2026-08-09

Inverter - Front Drive Unit (Remove & Replace)

Correction code 39200602 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2024-12-06: Added info on FUCA ride height tool for EMEA.
  • 2024-03-05: Fixed images and link to Alignment Requirements.
Special tools required for this procedure:
  • 1117845-00-A Wheel Nut Cover Removal Tool
  • 1705887-00-A ½" Dr. Electric Impact
  • 1098012-00-A Model S/X FUCA Ride Height Kit (all regions except EMEA)
  • 1098012-E2-B Model X FUCA Ride Height Torque Tool (EMEA region)
  • 1143989-00-A Torque Wrench ½ in Dr.
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.

Removal

  1. Verify there is no abnormal tire wear per Courtesy Inspection.
    Note
    SC-14-00-001 Standard Courtesy Inspection Checklist, While performing courtesy inspection, Note any abnormal tire wear that could indicate the need for an alignment.
  2. Set up A/C machine and perform hose flush.
  3. Open LH front door.
  4. Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2.
    Note
    2x 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.
  5. In toolbox, save Drive Inverter information to hard drive.
    Note
    Navigate 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.
  6. Verify drop down menu says "Start fluid drain/fill".
  7. Raise and support vehicle.
    Note
    Set air suspension to Jack Mode, Via Controls > Service > Jack Mode, Raise lift until arms contact the lift points.
  8. Install steering wheel lock to ensure proper placement of the steering wheel.
  9. Open hood.
    Note
    Via center display > Controls > Front Trunk.
  10. Remove underhood aprons.
    Note
    4x aprons, LH and RH aprons have 1x clip each.
  11. Remove dust caps from vehicle’s high-side and low-side service ports.
    Note
    2x threaded caps.
  12. 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.
  13. Remove frunk carpet.
    Note
    2x connectors.
  14. Remove underhood storage unit.
    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
  15. Remove HEPA filter.
    Note
    Lift up from bottom and pull out.
  16. Remove LH outer hood hinge cover.
    Note
    2x clips.
  17. Remove RH outer hood hinge cover.
    Note
    2x clips.
  18. Disconnect cowl drain hose from cowl trim.
    Note
    1x clamp.
  19. Disconnect wiper arm hose from cowl.
  20. Remove LH wiper arm.
    Note
    1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl.
  21. Remove RH wiper arm.
    Note
    2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl.
  22. Release cowl screen washer supply hose.
    Note
    1x one way valve.
  23. Remove wiper cowl screen panel.
    Note
    5x push clips, 1x windshield washer hose, 1x drain hose clamp.
  24. Remove HEPA filter duct.
    Note
    1x clip.
  25. Overlap time for A/C recovery.
  26. Remove A/C lines from vehicle.
  27. Power down vehicle.
    Note
    Via center display > Controls > Safety > Power Off.
  28. Disconnect 12V negative terminal.
    Note
    1x nut, 10mm, 5 Nm.
  29. Disconnect first responder loop.
    Note
    1x connector, push to release.
  30. Raise vehicle fully and lower onto locks.
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  31. Remove LH shear plate.
    Note
    2x push clips, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 1x nylon nut, 15mm, 35 Nm Discard nylon nut after removal.
  32. Remove RH shear plate.
    Note
    3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nylon nut, 15mm, 35 Nm Discard nylon nut after removal.
  33. Remove mid aero shield.
    Note
    20x bolts, 10mm, 4 Nm, 2x push clips.
  34. Remove front bash plate extrusion.
    Note
    2x bolts, T30, 16 Nm.
  35. Remove LH ski side covers.
    Note
    14x clips, 3x covers.
  36. Remove RH ski side covers.
    Note
    14x push clips, 3x covers.
  37. Remove four center bolts securing HV battery.
    Note
    4x patch bolts, E12, 38 Nm, Discard bolts after removal.
  38. Position battery table beneath vehicle.
  39. Lower vehicle to table.
    Note
    Recommend assistance, Align table to vehicle and raise casters to level table if necessary.
  40. Remove and discard remaining eight center bolts securing HV battery.
    Note
    8x bolts, E12, 38 Nm, Discard after removal.
  41. Remove front four HV battery bolts.
    Note
    4x patch bolts, 13mm, 30 Nm, Discard after removal.
  42. Remove and discard 21mm bolts securing front of HV battery.
    Note
    2x bolts, 21mm, 115 Nm, Discard after removal.
  43. Remove and discard LH rocker bolts.
    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  44. Remove and discard RH rocker bolts.
    Note
    8x patch bolts, 13mm, 55 Nm, Discard after removal.
  45. Raise vehicle and remove battery table.
    Note
    Recommend assistance.
  46. Move battery away from vehicle.
  47. Remove all items from pockets and ensure not wearing metal items.
  48. Inspect HV insulating gloves.
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003.
  49. Put on HV insulating gloves and leather over gloves.
  50. Verify no high voltage at HV rapid mate.
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
  51. Install HV and LV Rapid Mate covers.
    Note
    2x covers, If covers not available then use masking tape to protect Rapid Mate from debris.
  52. Remove front aero shield.
    Note
    6x bolts, 10mm, 3 Nm, 14x clips.
  53. Lower vehicle partially and set lift onto locks.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
  54. Remove cover and disconnect positive12V terminal.
    Note
    1x nut, 10mm, 5 Nm.
  55. Remove edge clips from battery cage.
    Note
    2x edge clips.
  56. Remove barrel clip from battery cage.
    Note
    1x barrel tree clip.
  57. Remove plastic harness clip.
    Note
    1x clip.
  58. Remove battery vent tube.
    Note
    1x vent tube.
  59. Release bolts securing lower portion of 12v battery cage.
    Note
    2x bolts, 10mm, 6 Nm.
  60. Release bolts securing top portion of 12v battery cage.
    Note
    2x bolts, 13mm, 15 Nm, Be careful and do not to get cordless impact stuck in between window motor casting.
  61. Remove 12v battery cage assembly from vehicle.
  62. Remove coolant reservoir cap.
    Note
    1x cap.
  63. Use vacuum suction tool to remove coolant from reservoir.
  64. Disconnect electrical connector for coolant level sensor.
    Note
    1x connector.
  65. Remove coolant reservoir fasteners and wire harness edge clip.
    Note
    4x bolts, 10mm, 6 Nm, 1x edge clip.
  66. Clamp and remove coolant hose and move reservoir off to the side.
    Note
    1x coolant hose, Place absorbent material below hose to capture fluid.
  67. Disconnect A/C compressor harness at FJB and release cable from drive unit.
    Note
    1x connector, 1x fir tree clip.
  68. Disconnect the A/C compressor logic connector.
    Note
    1x connector.
  69. Release edge clip for the A/C compressor logic connector.
    Note
    1x clip.
  70. Release the ground connection at the A/C compressor mount bracket.
    Note
    1x bolt, T25, 7 Nm.
  71. Remove A/C lines from compressor.
    Note
    2x nuts, 10mm, 10 Nm, Discard O-rings after removal.
  72. Remove A/C compressor from the vehicle.
    Note
    3x bolts, E10, 10 Nm.
  73. Clamp coolant hoses and remove from drive unit.
    Note
    2x coolant hoses.
  74. Disconnect ground strap from body.
    Note
    1x nut, 13mm, 9 Nm.
  75. Disconnector logic connector from drive unit.
    Note
    1x connector with lock tab.
  76. Remove LH front wheel center cap.
  77. Loosen LH front axle nut.
    Note
    1x nut, 32mm, 245 Nm.
  78. Remove LH front lug nut covers.
    Note
    5x lug nut covers.
  79. Loosen LH front lug nuts.
    Note
    5x nuts, 21mm, 175 Nm.
  80. Remove RH front wheel center cap.
  81. Loosen RH front axle nut.
    Note
    1x nut, 32mm, 245 Nm.
  82. Remove RH front lug nut covers.
    Note
    5x lug nut cover.
  83. Loosen RH front lug nuts.
    Note
    5x nuts, 21mm, 175 Nm.
  84. Raise vehicle partially and lower onto locks.
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  85. Remove RH front wheel.
    Note
    5x nuts, 21mm, 175 Nm.
  86. Remove LH front wheel.
    Note
    5x nuts, 21mm, 175 Nm.
  87. Release LH front wheel liner from body.
    Note
    11x push clips, 2x nuts, 10mm, 6 Nm.
  88. Remove LH front wheel liner from vehicle.
  89. Release power train pump 2 from bracket and disconnect harness.
    Note
    1x connector.
  90. Clamp hose and remove hose from pump and push towards the drive unit.
  91. Remove HV cables from DU.
    Note
    4x patch bolts, T30, 7 Nm, Discard after removal.
  92. Remove LH tie rod nut and move tie rod end away.
    Note
    1x Nyloc nut, 21mm, 103 Nm, Discard after removal.
  93. Remove RH tie rod nut and move tie rod end away.
    Note
    1x nyloc nut, 21mm, 103 Nm, Discard after removal.
  94. Raise vehicle fully and lower onto locks.
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
  95. Remove skid bar from front subframe.
    Note
    4x bolts, 10mm, 10 Nm.
  96. Remove skid plate from front subframe.
    Note
    2x bolts, 10mm, 9 Nm.
  97. Remove the fastener to steering gear and disconnect steering shaft from the rack and pinon.
    Note
    1x bolt, 13mm, 30 Nm.
  98. Disconnect 12v connection to rack and pinion.
    Note
    2x connectors.
  99. Release chiller from subframe.
    Note
    2x bolts, 13mm, 12 Nm.
  100. Disconnect battery pump 1 release coolant hose from subframe and remove pump from subframe bracket.
    Note
    1x connector, 1x fur tree clip.
  101. Release cowl drain hose from subframe.
    Note
    1x edge clip.
  102. Remove and discard the nut that secures the LH stabar to the stabar end links and remove end link from bar.
    Note
    1x nyloc nut, 15mm, 70 Nm, Discard after removal.
  103. Remove the RH stabar from the stabar end link and remove end link from bar.
    Note
    1x nyloc nut, 15mm, 70 Nm, Discard after removal.
  104. Remove nut and bolt securing LH front air spring module to front lower aft link.
    Note
    1x nut, 21mm, 1x bolt, 21mm, 140 Nm.
  105. Remove the bolt and nut that secure the RH front shock absorber to the rear lower control arm.
    Note
    1x nut, 21mm, 1x bolt, 21mm, 140 Nm.
  106. Remove LH side lower control arm nuts.
    Note
    2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage.
  107. Remove RH side lower control arm nuts.
    Note
    2x nyloc nuts, 21mm, 196 Nm, 2x washers, Discard after removal, Need to hold ball joint to prevent damage.
  108. Position subframe fixture beneath vehicle and raise fixture.
  109. Remove the bolts that secure the subframe to the chassis.
    Note
    2x bolts, 13mm, 20 Nm, 2x bolts, 16mm, 80 Nm, 2x bolts, 18mm, 115 Nm.
  110. Lower subframe and move it away from vehicle.
    Note
    Need to tilt subframe back to remove from carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar.
  111. Remove axle nut and washer securing LH drive axle to hub assembly.
    Note
    1x nut, 32mm, 245 Nm, 1x washer, Discard washer after removal, Nut can be reused.
  112. Install the hub puller onto the LH front brake rotor.
    Note
    5x lug nuts, 21mm, Hand tight.
  113. Use hub puller to free LH halfshaft from hub splines.
    Note
    Counter hold hub puller.
  114. Remove hub puller from LH hub assembly.
    Note
    5x lug nuts, Hand tight.
  115. Remove axle nut and washer securing RH drive axle to hub assembly.
    Note
    1x nut, 32mm, 245 Nm, 1x washer, Discard washer after removal, nut can be reused.
  116. Setup hub puller onto RH hub assembly.
    Note
    5x lug nuts, 21mm, Hand tight.
  117. Use hub puller to free RH halfshaft from hub splines.
    Note
    Counter hold hub puller.
  118. Remove hub puller from RH hub assembly.
    Note
    5x lug nuts, Hand tight.
  119. Remove LH axle from drive unit hub.
    Note
    1x axle.
  120. Remove RH axle from jack shaft and hub.
    Note
    1x axle.
  121. Remove jack shaft.
    Note
    2x bolts, 15mm, 30 Nm.
  122. Disconnect chiller harness.
    Note
    1x connector.
  123. Remove coolant hose from battery pump 2 to chillere.
    Note
    1x coolant hose.
  124. Disconnect and remove battery pump 2 from frame rail.
    Note
    1x connector, 1x screw, T30, 10 Nm.
  125. Remove NVH pad from drive unit to access drain plug.
  126. Drain drive unit oil.
    Note
    1x hex bolt, 8mm, 28 Nm, position oil drain under vehicle to reduce spilling as needed.
  127. Remove the lower RH section of the NVH pad.
    Note
    This will allow the drive unit fixture to fit.
  128. Position transmission jack fixture under drive unit.
  129. Remove bolts that secure clevis to LH front rail.
    Note
    2x bolts with washers, 15mm, 65 Nm, Discard after removal.
  130. Remove RH mount bolts to DU.
    Note
    4x bolts, 15mm, 35 Nm.
  131. Lower front drive unit with jack out of vehicle.
  132. Remove coolant hoses from drive unit.
    Note
    2x hose clamp.
  133. Remove the remaining NVH covers.
  134. Remove ground strap from drive unit.
    Note
    1x bolt, 10mm, 6 Nm.
  135. Move drive unit over to the gantry.
  136. Attach lifting sling to drive unit.
  137. Raise drive unit to gain access to HV lugs cover.
  138. Remove the inverter breather cover.
    Note
    1x bolt, 10mm, 6 Nm.
  139. Remove the sticker from HV lug cover.
  140. Remove the HV lug cover.
    Note
    2x bolts, 8mm, 5 Nm.
  141. Remove the HV lug fasteners.
    Note
    3x bolts, 10mm, 7 Nm.
  142. Support the inverter and remove all inverter fasteners.
    Note
    10x bolts, 8mm, 12 Nm.
  143. Pull inverter back to gain access to disconnect the connector.
    Note
    1x connector.
  144. Remove inverter from drive unit and place on an ESD mat.
  145. If the pyrotechnic fuse of the drive unit inverter has not been actuated, dispose of the drive unit inverter as hazardous material. If the pyrotechnic fuse has been actuated, follow the normal regulations for waste disposal.
    Note
    If Autodiag falsely indicated that the pyrotechnic fuse was actuated, but visual check confirms that it was not activated, list the serial number of the drive unit inverter in Autodiag using 'Report an Issue'.

Installation

  1. While supporting the inverter connect the drive unit connector.
    Note
    1x connector.
  2. Install inverter fasteners but leave them loose.
    Note
    10x bolts, 8mm, 12 Nm.
  3. With the inverter loose install the HV lug fasteners - don't torque yet.
    Note
    3x patch bolts, 10mm, 7 Nm, Install new bolts.
  4. Torque inverter cover down.
    Note
    10x bolts, 8mm, 12 Nm.
  5. Torque HV lug fasteners.
    Note
    3x patch bolts, 10mm, 7 Nm, install new bolts.
  6. Mark the HV lugs with a paint pen.
    Note
    Pink paint pen.
  7. Apply a small amount of O-ring lubricant to the O-rings on 1 HV lug cover.
  8. Install HV lug cover and install the fasteners.
    Note
    Makes sure cover is flush, 2x bolts, 8mm, 5 Nm.
  9. Install HV lug cover sticker.
  10. Push drive unit back to the vehicle.
  11. Install logic plug.
    Note
    1x plug.
  12. Install HV plugs.
    Note
    2x plugs.
  13. Install breather plug.
    Note
    1x plug.
  14. Connect air line to pressure regulator . Set pressure to 1 psi.
  15. Connect pressure regulator to hose in the breather hole. Open valve and fill inverter. Let it settle for 1 min.
  16. Run a 1 min leak down test.
    Note
    Max leak down in 1 min is .2 psi.
  17. Remove pressure tester from hose.
  18. Remove breather plug.
    Note
    1x hose.
  19. Remove logic connector plug.
    Note
    1x plug.
  20. Remove HV plugs.
    Note
    2x plug.
  21. Install new breather valve.
  22. Install breather cover.
    Note
    1x bolt, 10mm, 5 Nm.
  23. Install ground strap to drive unit.
    Note
    1x bolt, 10mm, 6 Nm.
  24. Install NVH pad on to the drive unit.
  25. Install coolant hose to drive unit.
    Note
    2x coolant hoses.
  26. Move drive unit under vehicle, lift into place and loosely install bolts by hand.
    Note
    2x bolts with washers, 15mm, 50 Nm, 4x bolts, 15mm, 35 Nm, Do not torque at this time.
  27. Check shim fitment and adjust prior to torquing mounts.
  28. Torque both drive unit mounts and check shim fitment.
    Note
    2x 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.
  29. Remove transmission jack from under vehicle.
  30. Install the lower RH section of the NVH pad.
  31. Install jack shaft.
    Note
    2x bolts, 15mm, 30 Nm.
  32. Apply Molykote M-77 to outboard side of LH axle shaft.
    Note
    Clean if necessary, Apply no more than 1 gram to axle only.
  33. Install RH axle and loosely install axle nut.
    Note
    1x nut, 32mm, 245 Nm, 1x washer, Install new nut and washer, Recommend assistance, Torque at a later step.
  34. Apply Molykote M-77 to outboard side of LH axle shaft.
    Note
    Clean if necessary, Apply no more than 1 gram to axle only.
  35. Install LH axle and loose install axle nut will be torqued at a later step.
    Note
    1x nut, 32mm, 205 Nm, 1x washer, Install new nut and washer, Assistance required, Torque at a later step.
  36. Install NVH covers on front of DU.
  37. Install battery pump 2 to frame rail and connect harness.
    Note
    1x connector, 1x bolt, T30, 10 Nm.
  38. Connect coolant hose from chiller to battery pump 2.
    Note
    1x coolant hose.
  39. Connect chiller harness.
    Note
    1x connector.
  40. Install subframe in position for install.
    Note
    Need to tilt subframe back to remove from carrier, Be mindful of coolant hoses and chiller, may need to feed them past the sway bar.
  41. Install the bolts that secure the subframe to the chassis.
    Note
    2x bolts, 13mm, 20 Nm, 2x bolts, 16mm, 80 Nm, 2x bolts, 18mm, 115 Nm.
  42. Remove subframe fixture from under vehicle.
  43. Install RH side lower control arm nuts.
    Note
    2x nyloc nuts and washers, 21mm, 195 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage.
  44. Install RH side lower control arm nuts.
    Note
    2x nyloc nuts and washers, 21mm, 196 Nm, Install new nuts and washers, Need to hold ball joint to prevent damage.
  45. Loosely install the bolt and nut that secure the RH front shock absorber to the rear lower control arm.
    Note
    1x nut, 21mm, 1x bolt, 21mm, 140 Nm, Torqued at a later step.
  46. Install nut and bolt securing LH front air spring module to front lower aft link.
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm, Torque at ride height on alignment rack.
  47. Install the RH stabar to the stabar end link.
    Note
    1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket.
  48. Install the LH stabar to the stabar end link.
    Note
    1x nyloc nut, 15mm, 70 Nm, Install new nut, Counter hold stud with 5mm hex socket.
  49. Install cowl drain hose to subframe.
    Note
    1x edge clip.
  50. Connect battery pump 1 to bracket and connect harness.
    Note
    1x connector, 1x fur tree clip.
  51. Secure chiller to subframe.
    Note
    2x bolts, 13mm, 12 Nm.
  52. Connect 12v connection to rack and pinion.
    Note
    2x connectors.
  53. Connect steering shaft to the rack pinon and install the fastener.
    Note
    1x bolt, 13mm, 30 Nm.
  54. Install skid plate to front subframe.
    Note
    2x bolts, 10mm, 9 Nm. Note: start bolts with cordless, torque using torque wrench. .
  55. Install skid bar to front subframe.
    Note
    4x bolts, 10mm, 10 Nm.
  56. Lower vehicle partially and set lift onto locks.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
  57. Install the nut that secures RH tie rod end to the knuckle.
    Note
    1x nyloc nut, 21mm, 103 Nm, Install new nut.
  58. Install nut that secures LH tie rod end to the knuckle.
    Note
    1x nyloc nut, 21mm, 103 Nm, Install new nut.
  59. Lower vehicle to comfortable working height.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  60. Install hub jack adapter onto LH front hub.
    Note
    5x lug nuts, 21mm, Hand tight, Use modified hydraulic hub tool if correct adapter is not available.
  61. Position and raise support stand to simulate LH front suspension at ride height.
  62. Install the ride height tool onto the LH front upper control arm and the body.
    Note
    For EMEA FUCA Ride Height Tool (1098012-E2-B): Clean debris in the shock tower, and then align the tool profile with the shock tower profile.
    Figure 1. FUCA Ride Height Tool - All Regions except EMEA
    Figure 2. FUCA Ride Height Tool - All Regions except EMEA
    Figure 3. FUCA Ride Height Tool - EMEA
    Figure 4. FUCA Ride Height Tool - EMEA
  63. Torque the LH fore link to subframe.
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
  64. Remove the existing paint mark from LH fore link.
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking.
  65. Mark the LH fore link nut and subframe to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  66. Torque LH aft link to subframe.
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
  67. Remove the existing paint mark from LH aft link.
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking.
  68. Mark LH front aft link bolt and subframe to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  69. Remove existing paint mark from LH air spring module bolt.
    Note
    Clean nut and surrounding area thoroughly so the new marking is not confused with the previous marking.
  70. Torque LH air spring module nut and bolt to LH aft link assembly.
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm.
  71. Mark LH air spring module nut to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  72. Remove ride height tool from LH front upper control arm.
  73. Remove support stand from underneath LH front suspension.
    Note
    Lower stand until suspension is unladen before removal.
  74. Remove hub jack adapter from LH front hub.
    Note
    5x lug nuts, 21mm, Hand tight.
  75. Install LH front wheel liner onto vehicle.
  76. Secure LH front wheel liner to body.
    Note
    11x push clips, 2x nuts, 10mm, 6 Nm.
  77. Release RH front wheel liner from body.
    Note
    11x push clips, 2x nuts, 10mm, 6 Nm.
  78. Remove RH front wheel liner from vehicle.
  79. Install hub jack adapter onto RH front hub.
    Note
    5x lug nuts, 21mm, Hand tight, Use modified hydraulic hub tool if correct adapter is not available.
  80. Position and raise support stand to simulate RH front suspension at ride height.
  81. Set ride height tool onto RH front upper control arm.
  82. Torque RH fore link to subframe.
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
  83. Remove the existing paint mark from RH fore link.
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking.
  84. Mark the RH fore link nut and subframe to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  85. Torque RH front aft link subframe.
    Note
    1x bolt, 21mm, 1x nut, 22mm, 130 Nm.
  86. Remove the existing paint mark from RH aft link.
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking.
  87. Mark the RH front aft link bolt and subframe to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  88. Torque RH air spring module nut and bolt to RH aft link assembly.
    Note
    1x bolt, 21mm, 1x nut, 21mm, 140 Nm.
  89. Remove the existing paint mark from RH air spring module.
    Note
    Clean the area thoroughly so the new marking is not confused with the previous marking.
  90. Mark RH air spring module nut to show the component has been torqued.
    Note
    Use a high visibility paint pen when marking components.
  91. Remove ride height tool from RH front upper control arm.
  92. Remove support stand from underneath RH front suspension.
    Note
    Lower stand until suspension is unladen before removal.
  93. Remove hub jack adapter from RH front hub.
    Note
    5x lug nuts, 21mm, Hand tight.
  94. Install RH front wheel liner onto vehicle.
  95. Secure RH front wheel liner to body.
    Note
    11x push clips, 2x nuts, 10mm, 6 Nm.
  96. Lower vehicle partially and set lift onto locks.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
  97. Install HV cables into DU.
    Note
    4x patch bolts, T30, 7 Nm, Install new bolts.
  98. Connect coolant hose to powertrain pump 2.
    Note
    1x coolant hose.
  99. Install pump on to bracket and connect harness.
    Note
    1x connector.
  100. Lower vehicle partially and set lift onto locks.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
  101. Connect Front Drive Unit logic connector.
    Note
    1x connector with locking tab.
  102. Connect ground strap to body.
    Note
    1x nut, 13mm, 9 Nm.
  103. Connect coolant hose from drive unit.
    Note
    2x coolant hoses.
  104. Install A/C compressor.
    Note
    3x bolts, E10, 10 Nm.
  105. Install both A/C lines to compressor.
    Note
    2x nuts, 10mm, 10 Nm, Replace the O-rings.
  106. Secure the ground connection at the A/C compressor mount bracket.
    Note
    1x bolt, T25, 7 Nm.
  107. Secure edge clip for the A/C compressor logic connector.
    Note
    1x edge clip.
  108. Connect the A/C compressor logic connector.
    Note
    1x connector.
  109. Connect A/C compressor harness to FJB .
    Note
    1x connector.
  110. Connect coolant hose to reservoir and remove hose clamp.
    Note
    1x coolant hose.
  111. Install fasteners securing coolant reservoir to shock tower cross member.
    Note
    4x bolts, 10mm, 6 Nm.
  112. Install battery cage assembly into vehicle.
  113. Install bolts into top of battery cage assembly.
    Note
    2x bolts, 13mm, 15 Nm.
  114. Install bolts in bottom of battery cage assembly.
    Note
    2x bolts, 10mm, 6 Nm.
  115. Install battery vent tube back into battery.
    Note
    1x vent tube.
  116. Install plastic harness clip.
    Note
    1x clip.
  117. Install clip onto battery cage.
    Note
    1x barrel clip.
  118. Install edge clips onto battery cage.
    Note
    2x edge clips.
  119. Connect 12V positive terminal.
    Note
    1x nut, 10mm, 5 Nm.
  120. Install positive 12V terminal cover.
  121. Raise vehicle fully and lower onto locks.
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side. 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.
  122. Remove HV and LV Rapid Mate covers.
    Note
    2x covers.
  123. Position HV battery underneath vehicle.
  124. Lower vehicle onto HV battery pack.
    Note
    Before lowering fully use assistance to align the pack using the alignment rods and guide via the borescope camera or a flexible inspection mirror checking HV and LV rapid mates.
  125. Loosely install 4 new front bolts for HV battery.
    Note
    4x patch bolts, 13mm, 30 Nm, Install new patch bolts.
  126. Install LH rocker bolts hand tight.
    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts.
  127. Install RH rocker bolts hand tight.
    Note
    8x patch bolts, 13mm, 55 Nm, Install new patch bolts.
  128. Install 21mm bolts at front of HV battery hand tight.
    Note
    2x bolts, 21mm, 115 Nm, Install new bolts.
  129. Install eight outer center bolts hand tight.
    Note
    8x patch bolts, E12, 38 Nm, Install new patch bolts.
  130. Torque rocker HV battery bolts on both sides.
    Note
    16x bolts, 13mm, 55 Nm.
  131. Torque remaining HV battery bolts.
    Note
    8x bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x bolts, 13mm, 30 Nm.
  132. Raise vehicle off of HV battery.
  133. Install inner center HV battery bolts with battery powered drill .
    Note
    4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts.
  134. Install LH ski side covers.
    Note
    14x clips, 3x covers.
  135. Install RH ski side covers.
    Note
    14x clips, 3x covers.
  136. Install front bash plate extrusion.
    Note
    2x bolts, T30, 16 Nm.
  137. Install front aero shield.
    Note
    6x bolts, 10mm, 3 Nm, 14x clips.
  138. Install mid aero shield.
    Note
    20x bolts, 10mm, 4 Nm, 2x push clips. Start bolts with cordless, torque with 1/4 torque wrench.
  139. Install LH shear plate.
    Note
    3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, Install new nyloc nut, 15mm, 35 Nm.
  140. Install RH shear plate.
    Note
    3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, Install new nyloc nut, 15mm, 35 Nm.
  141. Lower vehicle partially and set lift onto locks.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
  142. Install LH front wheel.
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool.
  143. Install RH rear wheel.
    Note
    5x nuts, 21mm, 175 Nm.
  144. Lower vehicle until tires are touching ground.
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  145. Torque LH front wheel.
    Note
    5x nuts, 21mm, 175 Nm.
  146. Torque RH front wheel.
    Note
    5x nuts, 21mm, 175 Nm.
  147. Torque LH front axle nut.
    Note
    1x nut, 32mm, 245 Nm.
  148. Torque RH front axle nut.
    Note
    1x nut, 32mm, 245 Nm.
  149. Install LH front wheel center cap.
    Note
    1x cap, Verify emblem is aligned with valve stem.
  150. Install LH front lug nut covers.
    Note
    5x covers.
  151. Install RH front wheel center cap.
    Note
    1x cap, Verify emblem is aligned with valve stem.
  152. Install RH front lug nut covers.
    Note
    5x covers.
  153. Connect first responder loop and then 12V negative terminal.
    Note
    1x connector, 1x nut, 10mm, 5 Nm.
  154. In toolbox, run the refrigerant drain and fill routine to enable A/C filling.
    Note
    Click Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play.
  155. 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.
  156. Remove fill plug.
    Note
    1x hex bolt, 8mm, 28 Nm.
  157. Fill front small drive unit with oil.
    Note
    1.8 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).
  158. Install fill plug.
    Note
    1x hex bolt, 8mm, 28 Nm.
  159. Install HEPA filter duct.
    Note
    1x clip.
  160. Remove wiper cowl screen panel.
    Note
    5x push clips, 1x windshield washer hose, 1x drain hose clamp.
  161. Connect cowl drain hose onto cowl trim.
    Note
    1x clamp.
  162. Conenct cowl screen washer supply hose.
    Note
    1x one way valve.
  163. Install RH wiper arm.
    Note
    2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl.
  164. Install LH wiper arm.
    Note
    1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl.
  165. Connect wiper arm hoses to cowl.
    Note
    2x washer hoses.
  166. Install LH outer hood hinge cover.
    Note
    2x clips.
  167. Install RH outer hood hinge cover.
    Note
    2x clips.
  168. Remove coolant reservoir cap.
    Note
    1x cap.
  169. Fill reservoir to "NOM" line .
    Note
    Monitor the coolant level once the purge routine is running, adding coolant as required using G-48 coolant.
  170. Remove steering wheel holder from vehicle.
  171. Place vehicle in service mode with touchscreen.
    Note
    Select 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.
  172. Unlock vehicle Gateway.
    Note
    After vehicle has been put into "Service Mode", hold down the brake pedal, while holding down break pedal simultaneously hold the turn signal stalk fully up for at least 10 seconds, "GTW UNLOCKING" should pop up on the instrument cluster right below the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the instrument cluster underneath the VIN, the gateway will remain unlocked for 90 minutes.
  173. Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 3.
    Note
    Remove cubby under MCU and connect laptop to vehicle, Open Toolbox 3 website and establish connection to vehicle.
  174. Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia 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
    via Toolbox:(link)    , click "Run", and allow routine to complete.
    Note
    Make 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.
  175. Top off the reservoir to the "NOM" line with G-48 coolant.
    Note
    Ensure coolant is filled to nominal level.
  176. Install coolant reservoir cap .
    Note
    1x cap.
  177. Install HEPA filter housing.
  178. Install underhood storage unit.
    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
  179. Install frunk carpet.
    Note
    2x connectors.
  180. Inject oil into the system.
    Note
    Refill with the amount removed during recovery.
  181. Perform A/C refrigerant refill.
    Note
    Run time, per fluid capacity spec.
  182. Remove A/C lines from vehicle.
    Note
    Press clear lines once lines have been removed.
  183. Install dust caps onto vehicle high and low side service ports.
    Note
    2x threaded caps.
  184. Test A/C functions in vehicle to ensure cabin cooling functions as designed.
  185. Perform A/C hose flush.
    Note
    Touch time only. No overlap from this since the machine is disconnected from the vehicle.
  186. In toolbox, run routine to write Drive Inverter Information to the new Inverter.
    Note
    Go 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.
  187. Perform a firmware update. See Firmware Update.
  188. Disconnect laptop from vehicle and install storage cubby.
    Note
    1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby.
  189. Install lower storage cubby.
  190. Install under hood aprons.
    Note
    4x aprons.
  191. Close hood.
  192. Calibrate falcon doors via UI.
    Note
    Via Controls > Calibrate, Required after 12V and FRL disconnect.
  193. Close LH front door.
  194. Remove vehicle from lift.
    Note
    Lower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode", Via Controls > Service > Jack Mode.
  195. Review wheel alignment requirements and add correction code as needed. See Alignment Requirement - Suspension.