25/03/2024 17:26:11
Inverter - Front Drive Unit (Remove & Replace)
Correction code 39200602 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See to make sure wearing proper PPE when performing the below procedure.
- 2024-03-05: Fixed images and link to Alignment Requirements.
Warning
This procedure is a DRAFT,
although it has been validated. Warnings and Cautions might be missing. Follow safety
requirements and use extreme caution when working on or near high voltage systems and
components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
Removal
-
Verify there is no abnormal tire wear
per Courtesy Inspection.
NoteSC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment.
-
Set up A/C machine and perform hose
flush.
-
Open LH front door.
-
Remove cubby under MCU and connect
laptop to vehicle with a tethered Ethernet connection via Toolbox 2.
Note2x clips, 1x connector, Drive rail must be ON, Toolbox 2 program must be in current service default. Toolbox 2.0 vehicle connection will enable diagnostic mode.
-
In toolbox, save Drive Inverter
information to hard drive.
NoteNavigate to Panels > Drive Inverter > Drive Inverter Replacement > Select save Drive Inverter info and press Play. In the interface drop down you need to select which Inverter you are replacing (DI or DIS), Make sure drive rails are on.
-
Verify drop down menu says "Start
fluid drain/fill".
-
Raise and support vehicle.
NoteSet air suspension to Jack Mode, Via Controls > Service > Jack Mode, Raise lift until arms contact the lift points.
-
Install steering wheel lock to ensure
proper placement of the steering wheel.
-
Open hood.
NoteVia center display > Controls > Front Trunk.
-
Remove underhood aprons.
Note4x aprons, LH and RH aprons have 1x clip each.
-
Remove dust caps from vehicle’s
high-side and low-side service ports.
Note2x threaded caps.
-
Connect hoses to vehicle and perform
A/C recovery.
Note(Touch time only) Ensure quick connects are fully engaged, turn connector dials clockwise to fully connect to A/C service ports.
-
Remove frunk carpet.
Note2x connectors.
-
Remove underhood storage unit.
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
-
Remove HEPA filter.
NoteLift up from bottom and pull out.
-
Remove LH outer hood hinge
cover.
Note2x clips.
-
Remove RH outer hood hinge
cover.
Note2x clips.
-
Disconnect cowl drain hose from cowl
trim.
Note1x clamp.
-
Disconnect wiper arm hose from
cowl.
-
Remove LH wiper arm.
Note1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl.
-
Remove RH wiper arm.
Note2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl.
-
Release cowl screen washer supply
hose.
Note1x one way valve.
-
Remove wiper cowl screen panel.
Note5x push clips, 1x windshield washer hose, 1x drain hose clamp.
-
Remove HEPA filter duct.
Note1x clip.
-
Overlap time for A/C recovery.
-
Remove A/C lines from vehicle.
-
Power down vehicle.
NoteVia center display > Controls > Safety > Power Off.
-
Disconnect 12V negative
terminal.
Note1x nut, 10mm, 5 Nm.
-
Disconnect first responder loop.
Note1x connector, push to release.
-
Raise vehicle fully and lower onto
locks.
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
-
Remove LH shear plate.
Note2x push clips, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 1x nylon nut, 15mm, 35 Nm Discard nylon nut after removal.
-
Remove RH shear plate.
Note3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nylon nut, 15mm, 35 Nm Discard nylon nut after removal.
-
Remove mid aero shield.
Note20x bolts, 10mm, 4 Nm, 2x push clips.
-
Remove front bash plate
extrusion.
Note2x bolts, T30, 16 Nm.
-
Remove LH ski side covers.
Note14x clips, 3x covers.
-
Remove RH ski side covers.
Note14x push clips, 3x covers.
-
Remove four center bolts securing HV
battery.
Note4x patch bolts, E12, 38 Nm, Discard bolts after removal.
-
Position battery table beneath
vehicle.
-
Lower vehicle to table.
NoteRecommend assistance, Align table to vehicle and raise casters to level table if necessary.
-
Remove and discard remaining eight
center bolts securing HV battery.
Note8x bolts, E12, 38 Nm, Discard after removal.
-
Remove front four HV battery
bolts.
Note4x patch bolts, 13mm, 30 Nm, Discard after removal.
-
Remove and discard 21mm bolts securing
front of HV battery.
Note2x bolts, 21mm, 115 Nm, Discard after removal.
-
Remove and discard LH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Remove and discard RH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Raise vehicle and remove battery
table.
NoteRecommend assistance.
-
Move battery away from vehicle.
-
Remove all items from pockets and
ensure not wearing metal items.
-
Inspect HV insulating gloves.
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003.
-
Put on HV insulating gloves and
leather over gloves.
-
Verify no high voltage at HV rapid
mate.
NoteMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
-
Install HV and LV Rapid Mate
covers.
Note2x covers, If covers not available then use masking tape to protect Rapid Mate from debris.
-
Remove front aero shield.
Note6x bolts, 10mm, 3 Nm, 14x clips.
-
Lower vehicle partially and set lift
onto locks.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
-
Remove cover and disconnect
positive12V terminal.
Note1x nut, 10mm, 5 Nm.
-
Remove edge clips from battery
cage.
Note2x edge clips.
-
Remove barrel clip from battery
cage.
Note1x barrel tree clip.
-
Remove plastic harness clip.
Note1x clip.
-
Remove battery vent tube.
Note1x vent tube.
-
Release bolts securing lower portion
of 12v battery cage.
Note2x bolts, 10mm, 6 Nm.
-
Release bolts securing top portion of
12v battery cage.
Note2x bolts, 13mm, 15 Nm, Be careful and do not to get cordless impact stuck in between window motor casting.
-
Remove 12v battery cage assembly from
vehicle.
-
Remove coolant reservoir cap.
Note1x cap.
-
Use vacuum suction tool to remove
coolant from reservoir.
-
Disconnect electrical connector for
coolant level sensor.
Note1x connector.
-
Remove coolant reservoir fasteners and
wire harness edge clip.
Note4x bolts, 10mm, 6 Nm, 1x edge clip.
-
Clamp and remove coolant hose and move
reservoir off to the side.
Note1x coolant hose, Place absorbent material below hose to capture fluid.
-
Disconnect A/C compressor harness at
FJB and release cable from drive unit.
Note1x connector, 1x fir tree clip.
-
Disconnect the A/C compressor logic
connector.
Note1x connector.
-
Release edge clip for the A/C
compressor logic connector.
Note1x clip.
-
Release the ground connection at the
A/C compressor mount bracket.
Note1x bolt, T25, 7 Nm.
-
Remove A/C lines from
compressor.
Note2x nuts, 10mm, 10 Nm, Discard O-rings after removal.
-
Remove A/C compressor from the
vehicle.
Note3x bolts, E10, 10 Nm.
-
Clamp coolant hoses and remove from
drive unit.
Note2x coolant hoses.
-
Disconnect ground strap from
body.
Note1x nut, 13mm, 9 Nm.
-
Disconnector logic connector from
drive unit.
Note1x connector with lock tab.
-
Remove LH front wheel center
cap.
-
Loosen LH front axle nut.
Note1x nut, 32mm, 245 Nm.
-
Remove LH front lug nut covers.
Note5x lug nut covers.
-
Loosen LH front lug nuts.
Note5x nuts, 21mm, 175 Nm.
-
Remove RH front wheel center
cap.
-
Loosen RH front axle nut.
Note1x nut, 32mm, 245 Nm.
-
Remove RH front lug nut covers.
Note5x lug nut cover.
-
Loosen RH front lug nuts.
Note5x nuts, 21mm, 175 Nm.
-
Raise vehicle partially and lower onto
locks.
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
-
Remove RH front wheel.
Note5x nuts, 21mm, 175 Nm.
-
Remove LH front wheel.
Note5x nuts, 21mm, 175 Nm.
-
Release LH front wheel liner from
body.
Note11x push clips, 2x nuts, 10mm, 6 Nm.
-
Remove LH front wheel liner from
vehicle.
-
Release power train pump 2 from
bracket and disconnect harness.
Note1x connector.
-
Clamp hose and remove hose from pump
and push towards the drive unit.
-
Remove HV cables from DU.
Note4x patch bolts, T30, 7 Nm, Discard after removal.
-
Remove LH tie rod nut and move tie rod
end away.
Note1x Nyloc nut, 21mm, 103 Nm, Discard after removal.
-
Remove RH tie rod nut and move tie rod
end away.
Note1x nyloc nut, 21mm, 103 Nm, Discard after removal.
-
Raise vehicle fully and lower onto
locks.
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
-
Remove skid bar from front
subframe.
Note4x bolts, 10mm, 10 Nm.
-
Remove skid plate from front
subframe.
Note2x bolts, 10mm, 9 Nm.
-
Remove the fastener to steering gear
and disconnect steering shaft from the rack and pinon.
Note1x bolt, 13mm, 30 Nm.
-
Disconnect 12v connection to rack and
pinion.
Note2x connectors.
-
Release chiller from subframe.
Note2x bolts, 13mm, 12 Nm.
-
Disconnect battery pump 1 release
coolant hose from subframe and remove pump from subframe bracket.
Note1x connector, 1x fur tree clip.
-
Release cowl drain hose from
subframe.
Note1x edge clip.
-
Remove and discard the nut that
secures the LH stabar to the stabar end links and remove end link from bar.
Note1x nyloc nut, 15mm, 70 Nm, Discard after removal.
-
Remove the RH stabar from the stabar
end link and remove end link from bar.
Note1x nyloc nut, 15mm, 70 Nm, Discard after removal.
-
Remove nut and bolt securing LH front
air spring module to front lower aft link.
Note1x nut, 21mm, 1x bolt, 21mm, 140 Nm.
-
Remove the bolt and nut that secure
the RH front shock absorber to the rear lower control arm.
Note1x nut, 21mm, 1x bolt, 21mm, 140 Nm.
-
Remove LH side lower control arm
nuts.
Note2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage.
-
Remove RH side lower control arm
nuts.
Note2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage.
-
Position subframe fixture beneath
vehicle and raise fixture.
-
Remove the bolts that secure the
subframe to the chassis.
Note2x bolts, 13mm, 20 Nm, 2x bolts, 16mm, 80 Nm, 2x bolts, 18mm, 115 Nm.
-
Lower subframe and move it away from
vehicle.
NoteNeed to tilt subframe back to remove from carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar.
-
Remove axle nut and washer securing LH
drive axle to hub assembly.
Note1x nut, 32mm, 245 Nm, 1x washer, Discard washer after removal, Nut can be reused.
-
Install the hub puller onto the LH
front brake rotor.
Note5x lug nuts, 21mm, Hand tight.
-
Use hub puller to free LH halfshaft
from hub splines.
NoteCounter hold hub puller.
-
Remove hub puller from LH hub
assembly.
Note5x lug nuts, Hand tight.
-
Remove axle nut and washer securing RH
drive axle to hub assembly.
Note1x nut, 32mm, 245 Nm, 1x washer, Discard washer after removal, nut can be reused.
-
Setup hub puller onto RH hub
assembly.
Note5x lug nuts, 21mm, Hand tight.
-
Use hub puller to free RH halfshaft
from hub splines.
NoteCounter hold hub puller.
-
Remove hub puller from RH hub
assembly.
Note5x lug nuts, Hand tight.
-
Remove LH axle from drive unit
hub.
Note1x axle.
-
Remove RH axle from jack shaft and
hub.
Note1x axle.
-
Remove jack shaft.
Note2x bolts, 15mm, 30 Nm.
-
Disconnect chiller harness.
Note1x connector.
-
Remove coolant hose from battery pump
2 to chillere.
Note1x coolant hose.
-
Disconnect and remove battery pump 2
from frame rail.
Note1x connector, 1x screw, T30, 10 Nm.
-
Remove NVH pad from drive unit to
access drain plug.
-
Drain drive unit oil.
Note1x hex bolt, 8mm, 28 Nm, position oil drain under vehicle to reduce spilling as needed.
-
Remove the lower RH section of the NVH
pad.
NoteThis will allow the drive unit fixture to fit.
-
Position transmission jack fixture
under drive unit.
-
Remove bolts that secure clevis to LH
front rail.
Note2x bolts with washers, 15mm, 65 Nm, Discard after removal.
-
Remove RH mount bolts to DU.
Note4x bolts, 15mm, 35 Nm.
-
Lower front drive unit with jack out
of vehicle.
-
Remove coolant hoses from drive
unit.
Note2x hose clamp.
-
Remove the remaining NVH covers.
-
Remove ground strap from drive
unit.
Note1x bolt, 10mm, 6 Nm.
-
Move drive unit over to the
gantry.
-
Attach lifting sling to drive
unit.
-
Raise drive unit to gain access to HV
lugs cover.
-
Remove the inverter breather
cover.
Note1x bolt, 10mm, 6 Nm.
-
Remove the sticker from HV lug
cover.
-
Remove the HV lug cover.
Note2x bolts, 8mm, 5 Nm.
-
Remove the HV lug fasteners.
Note3x bolts, 10mm, 7 Nm.
-
Support the inverter and remove all
inverter fasteners.
Note10x bolts, 8mm, 12 Nm.
-
Pull inverter back to gain access to
disconnect the connector.
Note1x connector.
-
Remove inverter from drive unit and
place on an ESD mat.
Installation
-
While supporting the inverter connect the drive unit connector.
Note1x connector.
-
Install inverter fasteners but leave them loose.
Note10x bolts, 8mm, 12 Nm.
-
With the inverter loose install the HV lug fasteners - don't torque yet.
Note3x patch bolts, 10mm, 7 Nm, Install new bolts.
-
Torque inverter cover down.
Note10x bolts, 8mm, 12 Nm.
-
Torque HV lug fasteners.
Note3x patch bolts, 10mm, 7 Nm, install new bolts.
-
Mark the HV lugs with a paint pen.
NotePink paint pen.
-
Apply a small amount of O-ring lubricant to the O-rings on 1 HV lug cover.
-
Install HV lug cover and install the fasteners.
NoteMakes sure cover is flush, 2x bolts, 8mm, 5 Nm.
-
Install HV lug cover sticker.
-
Push drive unit back to the vehicle.
-
Install logic plug.
Note1x plug.
-
Install HV plugs.
Note2x plugs.
-
Install breather plug.
Note1x plug.
-
Connect air line to pressure regulator . Set pressure to 1 psi.
-
Connect pressure regulator to hose in the breather hole. Open valve and fill
inverter. Let it settle for 1 min.
-
Run a 1 min leak down test.
NoteMax leak down in 1 min is .2 psi.
-
Remove pressure tester from hose.
-
Remove breather plug.
Note1x hose.
-
Remove logic connector plug.
Note1x plug.
-
Remove HV plugs.
Note2x plug.
-
Install new breather valve.
-
Install breather cover.
Note1x bolt, 10mm, 5 Nm.
-
Install ground strap to drive unit.
Note1x bolt, 10mm, 6 Nm.
-
Install NVH pad on to the drive unit.
-
Install coolant hose to drive unit.
Note2x coolant hoses.
-
Move drive unit under vehicle, lift into place and loosely install bolts by
hand.
Note2x bolts with washers, 15mm, 50 Nm, 4x bolts, 15mm, 35 Nm, Do not torque at this time.
-
Check shim fitment and adjust prior to torquing mounts.
-
Torque both drive unit mounts and check shim fitment.
Note2x bolts with washers, 15mm, 50 Nm, 4x bolts, 15mm, 35 NmSet the torque + angle wrench to the correct angle value. For vehicles with a front drive unit with a part number of: 1035000-01-J or later, set the torque angle to 55 degrees, 1035000-00-J or earlier, set the torque angle to 75 degrees.
-
Remove transmission jack from under vehicle.
-
Install the lower RH section of the NVH pad.
-
Install jack shaft.
Note2x bolts, 15mm, 30 Nm.
-
Apply Molykote M-77 to outboard side of LH axle shaft.
NoteClean if necessary, Apply no more than 1 gram to axle only.
-
Install RH axle and loosely install axle nut.
Note1x nut, 32mm, 245 Nm, 1x washer, Install new nut and washer, Recommend assistance, Torque at a later step.
-
Apply Molykote M-77 to outboard side of LH axle shaft.
NoteClean if necessary, Apply no more than 1 gram to axle only.
-
Install LH axle and loose install axle nut will be torqued at a later step.
Note1x nut, 32mm, 205 Nm, 1x washer, Install new nut and washer, Assistance required, Torque at a later step.
-
Install NVH covers on front of DU.
-
Install battery pump 2 to frame rail and connect harness.
Note1x connector, 1x bolt, T30, 10 Nm.
-
Connect coolant hose from chiller to battery pump 2.
Note1x coolant hose.
-
Connect chiller harness.
Note1x connector.
-
Install subframe in position for install.
NoteNeed to tilt subframe back to remove from carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar.
-
Install the bolts that secure the subframe to the chassis.
Note2x bolts, 13mm, 20 Nm, 2x bolts, 16mm, 80 Nm, 2x bolts, 18mm, 115 Nm.
-
Remove subframe fixture from under vehicle.
-
Install RH side lower control arm nuts.
Note2x nyloc nuts and washers, 21mm, 195 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage.
-
Install RH side lower control arm nuts.
Note2x nyloc nuts and washers, 21mm, 196 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage.
-
Loosely install the bolt and nut that secure the RH front shock absorber to the rear
lower control arm.
Note1x nut, 21mm, 1x bolt, 21mm, 140 Nm, Torqued at a later step.
-
Install nut and bolt securing LH front air spring module to front lower aft
link.
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Torque at ride height on alignment rack.
-
Install the RH stabar to the stabar end link.
Note1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket.
-
Install the LH stabar to the stabar end link.
Note1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket.
-
Install cowl drain hose to subframe.
Note1x edge clip.
-
Connect battery pump 1 to bracket and connect harness.
Note1x connector, 1x fur tree clip.
-
Secure chiller to subframe.
Note2x bolts, 13mm, 12 Nm.
-
Connect 12v connection to rack and pinion.
Note2x connectors.
-
Connect steering shaft to the rack pinon and install the fastener.
Note1x bolt, 13mm, 30 Nm.
-
Install skid plate to front subframe.
Note2x bolts, 10mm, 9 Nm. Note: start bolts with cordless, torque using torque wrench. .
-
Install skid bar to front subframe.
Note4x bolts, 10mm, 10 Nm.
-
Lower vehicle partially and set lift onto locks.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
-
Install the nut that secures RH tie rod end to the knuckle.
Note1x nyloc nut, 21mm, 103 Nm, Install new nut.
-
Install nut that secures LH tie rod end to the knuckle.
Note1x nyloc nut, 21mm, 103 Nm, Install new nut.
-
Lower vehicle to comfortable working height.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
-
Install hub jack adapter onto LH front hub.
Note5x lug nuts, 21mm, Hand tight, Use modified hydraulic hub tool if correct adapter is not available.
-
Position and raise support stand to simulate LH front suspension at ride
height.
-
Set ride height tool onto LH front upper control arm.
-
Torque LH fore link to subframe.
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
-
Remove the existing paint mark from LH fore link.
NoteClean the area thoroughly so the new marking is not confused with the previous marking.
-
Mark the LH fore link nut and subframe to show the component has been torqued.
NoteUse a high visibility paint pen when marking components.
-
Torque LH aft link to subframe.
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
-
Remove the existing paint mark from LH aft link.
NoteClean the area thoroughly so the new marking is not confused with the previous marking.
-
Mark LH front aft link bolt and subframe to show the component has been
torqued.
NoteUse a high visibility paint pen when marking components.
-
Remove existing paint mark from LH air spring module bolt.
NoteClean nut and surrounding area thoroughly so the new marking is not confused with the previous marking.
-
Torque LH air spring module nut and bolt to LH aft link assembly.
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm.
-
Mark LH air spring module nut to show the component has been torqued.
NoteUse a high visibility paint pen when marking components.
-
Remove ride height tool from LH front upper control arm.
-
Remove support stand from underneath LH front suspension.
NoteLower stand until suspension is unladen before removal.
-
Remove hub jack adapter from LH front hub.
Note5x lug nuts, 21mm, Hand tight.
-
Install LH front wheel liner onto vehicle.
-
Secure LH front wheel liner to body.
Note11x push clips, 2x nuts, 10mm, 6 Nm.
-
Release RH front wheel liner from body.
Note11x push clips, 2x nuts, 10mm, 6 Nm.
-
Remove RH front wheel liner from vehicle.
-
Install hub jack adapter onto RH front hub.
Note5x lug nuts, 21mm, Hand tight, Use modified hydraulic hub tool if correct adapter is not available.
-
Position and raise support stand to simulate RH front suspension at ride
height.
-
Set ride height tool onto RH front upper control arm.
-
Torque RH fore link to subframe.
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
-
Remove the existing paint mark from RH fore link.
NoteClean the area thoroughly so the new marking is not confused with the previous marking.
-
Mark the RH fore link nut and subframe to show the component has been torqued.
NoteUse a high visibility paint pen when marking components.
-
Torque RH front aft link subframe.
Note1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
-
Remove the existing paint mark from RH aft link.
NoteClean the area thoroughly so the new marking is not confused with the previous marking.
-
Mark the RH front aft link bolt and subframe to show the component has been
torqued.
NoteUse a high visibility paint pen when marking components.
-
Torque RH air spring module nut and bolt to RH aft link assembly.
Note1x bolt, 21mm, 1x nut, 21mm, 140 Nm.
-
Remove the existing paint mark from RH air spring module.
NoteClean the area thoroughly so the new marking is not confused with the previous marking.
-
Mark RH air spring module nut to show the component has been torqued.
NoteUse a high visibility paint pen when marking components.
-
Remove ride height tool from RH front upper control arm.
-
Remove support stand from underneath RH front suspension.
NoteLower stand until suspension is unladen before removal.
-
Remove hub jack adapter from RH front hub.
Note5x lug nuts, 21mm, Hand tight.
-
Install RH front wheel liner onto vehicle.
-
Secure RH front wheel liner to body.
Note11x push clips, 2x nuts, 10mm, 6 Nm.
-
Lower vehicle partially and set lift onto locks.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
-
Install HV cables into DU.
Note4x patch bolts, T30, 7 Nm, Install new bolts.
-
Connect coolant hose to powertrain pump 2.
Note1x coolant hose.
-
Install pump on to bracket and connect harness.
Note1x connector.
-
Lower vehicle partially and set lift onto locks.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
-
Connect Front Drive Unit logic connector.
Note1x connector with locking tab.
-
Connect ground strap to body.
Note1x nut, 13mm, 9 Nm.
-
Connect coolant hose from drive unit.
Note2x coolant hoses.
-
Install A/C compressor.
Note3x bolts, E10, 10 Nm.
-
Install both A/C lines to compressor.
Note2x nuts, 10mm, 10 Nm, Replace the O-rings.
-
Secure the ground connection at the A/C compressor mount bracket.
Note1x bolt, T25, 7 Nm.
-
Secure edge clip for the A/C compressor logic connector.
Note1x edge clip.
-
Connect the A/C compressor logic connector.
Note1x connector.
-
Connect A/C compressor harness to FJB .
Note1x connector.
-
Connect coolant hose to reservoir and remove hose clamp.
Note1x coolant hose.
-
Install fasteners securing coolant reservoir to shock tower cross member.
Note4x bolts, 10mm, 6 Nm.
-
Install battery cage assembly into vehicle.
-
Install bolts into top of battery cage assembly.
Note2x bolts, 13mm, 15 Nm.
-
Install bolts in bottom of battery cage assembly.
Note2x bolts, 10mm, 6 Nm.
-
Install battery vent tube back into battery.
Note1x vent tube.
-
Install plastic harness clip.
Note1x clip.
-
Install clip onto battery cage.
Note1x barrel clip.
-
Install edge clips onto battery cage.
Note2x edge clips.
-
Connect 12V positive terminal.
Note1x nut, 10mm, 5 Nm.
-
Install positive 12V terminal cover.
-
Raise vehicle fully and lower onto locks.
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side. Ensure the vehicle is stable by rocking the vehicle on the lift immediately after the tires have left the ground. Always lower the lift arms onto the locks after raising the vehicle.
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Remove HV and LV Rapid Mate covers.
Note2x covers.
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Position HV battery underneath vehicle.
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Lower vehicle onto HV battery pack.
NoteBefore lowering fully use assistance to align the pack using the alignment rods and guide via the borescope camera or a flexible inspection mirror checking HV and LV rapid mates.
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Loosely install 4 new front bolts for HV battery.
Note4x patch bolts, 13mm, 30 Nm, Install new patch bolts.
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Install LH rocker bolts hand tight.
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts.
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Install RH rocker bolts hand tight.
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts.
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Install 21mm bolts at front of HV battery hand tight.
Note2x bolts, 21mm, 115 Nm, Install new bolts.
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Install eight outer center bolts hand tight.
Note8x patch bolts, E12, 38 Nm, Install new patch bolts.
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Torque rocker HV battery bolts on both sides.
Note16x bolts, 13mm, 55 Nm.
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Torque remaining HV battery bolts.
Note8x bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x bolts, 13mm, 30 Nm.
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Raise vehicle off of HV battery.
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Install inner center HV battery bolts with battery powered drill .
Note4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts.
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Install LH ski side covers.
Note14x clips, 3x covers.
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Install RH ski side covers.
Note14x clips, 3x covers.
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Install front bash plate extrusion.
Note2x bolts, T30, 16 Nm.
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Install front aero shield.
Note6x bolts, 10mm, 3 Nm, 14x clips.
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Install mid aero shield.
Note20x bolts, 10mm, 4 Nm, 2x push clips. Start bolts with cordless, torque with 1/4 torque wrench.
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Install LH shear plate.
Note3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, Install new nyloc nut, 15mm, 35 Nm.
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Install RH shear plate.
Note3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, Install new nyloc nut, 15mm, 35 Nm.
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Lower vehicle partially and set lift onto locks.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
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Install LH front wheel.
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool.
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Install RH rear wheel.
Note5x nuts, 21mm, 175 Nm.
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Lower vehicle until tires are touching ground.
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
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Torque LH front wheel.
Note5x nuts, 21mm, 175 Nm.
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Torque RH front wheel.
Note5x nuts, 21mm, 175 Nm.
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Torque LH front axle nut.
Note1x nut, 32mm, 245 Nm.
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Torque RH front axle nut.
Note1x nut, 32mm, 245 Nm.
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Install LH front wheel center cap.
Note1x cap, Verify emblem is aligned with valve stem.
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Install LH front lug nut covers.
Note5x covers.
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Install RH front wheel center cap.
Note1x cap, Verify emblem is aligned with valve stem.
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Install RH front lug nut covers.
Note5x covers.
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Connect first responder loop and then 12V negative terminal.
Note1x connector, 1x nut, 10mm, 5 Nm.
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In toolbox, run the refrigerant drain and fill routine to enable A/C filling.
NoteClick Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play.
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Connect hoses to vehicle and perform A/C vacuum and leak test.
Note(Touch time only)30 minute vacuum, 10 minute leak testEnsure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports.
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Remove fill plug.
Note1x hex bolt, 8mm, 28 Nm.
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Fill front small drive unit with oil.
Note1.8 quarts, Front drive unit part number 1035000-00-F and earlier: Mobil SHC 629, Front drive unit part number 1035000-00-J and later: Automatic transmission fluid - SK lubricant 212-B – quart (part number 1031106-00-A).
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Install fill plug.
Note1x hex bolt, 8mm, 28 Nm.
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Install HEPA filter duct.
Note1x clip.
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Remove wiper cowl screen panel.
Note5x push clips, 1x windshield washer hose, 1x drain hose clamp.
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Connect cowl drain hose onto cowl trim.
Note1x clamp.
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Conenct cowl screen washer supply hose.
Note1x one way valve.
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Install RH wiper arm.
Note2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl.
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Install LH wiper arm.
Note1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl.
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Connect wiper arm hoses to cowl.
Note2x washer hoses.
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Install LH outer hood hinge cover.
Note2x clips.
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Install RH outer hood hinge cover.
Note2x clips.
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Remove coolant reservoir cap.
Note1x cap.
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Fill reservoir to "NOM" line .
NoteMonitor the coolant level once the purge routine is running, adding coolant as required using G-48 coolant.
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Remove steering wheel holder from vehicle.
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Place vehicle in service mode with touchscreen.
NoteSelect Controls > Software, Touch and hold "Model" for 2 seconds then release, Use the screen keyboard to type "service" into dialog box and select "OK" button, Select "X" at upper left corner to exit "Service Settings" dialogue box.
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Unlock vehicle Gateway.
NoteAfter vehicle has been put into "Service Mode", hold down the brake pedal, while holding down break pedal simultaneously hold the turn signal stalk fully up for at least 10 seconds, "GTW UNLOCKING" should pop up on the instrument cluster right below the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 90 minutes.
-
Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet
connection via Toolbox 3.
NoteRemove cubby under MCU and connect laptop to vehicle, Open Toolbox 3 website and establish connection to vehicle.
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Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start,
click "Run", and allow routine to complete.
NoteMake sure vehicle is not in drive state, Routine is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required.
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Top off the reservoir to the "NOM" line with G-48 coolant.
NoteEnsure coolant is filled to nominal level.
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Install coolant reservoir cap .
Note1x cap.
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Install HEPA filter housing.
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Install underhood storage unit.
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
-
Install frunk carpet.
Note2x connectors.
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Inject oil into the system.
NoteRefill with the amount removed during recovery.
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Perform A/C refrigerant refill.
NoteRun time, per fluid capacity spec.
-
Remove A/C lines from vehicle.
NotePress clear lines once lines have been removed.
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Install dust caps onto vehicle high and low side service ports.
Note2x threaded caps.
-
Test A/C functions in vehicle to ensure cabin cooling functions as designed.
-
Perform A/C hose flush.
NoteTouch time only. No overlap from this since the machine is disconnected from the vehicle.
-
In toolbox, run routine to write Drive Inverter Information to the new
Inverter.
NoteGo to Panels > Drive Inverter > Drive Inverter Replacement > Select Write Drive Inverter Information and press Play. In the interface drop down you need to select which Inverter you are replacing (DI or DIS), Make sure drive rails are on.
-
Perform firmware update.
NotePer current FRT (00020007) 0.3 hrs.
-
Disconnect laptop from vehicle and install storage cubby.
Note1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby.
-
Install lower storage cubby.
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Install under hood aprons.
Note4x aprons.
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Close hood.
-
Calibrate falcon doors via UI.
NoteVia Controls > Calibrate, Required after 12V and FRL disconnect.
-
Close LH front door.
-
Remove vehicle from lift.
NoteLower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode", Via Controls > Service > Jack Mode.
- Review wheel alignment requirements and add correction code as needed. See Alignment Requirement - Suspension.