21/08/2023 14:47:02

Evaporator (Remove and Replace)

Correction code 18201012

2023-08-21: Revised procedure using the latest vehicle validation.

Removal

Open LH front door
Open all doors and liftgate

Note
Using MCU touchscreen > Controls > Trunk , touchscreen > Controls > Front doors
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
Open hood

Note
Via center display > Controls > Front Trunk
Remove underhood aprons

Note
4x aprons, LH and RH aprons have 1x clip each
Set up A/C machine and perform hose flush
Remove dust caps from vehicle’s high-side and low-side service ports

Note
2x 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
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
Move LH front seat forward
Remove the LH seat rear track covers

Note
2x covers
Remove LH front seat rear fasteners

Note
2x patch bolts, T45P, 34 Nm, Discard after removal, Use Torchless heat induction tool to help remove bolts if necessary
Move LH front seat backward
Remove both LH rear screws securing the seat track cover and remove covers from seat

Note
2x screws, T15, 2 Nm
Remove the LH seat front track covers

Note
2x covers
Remove LH front seat front fasteners

Note
2x patch bolts, T45P, 34 Nm, Discard after removal, Use Torchless heat induction tool to help remove bolts if necessary
Adjust the position of the LH seat for easy removal

Note
Middle of track, most upright position, seat fully up off the floor
Move RH front seat forward
Remove both LH front screws securing the seat track cover

Note
2x screws, T15, 2 Nm
Remove the RH seat rear track covers

Note
2x covers
Remove RH front seat rear fasteners

Note
2x bolts, T45+, 34 Nm, Discard after removal, Use Torchless heat induction tool to help remove bolts
Move RH front seat backward
Remove both LH rear screws securing the seat track cover and remove covers from seat

Note
2x screws, T15, 2 Nm
Remove the RH seat front track covers

Note
2x covers
Remove RH front seat front fasteners

Note
2x bolts, T45, 34 Nm, Discard after removal, Use Torchless heat induction tool to help remove bolts
Adjust the position of the RH seat for easy removal

Note
Middle of track, most upright position, seat fully up off the floor
Remove frunk carpet

Note
2x connectors
Remove underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Remove HEPA filter

Note
Lift up from bottom and pull out
Disconnect 12V negative terminal and First Responder Loop

Note
1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
Disconnect the LH seat connectors

Note
3x connectors. Number of connectors may vary depending on vehicle production level
Remove LH front seat from vehicle

Note
Recommend Assistance, Caution: Do not damage other components
Release the LH center console side trim panel

Note
13x clips
Remove LH center console closeout extension

Note
6x clips
Release the RH center console side trim panel

Note
13x clips
Remove RH center console closeout extension

Note
6x clips
Remove rear air outlet trim panel

Note
4x clips
Disconnect the USB ports from the trim panel

Note
2x connectors
Open the rear cup holder
Remove the rear cupholder trim panel

Note
Slide up to remove
Close rear cup holder
Release the rear center console trim panel

Note
8x clips
Disconnect the harnesses from the module at rear trim panel

Note
6x connectors
Remove the front cup holder dividers, then remove the rubber mat at the base of the console
Disconnect center console harness

Note
4x connectors, Number of connectors may vary depending on vehicle production level
Remove the bolts securing center console assembly

Note
1x screw, T20, 2 Nm, 6x bolts, 10mm, 5 Nm
Remove center console from vehicle

Note
Recommend assistance
Remove LH IP side cover

Note
5x clips
Remove LH SWD bezel

Note
3x locating tabs, Slides out to the side
Remove screw securing LH side of top pad to IP carrier

Note
1x screw, T20, 1.2 Nm
Remove LH lower IP trim

Note
9x clips
Remove lower binnacle cover from IP area of vehicle

Note
4x clips
Remove screws securing top pad to binnacle

Note
2x screws, T20, 1.2 Nm
Release clips securing upper steering column gap hider to IC bezel

Note
2x clips
Remove RH IP side cover

Note
5x clips
Remove RH SWD bezel

Note
3x locating tabs, Slides out to side
Remove screw securing RH side of top pad

Note
1x screw, T20, 1.2 Nm
Remove lower glove box trim

Note
6x clips
Open glove box

Note
Release button on RH side of MCU bezel
Remove RH instrument panel lower trim

Note
13x clips
Remove the glove box assembly

Note
6x screws, T20, 2.3 Nm, 3x connectors
Remove passenger footwell cover

Note
2x clips, 1x connector
Remove fasteners securing passenger knee air bag bracket to IP carrier

Note
3x screws, T20, 2.3 Nm
Cover the aluminum strip on the top pad and MCU bezel with tape for protection
Disconnect the connectors from the RH side of the AP ECU

Note
4x connectors, Number of connections may vary depending on hardware type
Remove nuts securing the AP ECU to the cross car beam

Note
4x nuts, 8mm, 5 Nm. Discard the nuts
Disconnect the connectors from the LH side of the AP ECU and remove the AP ECU from vehicle

Note
7x connectors
Remove recirculation hood

Note
2x clips
Remove the air bag mounting bolts

Note
2x bolts, 10mm, 10 Nm, Discard after removal
Disconnect air bag connectors

Note
3x connectors, Release locking tab then release connector
Release the top pad from the vehicle

Note
Lifting with an inflatable wedge is recommended to reduce the risk of bending the top pad, Place the inflatable wedge above the vent outlet at the left and right side of the touchscreen
Release ground strap from top of MCU

Note
1x connector
Remove top pad from vehicle

Note
Recommend assistance
Remove the instrument cluster bezel from the IP carrier

Note
4x screws, T20, 2.3 Nm
Remove screws securing LH IP finisher with vent to IP carrier

Note
2x screws, T20, 2.3 Nm
Release clips securing LH IP finisher with vent to the IP carrier and remove from vehicle

Note
3x clips
Remove the instrument cluster

Note
4x screws, T20, 2 Nm2x connectors
Remove screws securing RH instrument panel finisher assembly to the IP carrier

Note
2x screws, T20, 2.3 Nm
Release the clips for the RH finisher and remove from vehicle

Note
6x clips
Remove the MCU mounting bolts

Note
4x bolts, T25, 7 Nm, Note locations of washers if present
Tilt the MCU out from the IP carrier at the top in order to access connectors

Note
Caution: Do not pull on harnesses as it can damage the connectors
Disconnect harness connectors from MCU and remove from vehicle

Note
17x connectors, Recommend assistance, Number of connectors may vary depending on vehicle configuration and MCU part number revision, Start by disconnecting the hazard and glovebox switches first
Gently place the MCU on the ESD foam container with the touchscreen facing down
Remove LH rear welcome plate

Note
8x clips
Remove LH rear door sill trim

Note
1x bolt, T25, 2x clips, 2.5 Nm. Discard bolt after removal
Release LH front door seal from lower door sill
Remove LH front lower door sill

Note
8x clips, 3x datums
Remove LH lower A-pillar trim

Note
1x bolt, T25, 5 Nm, 4x clips
Remove RH rear welcome plate

Note
8x clips
Remove RH rear door sill trim

Note
1x patch bolt, T25, 2.5 Nm, 2x clips
Remove RH front door sill trim

Note
7x clips
Release RH front door seal from lower door sill
Remove RH lower A-pillar trim

Note
1x bolt, T25, 5 Nm, 4x clips
Disconnect cowl drain hose from cowl trim

Note
1x clamp
Remove RH outer hood hinge cover

Note
2x clips
Remove LH outer hood hinge cover

Note
2x clips
Remove RH wiper arm

Note
2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl
Remove LH wiper arm

Note
1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl
Release cowl screen washer supply hose

Note
1x one way valve
Remove cowl screen from windshield

Note
5x push clips, 1x FRL anchor from cowl screen
Remove HEPA filter duct

Note
1x clip
Remove wiper motor assembly

Note
3x bolts, 10mm, 9 Nm, 1x connector
Disconnect 12V harness from center support bracket

Note
1x clip
Remove center support bracket

Note
2x bolts, 13mm, 20 Nm, 2x nuts, 13mm, 20 Nm
Remove bolts securing air suspension reservoir brackets to vehicle

Note
4x bolts, 10mm, 6 Nm
Carefully move the air suspension reservoir to the RH side to allow for access to the bulkhead dust boot
Remove A/C hoses from vehicle
Remove passenger knee air bag and bracket

Note
4x patch bolts, 10mm, 10 Nm, 1x connector, 1x fir tree clip, With pick pull out latch on air bag connector to release connector, Discard patch bolts after removal, some vehicles may not be equipped with airbag
Remove LH footwell cover

Note
2x clips, 1x connector, Release clips and disconnect puddle lamp
Remove driver knee airbag from cross car beam

Note
2x nuts, 10mm, 10 Nm, 1x connector, Discard fasteners after removal
Unbolt the screws securing airbag to steering wheel

Note
2x screws, T25, 7 Nm, The screws will remain inside the steering wheel, If required rotate the steering wheel to gain access to screws, Afterwards return steering wheel to straight and center position
Carefully separate the driver's airbag from steering wheel

Note
Use a plastic trim tool, Carefully work your way around the airbag assembly, Do not damage any components
Carefully release the driver's airbag from the steering wheel assembly and disconnect the airbag and steering wheel controls

Note
3x connectors
Remove bolt that secures the steering wheel to the column

Note
1x patch bolt, 10mm allen, 80 Nm, Discard after removal
Position the wheels straight ahead and mark the steering wheel relative position to the column
Remove steering wheel
Tape the clockspring cassette to prevent rotation

Note
Do not rotate the clockspring
Rock SCCM back and forth to release from column
Release harness connector from SCCM and remove SCCM

Note
1x connector, Remove black locking tab then depress connector release tab to release connector, Locking tab is one time use discard after removal
Remove bracket under steering column area

Note
2x screws, T20, 2 Nm
Disconnect harness connectors for steering column motors

Note
2x connectors
Mark the steering column relative position to the upper i-shaft joint
Remove bolt securing upper i-shaft to steering column

Note
1x bolt, 13mm, 30 Nm
Release steering column from upper i-shaft

Note
Slide joint down upper i-shaft
Remove fasteners securing steering column to cross car beam

Note
2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm
Remove steering column from vehicle
Remove LH sunvisor bezel

Note
6x clips, 5x tabs, Release clips then slide bezel toward front of vehicle
Remove LH upper A-pillar trim

Note
1x nut, 13mm, 8 Nm, 1x screw, T20, 2 Nm, 2x bolts, 10mm, 5 Nm, 2x connectors
Remove RH sunvisor bezel

Note
6x clips, 5x tabs, Release clips then slide bezel toward front of vehicle
Remove RH upper A - pillar trim

Note
1x nut, 13mm, 8 Nm, 1x screw, T20, 2 Nm, 2x bolts, 10mm, 5 Nm, 2x connectors
Remove mesh grille from IP carrier

Note
4x screws, T20, 2 Nm, 2x clips
Remove IP carrier speakers

Note
6x screws, T-20, 2 Nm 3x Electrical connections
Release IP harness clips from IP carrier

Note
2x clips, 1 near cubby and 1 near steering column
Remove IP carrier from cross car beam

Note
13x screws, T20, 2 Nm, 1x clip, Release clip securing speaker connection on underside of carrier, Recommend assistance
Remove LH inner podium cover

Note
6x clips
Remove RH inner podium cover
Release LH and RH seat harnesses from seat riser podium

Note
2x clips
Remove the inner seat riser fasteners and washers

Note
4x bolts, T45P, 34 Nm, Discard after removal
Remove inner seat riser

Note
Fold carpet back to ease removal of inner seat riser
Remove LH outer seat riser

Note
2x bolts, T45, 34 Nm
Remove RH outer seat riser

Note
2x bolts, T45, 34 Nm
Remove front main carpet

Note
4x clips
Remove foam floor support

Note
2x fan clips, 2x fir tree clips
Remove console outlet duct from front HVAC assembly
Remove 2nd row foot ducts
Release IP harness from LH upper A-pillar

Note
2x connectors, 3x clips
Release IP harness from LH lower A-pillar

Note
4x connectors, 1x clip, Release connectors from bracket mounted to body if necessary
Release IP harness from LH side of fuse box

Note
2x connectors
Release IP harness from RH upper A-pillar

Note
4x connectors, 3x clips
Release IP harness from RH lower A-pillar

Note
4x connectors, 1x clip, Release bracket from body, then disconnect connectors
Release coax connectors at cross car beam

Note
4x connectors, Remove connectors from bracket if necessary
Release IP harness from BCCEN

Note
4x connectors
Release IP harness from RH side of fuse box

Note
7x connectors
Release IP harness from center console area

Note
5x connectors, 1x clip, Push tab on side to open cover
Remove cross car beam

Note
10x bolts, 13mm, 27 Nm, Recommend assistance
Remove fasteners securing TXV to evaporator

Note
2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
Disconnect sensor from RH lower air duct on HVAC assembly

Note
1x connector
Remove the fasteners securing the RH lower air duct to the HVAC assembly

Note
2x screws, PH2, 1 Nm
Remove the RH lower air duct from the HVAC assembly

Note
Lower left slide of duct and slide out to the left to release from HVAC assembly
Remove the fasteners securing the HVAC assembly cross brace

Note
2x screws, PH2, 1 Nm
Remove the HVAC assembly cross brace

Note
Gently push brace to the left to release from HVAC box on RH side, Pull the brace towards the rear for the vehicle then side out to the right to release from HVAC assembly
Remove fasteners securing the PTC heater to the HVAC assembly

Note
3x screws, PH2, 1 Nm
Remove the PTC heater from the HVAC assembly

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

Note
3x connectors, 3x clips
Remove the bolts that secure the HVAC assembly to the cowl

Note
2x bolts, 10mm, 6 Nm
Remove the nuts that secure the HVAC assembly to the bulkhead

Note
5x nuts, 10mm, 6 Nm
Release the HVAC drain hose from the nipple on the HVAC assembly while removing the HVAC assembly from the vehicle

Note
Recommend assistance, Plug pipe connections to prevent ingress of moisture or dirt. Place suitable absorbent material around the affected area to absorb any possible fluid spillage
Remove the foam spacer from the HVAC pipe inlet area

Note
Reuse if not damaged
Remove lower evaporator cover

Note
9x screws, Phillips Head
Remove upper evaporator cover

Note
6x screws, PH2, 2 Nm
Remove the screws for the HVAC box for the evaporator inlet pipe

Note
2x screws, PH2, 2 Nm
Remove evaporator from HVAC box
With the evaporator on the bench remove the plastic mounting bracket

Note
3x screws, PH2, 2 Nm

Installation

Install the evaporator mounting bracket on to the new evaporator

Note
3x screws, PH2, 2 Nm
Install new evaporator into HVAC box
Install the upper evaporator cover onto the HVAC box assembly

Note
6x screws, PH2, 2 Nm
Install the lower evaporator cover onto the HVAC box assembly

Note
9x screws, PH2, 2 Nm
Install the HVAC evaporator inlet pipes onto the HVAC box assembly

Note
2x screws, PH2, 2 Nm
Install new foam seal onto HVAC box

Note
Reuse if not damaged
Place the HVAC assembly back into the vehicle for installation

Note
Recommend assistance, Move all loose harness connections out of the way to prevent damage while re-installing the HVAC assembly in the vehicle
Route the PTC heater to the HVAC assembly for installation and slide into HVAC assembly
Install the fasteners securing the PTC heater to the HVAC assembly

Note
3x screws, PH2, 1 Nm
Position the HVAC assembly cross brace for installation to the HVAC assembly
Install the fasteners securing the HVAC assembly cross brace to the HVAC assembly

Note
2x screws, PH2, 1 Nm
Position the HVAC assembly RH lower air duct for installation
Install the fasteners securing the RH lower air duct to the HVAC assembly

Note
2x screws, PH2, 1 Nm
Connect sensor for RH lower air duct on HVAC assembly

Note
1x connector
Move HVAC assembly into position for installation and secure the drain hose

Note
1x hose connection
Install fasteners securing the HVAC assembly to the body

Note
5x nuts, 10mm, 6 Nm, 2x bolts, 10mm, 6 Nm
Connect connectors to HVAC assembly

Note
3x connectors, 3x clips
Install bolts securing TXV to evaporator

Note
2x bolts, T30, 6 Nm, Install new O-rings
Position air suspension reservoir to body
Install bolts securing air suspension reservoir to body

Note
4x bolts, 10mm, 6 Nm. Note: start bolts using cordless, torque with torque wrench
Install LH front air suspension line to air suspension reservoir

Note
2x clips
Install wiper bracket

Note
2x nuts, 13mm, 20 Nm, 2x bolts, 13mm, 20 Nm
Install 12V harness to center support bracket
Install wiper motor assembly

Note
3x bolts, 10mm, 9 Nm
Install HEPA filter duct

Note
1x clip
Remove wiper cowl screen panel

Note
5x push clips, 1x windshield washer hose, 1x drain hose clamp
Install LH outer hood hinge cover

Note
2x clips
Install RH outer hood hinge cover

Note
2x clips
Install RH wiper arm

Note
2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
Install LH wiper arm

Note
1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
Install wiper arm hoses
Install cowl drain hose

Note
1x hose clamp
Connect cowl screen washer supply hose

Note
1x one way valve
Position cross car beam into the vehicle for installation

Note
Recommend assistance, Exercise caution when installing the cross car beam
Secure cross car beam to bulkhead

Note
10x bolts, 13mm, 27 Nm, Recommend assistance
Secure IP harness to LH upper A-pillar

Note
2x connectors, 3x clips
Secure IP harness to LH lower A-pillar

Note
4x connectors, 1x clip, Secure bracket if removed from body
Secure IP harness to LH side of fuse box

Note
2x connectors
Secure IP harness to RH upper A-pillar

Note
4x connectors, 3x clips
Secure IP harness to RH lower A-pillar

Note
4x connectors, 1x clip, Secure bracket if removed
Connect coax connectors at cross car beam

Note
5x connectors, Secure bracket if removed
Connect IP harness at center console area

Note
5x connectors, 1x clip, Latch cover
Secure IP harness to BCCEN

Note
4x connectors
Secure IP harness to RH side of fuse box

Note
4x connectors
Install the 2nd row passenger ducts

Note
Install the front HVAC outlet duct.

Note
Install foam floor support

Note
2x metal fan clips, 2x fir tree clips
Install front main carpet

Note
4x clips
Install inner seat riser and secure seat harness

Note
4x bolts with washers, T45+, 34 Nm, Install new bolts, 2x harness clips
Install LH outer seat riser

Note
2x bolts with washers, T45+, 34 Nm, Install new bolts
Install RH outer seat riser

Note
2x bolts with washers, T45+, 34 Nm, Install new bolts
Install IP carrier into vehicle

Note
1x clip, Secure middle speaker harness before fully installing, Recommend assistance
Install IP speakers

Note
6x screws, T20, 2 Nm, 3x connector, Pull the IP carrier forward for better access for speakers
Install fasteners securing IP carrier to cross car beam

Note
15x screws, T20, 2 Nm
Secure harness clips to the IP carrier

Note
2x clips
Install defrost grill assembly

Note
4x screws, T20, 2 Nm, 2x clips
Place steering column into vehicle for installation
Install fasteners securing steering column to cross car beam

Note
2x bolts, 13mm, 17 Nm, 2x nuts, 13mm, 30 Nm
Install bolt securing upper i-shaft to steering column

Note
1x bolt, 13mm, 30 Nm
Connect harness connectors for steering column motors

Note
2x connectors
Install bracket under steering column area

Note
2x screws, T20, 2 Nm
Connect harness to SCCM

Note
1x connector, Install new retaining clip
Slide SCCM over upper steering column

Note
Gently jiggle the SCCM while pressing it onto the column if needed
Remove tape previously applied to the clockspring

Note
Do not rotate the clockspring
Install steering wheel

Note
Ensure the position of the steering wheel matches the index marks previously made on the column and the wheel
Install bolt securing steering wheel to steering column

Note
1x patch bolt, 10mm allen, 80 Nm,Pay attention to the installation according to the marked position, Install new patch bolt
Connect the drivers front airbag and steering wheel control connectors

Note
3x connectors
Place airbag into steering wheel
Install screws securing airbag to steering wheel

Note
2x screws, T25, 7 Nm
Install instrument cluster

Note
4x screws, T20, 2 Nm, 3x connectors
Install driver knee airbag

Note
2x nuts, 10mm, 10 Nm, 1x connector, Engage red locking tab to fully secure connector, Install new fasteners
Install LH footwell cover

Note
2x clips, 1x connector, Reconnect puddle lamp
Position MCU for installation
Connect harness connectors to MCU

Note
17x connectors, Recommend assistance, Number of connectors may vary depending on vehicle configuration and MCU part number revision.
Install MCU into IP carrier

Note
If necessary, gently lift IP top pad to clear the MCU ground tab and ensure the MCU seats fully back into the IP carrier
Install bolts securing MCU to the IP carrier

Note
4x bolts, T25, 7 Nm
Install the RH instrument panel finisher assembly

Note
6x clips, Ensure vent ducting is properly aligned to vents during installation
Install fasteners for the RH instrument panel finisher assembly

Note
2x screws, T20, 2.3 Nm
Install the LH inner IP finisher trim assembly

Note
3x clips, 2x screws, T20, 2.3 Nm, Ensure vent ducting is properly aligned to vent during installation
Install LH outer IP finisher trim assembly

Note
2x clips, 3x screws, T20, 2.3 Nm, Ensure vent ducting is properly aligned to vent during installation
Install instrument cluster bezel to the IP carrier

Note
4x screws, T20, 2.3 Nm
Secure the steering column gap hider trim to the IC bezel

Note
2x clips
Set top pad in place and connect ground strap

Note
Assistance required
Fully seat top pad

Note
23x clips, Make sure all clips are aligned and securely fastened
Remove the protective tape from the top pad aluminum trim
Install passenger knee air bag and bracket

Note
4x patch bolts, 10mm, 10 Nm, 1x connector, Fir tree clip, Insert connect and press in latch to secure air bag connector, Install new patch bolts, some vehicles may not be equipped with airbag
Install the air bag mounting bolts

Note
2x bolts, 10mm, 10 Nm, Install new bolts
Install passenger air bag connectors

Note
2x connectors, Be sure to seat connector locks fully
Install the RH recirculation NVH hood

Note
2x clips, If vehicle is equipped with DAS 2.0 and module was removed in order to access the passenger air bag bolts, re install the DAS 2.0 Module.
Connect LH side ECU connectors

Note
6x connectors, Single white coax connector on ECU is intentionally left open
Install nuts securing ECU

Note
4x nuts, 8mm, 3 Nm, Install new nuts
Connect the connectors to the RH side of the AP ECU

Note
4x connectors, Number of connections may vary depending on hardware type
Install passenger footwell cover

Note
1x connector, 2x clips, 2x datums, Make sure datums are aligned
Place center console into vehicle

Note
Recommend assistance
Make connections at center console harness

Note
2x connectors
Install the bolts securing center console assembly

Note
6x bolts, 10mm, 7 Nm, 1x screw, T20, 2 Nm
Install rubber mat at the base of the console before installing the cup holder dividers
Install LH center console closeout extension

Note
6x clips
Install RH center console closeout extension

Note
6x clips
Secure the LH center console side trim panel

Note
13x clips
Secure the RH center console side trim panel

Note
13x clips
Connect module at rear console panel

Note
6x connectors
Install the center console back panel

Note
8x clips
Open rear cup holder
Install the rear cup holder trim panel

Note
5x tabs, Slide down to install
Install USB ports into rear air outlet

Note
2x connectors
Install the center console rear air outlet

Note
4x clips
Connect RH front seat harness

Note
1x connector
Place RH seat into vehicle

Note
Recommend assistance
Install LH front seat into vehicle

Note
Recommend assistance, Be cautious not to damage other components
Connect LH front seat connectors

Note
3x connectors
Connect first responder loop and then 12V negative terminal

Note
1x connector, 1x nut, 10mm, 5 Nm
Move LH front seat fully rearward
Install LH front seat front fasteners

Note
2x patch bolts, T45P, 34 Nm, Install new patch bolts
Move LH front seat fully forward
Install LH front seat rear fasteners

Note
2x patch bolts, T45P, 34 Nm, Install new patch bolts
Move LH front seat to original position
Power the RH seat fully forward for access
Install RH front seat rear fasteners

Note
2x bolts, T45+, 34 Nm, Install new bolts
Move RH front seat fully rearward
Install RH front seat front fasteners

Note
2x bolts, T45+, 34 Nm, Install new bolts
Move RH front seat to original position
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
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
Connect hoses to vehicle and perform A/C vacuum and leak test

Note
(Touch time only)30 minute vacuum, 10 minute leak test. Ensure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports
Install glovebox assembly

Note
6x screws, T20, 2.3 Nm, 3x connectors
Install RH instrument panel lower assembly

Note
13x clips, Replace any damaged or missing clips prior to installation
Install lower glove box trim

Note
6x clips, Replace any damaged or missing clips prior to installation
Install screw securing RH side of top pad

Note
1x screw, T20, 1.2 Nm
Install RH SWD bezel

Note
3x retaining tabs, Slides into place
Install RH IP side cover

Note
5x clips
Install the fasteners securing the IP top pad to the binnacle

Note
2x screws, T20, 1.2 Nm
Install binnacle cover panel

Note
4x clips, Replace any damaged or missing clips
Install LH lower IP trim panel

Note
9x clips
Install screw securing LH side of top pad

Note
1x screw, T20, 1.2 Nm
Install LH SWD bezel

Note
3x retaining tabs, Slides into place
Install LH IP side cover

Note
5x clips
Install HEPA filter housing
Install underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Install frunk carpet

Note
2x connectors
Install RH lower A-pillar trim

Note
1x screw, T25, 5 Nm, 4x clips
Install RH front door sill trim

Note
8x clips, 3x datums
Install RH rear door sill trim

Note
2x clips, 1x screw, T25, 2.5 Nm, Install new patch bolt
Install RH welcome plate

Note
8x clips
Install passenger footwell cover

Note
1x connector, 2x clips, 2x datums, Make sure datums are aligned
Install LH lower A-pillar

Note
1x bolt, T25, 5 Nm, 1x clip
Install LH front lower door sill

Note
7x clips
Install LH front door seal
Install LH lower B-pillar sill trim

Note
1x bolt, T25, 2 Nm, 2x clips
Install LH welcome plate

Note
8x clips
Position the LH side upper A-pillar trim for installation
Connect the electrical connections for the microphone and tweeter on the LH side

Note
2x electrical connectors
Install the LH upper A-pillar trim to the body

Note
4x clips
Install bolts securing LH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install bolts securing LH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install bolts securing LH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install LH sunvisor bezel

Note
6x clips, 5x tabs, Insert tabs and slide bezel toward rear of vehicle then secure clips
Install RH upper A-pillar

Note
2x connectors, 2x datums, 7x tabs, 2x clips, Connect connectors then secure tabs downward onto IP sub assembly and lower trim, Secure rear of trim
Connect the electrical connections for the microphone and tweeter on the RH side

Note
2x electrical connectors
Install the RH upper A-pillar trim to the body

Note
4x clips
Install bolts securing RH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install bolts securing RH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install bolts securing RH upper A-pillar to body

Note
2x bolts, 10mm, 5 Nm, 1x screw, T20, 2.5 Nm, 1x nyloc nut, 13mm, 5 Nm, Install new nut
Install RH sunvisor bezel

Note
6x clips, 5x tabs, Insert tabs and slide bezel toward rear of vehicle then secure clips
Install LH upper A pillar

Note
1x nut, 13mm, 8 Nm1x screw, T-20, 2 Nm2x bolts, 10mm, 5 Nm2x Electrical connections
Perform A/C refrigerant refill

Note
Run time, per fluid capacity spec
Remove A/C hoses from vehicle
Install under hood aprons

Note
4x aprons
Close hood
Calibrate falcon doors via UI

Note
Via Controls > Calibrate, Required after 12V and FRL disconnect
Disconnect laptop from vehicle and install storage cubby

Note
1x connect, 2x clips, Ensure diagnostic cables are tucked into the appropriate position
Using MCU close all doors and liftgate
Close LH front door