers (x4) onto the rear breather assembly.
     Note

     If the breathers were damaged, replace as needed.

     

209. Verify that the black release lever of the rear drive unit LH HV harness connector is in the open position, install the connector square to the rear drive unit HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
     CAUTION

     Be careful not to damage any pins.

     

     

210. Verify that the black release lever of the rear drive unit RH HV harness connector is in the open position, install the connector flat and square to the rear drive unit HV battery RH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
     Note

     Long Range configuration vehicles will have a dummy plug.

     

     

     

211. Install the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
212. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
213. Lower the vehicle fully.
214. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.

     

215. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.

     

216. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.

     

217. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
     

     9 Nm (6.6 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 10 mm socket

     

     

218. Inspect the HV insulating gloves.
     Note

     Refer to service document TN-15-92-003, for information on inspecting HV gloves.
219. Put on the HV insulating gloves and then leather over gloves.
     
220. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
     Note

     The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.

     Note

     If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
     
221. Remove leather over gloves and HV insulating gloves.
222. Install the bolt that secures the charge port busbar connector access door.
     

     9 Nm (6.6 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 10 mm socket

     

223. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
224. With assistance, position the LH 2nd row seat into the vehicle.
     Note

     Make sure the guide pins are properly aligned.

     

     

     

     

225. Loosely install new bolts (x6) that attach the LH 2nd row seat assembly front brackets to the vehicle.
     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

226. Install new bolts (x4) that attach the LH 2nd row seat assembly rear brackets to the vehicle.
     

     45 Nm (33.2 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

227. Tighten the bolts (x6) that attach the LH 2nd row seat assembly front brackets to the vehicle.
     

     45 Nm (33.2 lbs-ft)
     Note

     Torque the most forward bolt on each side before the outer bolts.

     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

228. Secure the clips (x2) that attach the LH 2nd row seat harness to the floor support bracket.

     

229. Connect the LH 2nd row seat harness electrical connectors (x3).
     Note

     Secure the connector housing to the bracket.

     

     

230. Install LH bench seat floor supports
     Note

     3x supports, Rework will need foam that fits 3 phase header plate

     

     

     

231. With assistance, position the RH 2nd row seat assembly into the vehicle.
     Note

     Make sure the guide pins are aligned properly.

     

     

232. Connect the RH 2nd row seat harness electrical connectors (x4), secure the connector locks, and then secure the connector housings to the bracket.
     Note

     Secure the connector housings to the bracket.

     

     

     

     

233. Secure the clips (x2) that attach the seat harness to the RH floor support bracket.

     

234. Position the RH 2nd row seat carpet support bracket into the vehicle, and then install the bolts (x2) that attach the bracket to the vehicle.
     

     5 Nm (3.7 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 10 mm socket

     

     

     

235. Install and hand tighten new bolts (x6) that attach the front of the RH 2nd row seat assembly seat track to the vehicle.
     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

236. Install new bolts (x4) that attach the rear of the RH 2nd row seat assembly seat track to the vehicle.
     

     45 Nm (33.2 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

237. Tighten the bolts (x6) that attach the front of the RH 2nd row seat assembly seat track to the vehicle.
     

     45 Nm (33.2 lbs-ft)
     Tip: Use of the following tool(s) is recommended:

     • 11 mm socket

     

238. Install the RH 2nd row seat floor support.

     

239. Verify that the black release lever of the HV 6 pin jumper plug is in the open position, install the jumper plug flat and square to the 3 phase header, secure the release lever to the closed position, and then slide the red connector locking tab.
     Note

     Only applicable to revision F and later North America packs.

     

     

     

     

240. Remove the coolant bottle cap.

     

241. Inspect the coolant level and top off as necessary.
     Note

     Ensure that the fluid level is at the Max line.

     

     

242. Install the vacuum refill cap onto the coolant bottle assembly.

     

243. Put an empty coolant container in the underhood storage unit.
     Note

     CFM fan shroud assembly cannot support a full coolant container. Make sure the overflow container is empty.

     Note

     Place a fender cover over the FEM and front fascia.

     

244. Fill another container with at least 15L of coolant.

     

245. Place the filled coolant container onto the coolant drain and fill cart.
     CAUTION

     Do not place the container with 15L of coolant on top of CFM fan shroud.

     Note

     Position cart as close as possible to the front of vehicle.

     

246. Setup the coolant refill tool.
     Note

     Verify all valves on the refill tool are in the closed position.

     

     

247. Install the vacuum refill hose into the refill cap on the coolant bottle.
     Note

     Perform a push-pull-push test to verify that the hose is fully installed.

     

248. Position the overflow hose into the empty container.

     

249. Place the refill hose inside the filled coolant container.
     Note

     Make sure the hose end is fully submerged into the coolant.

     

     

250. Connect shop air supply to the coolant refill tool.
     Note

     If not already done, verify that the refill valve is set to off.

     

251. Open the air inlet valve to draw a vacuum. Once the gauge stabilizes, close the valve fully.
     Note

     The gauge stabilizes roughly at 60-70 cmHg. Vacuum should not drop after the valves are closed.

     

     

252. Slowly open the refill valve to allow coolant to be drawn into the cooling system.
     Note

     Make sure the hose end of refill hose is fully submerged during entire process.

     

253. Once the gauge reads zero, close the coolant refill valve.

     

     

254. Disconnect shop air supply to coolant refill tool.
     Note

     If not already done, verify the refill valve is set to off.

     

255. Remove the coolant refill hose from the coolant container.
256. Remove the coolant overflow hose from the coolant container.
257. Remove the vacuum refill hose from the refill cap on the coolant bottle.

     

258. Remove the vacuum refill tool cap.

     

259. Remove the coolant refill tool from the vehicle.
260. Remove both the coolant container and fender cover from inside the underhood area.
261. Secure the First Responder Loop and then secure a 12v maintainer. Leave the LV battery disconnected.
     Note

     Release the positive jump post cover behind wiper module. Place a shop towel to prevent shorting jump post to multi system beam. Connect first responder loop then secure 12v maintainer to positive jump post and chassis ground. Vehicle will power on with 0% Low Voltage message at UI.

     

     

     

     

     

262. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Diagnostics > Thermal to access thermal system routines.
263. Authorize thermal routines by holding the right turn signal, and then pressing the brake pedal for 10 seconds with the key on the phone dock.
264. Touch the Start button next to "Start Coolant Air Purge", and allow the routine to complete.
     Note

     A window displaying "TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:

     • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
     • Thermal ➜ Coolant System ➜ Coolant Purge Start

     via Service Mode Plus:

     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge

     - SUCCESS" will appear.

     CAUTION

     Make sure the vehicle is not in drive. The test runs for approximately 10 minutes. Putting vehicle into a drive state will stop this routine. Monitor the coolant level and add more coolant as needed.

     Note

     Touch the X in the top left of the window to close once the routine is completed.
265. Inspect the coolant level and top off as necessary.
     Note

     Make sure that the fluid level is at the Max line.
266. Install the coolant bottle cap.

     

267. Calibrate the LH and RH falcon wing doors.
     Note

     Hold the upper B-pillar button in the down position to manually calibrate.
268. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Software Reinstall.
269. Touch the Request button in the "Software Reinstall" dialogue box.
     Note

     Confirm that a successful request message appears.

     Note

     Touch the X in the top left of the window to close once the routine is completed.
270. On the vehicle touchscreen, touch the clock, and then touch the Install Now button to start the software update.
271. Secure the LV battery, and then remove the maintainer.

     

272. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Software Reinstall.
273. Touch the Request button in the "Software Reinstall" dialogue box.
     Note

     Confirm that a successful request message appears.

     Note

     Touch the X in the top left of the window to close once the routine is completed.
274. On the vehicle touchscreen, touch the clock, and then touch the Install Now button to start the software update.
     Note

     Verify the release notes are present on the UI.
275. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
276. Install the underhood storage unit access panel. See Underhood Storage Unit Access Panel (Remove and Replace).
277. Install the front underhood apron. See Underhood Apron - Front (Remove and Replace).
278. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
279. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
280. Open the rear doors.
281. Install the 2nd row rear floor panel. See Floor Panel - Rear - 2nd Row (5 Seat) (Remove and Replace).
282. Install the 2nd row mid floor panel. See Floor Panel - Mid - 2nd Row (5 Seat) (Remove and Replace).
283. Fold the trunk carpet to the original position.
     Note

     Fold carpet down over the harpoon brackets.

     

     

284. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
285. Install the LH and RH mid C-pillar trims. See Trim - C-Pillar - Mid - LH (Remove and Replace).
286. Install the LH and RH side rear trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
287. Lower and remove the vehicle from the lift.
288. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
289. Remove the tape from the LH and RH racetracks.
290. Install the LH and RH rear sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
291. Calibrate the LH and RH falcon wing doors.
     Note

     Hold the upper B-pillar button in the down position to manually calibrate.
292. Move the front seats to the original positions.
293. Raise all the windows and close all the doors.
294. Close the LH front door.