2026-05-07

Brake Lines - Pipe - Side Sill (Remove and Replace)

Correction code 3303010202 FRT 5.28 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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.

Remove

Open all doors and lower all windows.
Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
Remove the LH and RH rocker carriers. See Rocker Carrier - LH (Remove and Replace).
Remove the butyl patches (x2) that cover the LH rocker access holes, and clean excess butyl from area.
Install lift pad adapters (x2) onto the LH lift.
Remove the butyl patches (x2) that cover the RH rocker access holes, and clean excess butyl from area.
Unlock the vehicle gateway. See Gateway (Unlock).
On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
Remove the 2nd row LH seat. See Seat Assembly - 2nd Row - LH (5-Seat) (Remove and Install).
Remove the 2nd row RH seat. See Seat Assembly - 2nd Row - RH (5-Seat) (Remove and Install).
Separate the carpet perforations below the rear of the LH and RH front seats, and remove the LH and RH middle inner HV battery bolts.

Note
Expand the hole if necessary.

TIp
Position an inflatable air bag beneath the rear cabin carpet to raise and allow access to the rear inner HV battery bolts.
Remove the LH and RH rear inner HV battery bolts.

Note
1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
Remove the center console LH front side panel. See Side Panel - Front - Center Console - LH (Remove and Replace).
Fold the LH front cabin carpet rearward.

Note
Maneuver the carpet below the brake pedal and the accelerator pedal. If the carpet and foam are stuck together, tear them apart.
Remove the foam plug to access the LH front inner HV battery bolts.
Remove the LH front inner HV battery bolts (x2).

Note
2x bolts, EP20, 136 Nm
Repeat step 16 to 20 for the RH side.

Note
For the center console RH front side panel. See Side Panel - Front - Center Console - RH (Remove and Replace).
Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
Release the LH body harness from the rear body and move it aside.
Partially remove the LH B-pillar lower trim.
Partially pull out the LH rear body harness.
Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
Remove the bolt that secures the busbar cover access door.

Note
1x bolt, 10mm, 9 Nm
Remove the bolts (x2) that attach the charge port busbar kit to the HV header.

Note
2x bolts, 10mm, 9 Nm
Lift the busbar kit connector to remove it from the HV header.

Note
Use an inflatable air bag to suspend the busbar away from the HV header during removal and installation. Hold the busbar firmly as there is tension on. Avoid damaging the harness bracket.
Disconnect the AC charge port inlet harness from the HV header.

Note
Release the red locking tab and rotate the lever arm to release.
Remove the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
Remove the HVC logic cap.
Inspect ancillary bay walls for damage.

Note
Any dent or depression in the sealing surface that causes it to not be flat will result in a leak. Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled. It can still be reused.
Inspect the ancillary bay cover seal to confirm it has no visual damage.

Note
Delaminated or torn seals cannot be reused.
Use IPA wipes to clean the ancillary bay cover surface, and allow 1 minute to dry.
Position ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Remove HV insulating gloves
Remove nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
Gently lift the DCDC ground busbar upwards
Close all four doors
Install lift pad adapters onto RH lift

Note
2x lift pad adapters
Raise and support vehicle

Note
Recommended assistance, Before lifting, ensure that the vehicle is not connected to a charging device, The positioning pin must be inserted into the car body holes
Remove LH front fender garnish

Note
1x push clip, 11x clips, 1x tab, 1x location tab, Release from front end of garnish and work your way outward towards rear ends, then release tab
Remove LH front wheel cap

Note
1x cap, Use tool to gently pull the center wheel cap to release the clips, Wheels may be equipped with different caps
Loosen LH front wheel nuts

Note
5x nuts, 21mm, 175 Nm
Remove RH front wheel cap

Note
1x cap, Use tool to gently pull the center wheel cap to release the clips, Wheels may be equipped with different caps
Loosen RH front wheel nuts

Note
5x nuts, 21mm, 175 Nm
Remove LH rear wheel cap

Note
1x cap, Use tool to gently pull center wheel cap to release clips, Wheels may be equipped with different caps
Loosen LH rear wheel nuts

Note
5x nuts, 21mm, 175 Nm
Remove RH rear wheel cap

Note
1x cap, Use tool to gently pull center wheel cap to release clips, Wheels may be equipped with different caps
Loosen RH rear wheel nuts

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a 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 front wheel

Note
5x nuts, 21mm, 175 Nm
Remove bolt securing LH front wheel liner to skid plate

Note
1x bolt, 10mm, 5 Nm
Remove clips securing LH front wheel liner to body

Note
15x push clips, 2x push nuts
Remove LH front wheel liner
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove clips securing LH rear wheel liner to body

Note
17x clips
Remove LH rear wheel liner
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove bolt securing RH front wheel liner to skid plate

Note
1x bolt, 10mm, 5 Nm
Remove clip securing RH wheel liner to body

Note
1x push clip
Use bungee strap to pull back RH front wheel liner

Note
Secure to subframe
Remove RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
Remove bolts securing front aero shield

Note
7x bolts, 10mm, 5 Nm
Remove front aero shield from studs

Note
2x nuts, 15mm, 8 Nm
Remove front skid plate

Note
4x bolts, EP10, 13 Nm, 2x tabs, Move foward to remove
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
Disconnect AC compressor HV harness connector

Note
1x locking connector, 3 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, depress yellow tab and pull the connector backward then depress the green tab to release
Remove bolt securing FDU HV harness to FDU

Note
1x bolt,10mm, 10 Nm
Release FDU HV harness connector

Note
1x connector. Release red locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
Release FDU HV harness from casting and move aside

Note
1x casting datum
Remove HV insulating gloves
Remove FDU ground strap bolt from HV battery

Note
1x bolt, 10mm, 10 Nm
Position coolant drain container underneath LH front of HV battery
Disconnect HV battery return hose at LH side of vehicle and plug hoses

Note
1x spring clip
Remove HV battery front manifold hose clip from body

Note
1x clip
Disconnect HV battery manifold hoses and plug hoses

Note
1x spring clip, Loss of coolant greater than 1L requires coolant vacuum fill.
Position coolant drain container underneath RH front of HV battery
Disconnect FDU inverter inlet hose to rear powertrain return hose and plug hoses

Note
1x spring clip
Disconnect powertrain supply hose from powertrain supply tube and plug hoses

Note
1x spring clip, Coolant loss greater than 1 L will require vacuum fill
Position coolant drain container underneath front of HV battery
Remove manifold tube from front of HV battery and plug HV battery

Note
4x spring clips
Remove coolant drain container from underneath vehicle
Remove LH and RH push clips securing mid aero shield to wheel house liner

Note
2x clips
Remove mid aero shield

Note
11x bolts, 2x tabs, 10mm, 5 Nm
Remove nut securing LH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from LH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link
Remove nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from RH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link
Position support stand to support front portion of rear subframe

Note
Prevent the real stabilizer bar from falling off
Remove bolts securing rear stabilizer bar to subframe and remove assembly

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal
Remove support stand from front portion of rear subframe
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate

Note
1x fir tree clip
Release RH side hose clips from rear battery skid plate

Note
2x fir tree clips
Remove lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm
Remove upper bolts securing HV battery rear skid plate enclosure

Note
4x bolts, 13mm, 64 Nm
Remove HV battery rear skid plate enclosure
Put on HV insulating gloves and leather over gloves
Remove nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Disconnect RDU HV cable from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Remove HV insulating gloves
Position coolant drain container under LH rear of vehicle
Disconnect LH coolant hose from rear of HV battery

Note
1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends

Note
1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill
Position coolant drain underneath RH rear of HV battery
Disconnect coolant outlet hose to rear return hose and plug hoses

Note
1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary, Coolant loss greater than 1 L will require vacuum fill
Release clip securing coolant hoses to RH shear plate

Note
1x fir tree clip
Position support stand to support front portion of rear subframe
Remove the HV battery. See HV Battery (AWD) (Remove and Install).
Place oil drain under front brake line junction area

Note
Lower vehicle if necessary
Release brake pipes from coupling

Note
2x nuts, 12mm, 16 Nm
Place oil drain pan under LH rear brake line junction block

Note
Raise vehicle if necessary
Remove LH rear brake line tube outer nut

Note
1x nut, 12mm, 16 Nm
Remove LH rear brake line tube inner nut

Note
1x nut, 12mm, 16 Nm
Remove black clip from LH rear junction block

Note
1x clip
Release brake lines from LH rear junction block

Note
2x brake lines
Remove side sill brake lines from vehicle

Note
5x clips, 2x brake lines

Install

Install side sill brake lines to vehicle

Note
5x clips, 2x brake lines, Replace damaged clips
Position brake lines into LH rear brake junction block

Note
2x brake lines
Install black clip securing brake lines to LH rear junction block

Note
1x clip
Install LH rear brake line tube inner nut

Note
1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
Install LH rear brake line tube outer nut

Note
1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
Remove oil drain under LH rear brake line junction block
Install brake pipes to coupling

Note
2x nuts, 12mm, 16 Nm, Start nut by hand to avoid cross threading
Remove oil drain under LH front brake line junction area
Install penthouse engagement seal onto HV battery pack

Note
This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped
Install HV battery alignment rods

Note
2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
Position HV battery under vehicle

Note
Recommend assistance
Lower vehicle onto HV battery and align holes

Note
Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
Loosely install RH bolts securing HV battery to vehicle hand tight

Note
8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
Loosely install LH bolts securing HV battery to vehicle hand tight

Note
8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
Remove HV battery alignment rods

Note
2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
Install LH rear inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Install LH middle inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Install RH rear inner battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Install RH inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Install both LH front inner HV battery bolts hand tight

Note
2x bolts, EP20, 136 Nm, Torque at later step
Install both RH front inner HV battery bolts hand tight

Note
2x bolts, EP20, 136 Nm, Torque at later step
Set bolts securing RH front support bracket to vehicle with cordless impact

Note
4x bolts, 16mm, 110 Nm, Torque at later step
Set bolts securing LH front support bracket to vehicle with cordless impact

Note
4x bolts, 16mm, 110 Nm, Torque at later step
Set central bolts securing HV battery center ski cover with cordless impact

Note
4x bolts, EP14, 34 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
Lower vehicle onto pack completely

Note
Recommend assistance
Torque RH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque LH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque bolts securing RH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque bolts securing LH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque central bolts securing HV battery through center ski cover

Note
4x bolts, EP14, 34 Nm
Raise vehicle and lower onto locks, then remove battery table from under vehicle

Note
Recommend assistance, 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
Position support stand to support front section of rear subframe
Remove bolt securing LH side of rear subframe to body

Note
1x bolt, 21mm, 125 Nm
Install bolts securing LH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 64 Nm, Torque at later step
Install bolt and shear plate to LH side of rear subframe hand tight

Note
1x bolt, 21mm, 125 Nm, Torque at later step
Torque bolt securing subframe and LH shear plate to body

Note
1x front bolt, 21mm, 125 Nm, Mark bolt after torque
Torque bolts securing LH shear plates to vehicle

Note
2x bolts, 13mm, 64 Nm
Remove bolt securing RH side of rear subframe to body

Note
1x bolt, 21mm, 125 Nm
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 65 Nm, Torque at later step
Install bolt and shear plate to RH side of rear subframe hand tight

Note
1x bolt, 21mm, 125 Nm, Torque at later step
Torque bolt securing subframe and RH rear shear plate to body

Note
1x bolt, 21mm, 125 Nm
Torque bolts securing RH shear plates to vehicle

Note
2x bolts, 13mm, 64 Nm
Remove support stand from under vehicle
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Position coolant drain underneath RH rear of HV battery
Install clip securing coolant hoses to RH shear plate

Note
1x fir tree clip
Remove hose plugs and connect coolant outlet hose to rear return hose

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Position coolant drain container under LH rear of vehicle
Remove plugs and connect RDU inverter inlet hose to rear of HV battery

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect LH coolant hose to rear of HV battery

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Remove coolant drain container from underneath vehicle
Put on HV insulating gloves and leather over gloves
Connect RDU HV cable to HV battery

Note
1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
Install nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Remove HV insulating gloves
Position HV battery rear skid plate enclosure onto HV battery for installation

Note
Recommend assistance if needed
Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note
4x bolts, 13mm, 64 Nm
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm
Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note
4x bolts, 13mm, 64 Nm
Install RH side hose clips to HV battery rear skid plate enclosure

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
1x fir tree clip
Install stabilizer bar onto vehicle
Place stabilizer bar into position for installation and raise stand to support stabilizer bar

Note
Prevent the real stabilizer bar from falling off
Install stabilizer bar fastening bolts

Note
4x patch bolts, 11mm, 30 Nm, Thread in fasteners and torque down evenly, Install new patch bolts
Remove support stand from front portion of rear subframe
Position LH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing LH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Install new nut, Counter-hold ball joint with 5mm hex, Mark bolt after torque
Position RH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing RH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Install new nut, Counter-hold ball joint with 5mm hex, Mark bolt after torque
lnstall mid aero shield

Note
2x tabs, 11x bolts, 10mm, 5 Nm, Position rear datums first, Apply Loctite 222 onto rear aero shield bolts
Install LH and RH push clips securing mid aero shield to wheel house liner

Note
2x clips
Position coolant drain container underneath front of HV battery
Install manifold tube of front of HV battery

Note
4x spring clips, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
Position coolant drain container underneath LH front of HV battery
Connect HV battery front manifold coolant hose

Note
1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
Install HV battery front manifold hose clip to body

Note
1x clip
Connect HV battery coolant return hose

Note
1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
Position coolant drain container underneath RH front of HV battery
Connect FDU inverter inlet hose to rear powertrain return hose

Note
1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
Connect powertrain supply hose

Note
1x spring clip, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
Remove coolant drain container from underneath vehicle
Put on HV insulating gloves and leather over gloves
Connect AC compressor HV harness connector

Note
1x locking connector, 3 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector, Engage locking tab
lnstall FDU HV harness to casting

Note
Install HV connector lever lock to FDU HV cable connector
Install FDU HV harness connector to FDU

Note
1x connector, Align connector to FDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
Install bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Remove HV insulating gloves
Install FDU ground strap and bolt to HV battery

Note
1x bolt, 10mm, 10 Nm
Install front skid plate

Note
4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation
Position front aero shield onto vehicle

Note
2x datums, 2x nuts, 15mm, 8 Nm, Hand-tighten the nuts to temporarily hold the panel in place
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
7x bolts, 10mm, 5 Nm
Torque front aero shield nuts

Note
2x nuts, 15mm, 5 Nm
Lower vehicle partially and set 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
Remove HVC logic cap

Note
1x logic cap
Put on HV insulating gloves and leather over gloves
Remove ancillary bay cover from HV battery
Install HVC logic cap

Note
1x logic cap
Clean mating surfaces

Note
Allow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect
Set multimeter to "LoZ" (low impedance) mode
Measure voltage between busbar and shunt

Note
While still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars
Position pyro disconnect to ancillary bay for installation

Note
1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
Install bolts securing pyro disconnect to ancillary bay

Note
2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen
Measure resistance from module 2 busbar to pyro disconnect

Note
1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing
Measure resistance from pyro disconnect to shunt

Note
1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing
Remove service insulator kit
Remove HVC logic cap

Note
1x logic cap
Inspect ancillary bay walls for damage

Note
Any dent or depression in the sealing surface that causes it to not be flat will result in a leak, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
Inspect ancillary bay cover seal to confirm it has no visual damage

Note
Delaminated and torn seals cannot be reused
Wipe ancillary bay cover with IPA to clean surface

Note
Allow to 1 minute dry time
Position ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Remove HV insulating gloves
Install HVC logic cap

Note
1x logic cap
Install bolts securing ancillary bay cover to HV battery

Note
18x bolts, EP10 5-Lobe, 8 Nm, Fasteners are captive, Follow torque sequence per image
Install bolts securing ancillary bay cover to HVC

Note
3x bolts, E10, 5 Nm + 30 degrees
Install DCDC ground busbar to HV battery

Note
Gently press down
Install nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
Install positive 12V output from PCS cable and torque nut securing it

Note
1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque
Install positive 12V output cover to PCS cable

Note
1x cover
Remove logic cap and connect HVC logic connector

Note
1x connector, 1x logic cap, Align connector then pull the handle to locking position get connector fully seated
Put on HV insulating gloves and leather over gloves
Clean HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
Clean busbar HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
Apply Penetrox onto HV connector joints

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
Remove Inflatable Air Bag from under HV header
Position busbar kit connector and lower onto HV header

Note
4x guide tabs, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
Install bolts securing charge port busbar kit to HV header

Note
2x bolts, 10mm, 9 Nm, Mark after torque
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

Note
2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step
Install fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Connect 3PH chargeport inlet harness to HV header

Note
1x connector, Rotate lever arm and secure locking tab
Remove HV insulating gloves
Position LH rear body harness under LH lower C pillar trim
Install LH body harness onto rear body

Note
1x clip
Partially install LH B-pillar lower trim

Note
1x push clip
Remove coolant bottle cap

Note
Vacuum fill required if greater than 1L lost during repair
Place empty coolant container into front storage area
Fill container with coolant

Note
Do not draw in air during fill process, for RWD, the entire system requires coolant is 15l, for AWD, the entire system requires coolant is 18l
Place filled coolant container into front storage area
Install refill tool cap onto coolant bottle assembly
Setup vacuum refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully engaged
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
Slowly open refill valve to allow coolant to be drawn into system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once gauge reads zero, close refill valve
Disconnect shop air supply from coolant refill tool
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove refill tool cap from coolant bottle assembly
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect First Responder Loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Run ODIN routine
Run ODIN routine
Run ODIN routine
PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAIN
via Service Mode:
Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
via Toolbox:(link)
Place absorbent material underneath brake lines and brake fluid reservoirto catch any fluid lost
Clean area around brake fluid reservoir and remove brake reservoir cap
Top off brake fluid reservoir

Note
Top off brake fluid as needed
Fill brake bleeder reservoir to full level
Install pressure bleeder adapter onto reservoir
Setup brake bleeder

Note
Connect power supply to bleeder and turn on the power to set pressure to 30 psi, Attach the brake reservoir hose to the brake adapter at this time
Remove LH front caliper bleed valve covers then install fluid catcher to outer bleed valve

Note
2x covers
Run ODIN routine PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
Repeat bleed process until LH front caliper fluid is free of air bubbles

Note
Brembo: 2x bleed valves, 11mm, 18.5 Nm
Remove fluid catcher then torque LH front caliper bleed valves

Note
2x bleed valves, 11mm, 18.5 Nm, 2x covers, Install covers when torqued
Remove RH front caliper bleed valve covers then install fluid catcher to outer bleed valve

Note
2x covers
Run ODIN routine PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link)
Repeat bleed process until RH front caliper fluid is free of air bubbles

Note
Brembo: 2x bleed valves, 11mm, 18.5 Nm
Remove fluid catcher then torque RH front caliper bleed valves

Note
2x bleed valves, 11mm, 18.5 Nm, 2x covers, Install covers when torqued
Remove RH rear caliper bleed valve cover then install fluid catcher

Note
1x cover
Run ODIN routine PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
Repeat bleed process until RH rear caliper fluid is free of air bubbles

Note
1x bleeding valve, Base: 11mm, 10 Nm
Remove fluid catcher then torque RH rear caliper bleed valve

Note
1x cover, 1x bleeding valve, Base: 11mm, 10 Nm, Install cover when torqued
Remove LH rear caliper bleed valve cover then install fluid catcher

Note
1x cover
Run ODIN routine PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link)
Repeat bleed process until LH rear caliper fluid is free of air bubbles

Note
1x bleeding valve, Base: 11mm, 10 Nm
Remove fluid catcher then torque LH rear caliper bleed valve

Note
1x cover, 1x bleeding valve, Base: 11mm, 10 Nm, Install cover when torqued
Turn off and remove pressure brake bleeder kit from vehicle
Check brake fluid level

Note
Top off if necessary
Install brake reservoir cap
Remove absorbent material from underneath brake booster assembly and reservoir area
Pump brake pedal a few times to ensure brake pedal feels normal
Run ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICEvia Service Mode:Chassis ➜ Brakes ➜ Brake Stiffness Testvia Service Mode Plus:chassis ➜ ESP Replacement Panel ➜ Stiffness Testvia Toolbox:(link)
Install LH front wheel liner
Install clips securing LH wheel liner to body

Note
15x push clips, 2x push nuts
Install bolt securing LH front wheel liner to skid plate

Note
1x bolt, 10mm, 5 Nm
Install LH front fender garnish

Note
1x push clip, 11x clips, 1x tab, 1x location tab, Start at rear and maneuver into rocker panel
Install LH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Release RH front wheel liner from bungee strap

Note
Remove strap from vehicle
Install bolt securing RH front wheel liner to skid plate

Note
1x bolt, 10mm, 5 Nm
Install clip securing RH wheel liner to body

Note
1x push clip
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Position LH rear wheel liner for installation
Install clips securing LH rear wheel liner to body

Note
17x clips
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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
Torque LH front wheel nuts

Note
5x nuts, 21mm, 175 Nm
Install LH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
Torque RH front wheel nuts

Note
5x nuts, 21mm, 175 Nm
Install RH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
Torque LH rear wheel nuts

Note
5x nuts, 21mm, 175 Nm
Install LH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
Torque RH rear wheel nuts

Note
5x nuts, 21mm, 175 Nm
Install RH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Move rack arms away from vehicle
Install butyl patches onto LH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install LH rocker carrier onto body

Note
10x clips, 1x location pin
Install bolts securing LH rocker carrier to body

Note
2x bolts, 10mm, 9 Nm
Install LH rocker cover onto rocker carrier

Note
11x clips, 11x tabs, 1x location pin, Tabs go into cavities on rocker carrier and cannot be accessed from outer side of cover, Ensure that all tabs are installed properly
Install clips securing LH rocker cover and rocker carrier to LH front wheel liner

Note
2x clips
Install clips securing LH rocker cover and rocker carrier to LH rear wheel liner

Note
2x clips
Install butyl patches onto RH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install RH rocker carrier onto body

Note
10x clips, 1x location pin
Install bolts securing RH rocker carrier to body

Note
2x bolts, 10mm, 9 Nm
Install RH rocker cover onto rocker carrier

Note
11x clips, 11x tabs, 1x location pin, Tabs go into cavities on rocker carrier and cannot be accessed from outer side of cover, Ensure that all tabs are installed properly
Install clips securing RH rocker cover and rocker carrier to RH front wheel liner

Note
2x clips
Install clips securing RH rocker cover and rocker carrier to RH rear wheel liner

Note
2x clips
Run ODIN routine
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
via Toolbox:(link)
Torque both RH forward HV battery bolts

Note
2x bolts, EP20, 136 Nm
Install RH front cabin carpet support access plug

Note
1x plug
Fold RH front main cabin carpet back to original position
Install console RH front side panel

Note
14x clips, 2x locating pins, Ensure all clips and pins seat propely
Install RH knee air bag cover to IP carrier

Note
1x connector, 5x tabs, 1x location pin
Secure front RH cabin carpet cover to RH knee air bag cover

Note
1x connector, 2x magnets, 2x datums
Install RH lower A pillar trim

Note
8x clips, 2x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar
Install RH IP end cap

Note
5x clips, 2x guide tabs
Install RH front primary door seal

Note
Verify seal is seated properly on all trim panels
Move RH front seat forward

Note
Adjust seat back if needed to avoid contacting headliner
Torque both LH front inner HV battery bolts

Note
2x bolts, EP20, 136 Nm
Install LH front cabin carpet support access plugs

Note
1x plug
Fold LH front main cabin carpet back to original position
Install OBD port

Note
2x tabs, Ensure black tabs in lock position
Install console LH front side panel

Note
14x clips, 2x locating pins, Ensure all clips and pins seat propely
Install driver footwell hush panel

Note
1x connector, 8x tabs, 2x location pins
Secure front LH cabin carpet cover to driver footwell hush panel

Note
2x magnets, 2x datums
Install LH lower A pillar trim

Note
7x clips, 3x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar
Install LH IP end cap

Note
5x clips, 2x guide tabs
Install LH front primary door seal

Note
Verify seal is seated properly on all trim panels
Move LH front seat forward

Note
Adjust seat back if needed to avoid contacting headliner
Torque LH rear inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
Torque RH rear inner battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
Remove air bag from between rear cabin carpet and body
Torque LH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Fold LH side of rear main carpet to its original position
Torque RH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Fold RH side of rear main carpet to its original position
Install 2nd row 40 seat assembly into vehicle

Note
Recommend assistance
Secure 2nd row 40 seat frame to vehicle

Note
4x bolts, 11mm, 37 Nm, Install new bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
Connect 2nd row 40 seat connector

Note
1x connector, Engage the tab
Install 2nd row 60 seat assembly

Note
Recommend assistance
Install fasteners securing 2nd row 60 seat frame to body

Note
5x bolts, 11mm, 37 Nm, Install new bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
Install clips securing rear main cabin carpet to vehicle

Note
3x push clips
Connect 2nd row 60 seat connector

Note
1x connector, Engage the tab
Install LH lower C pillar trim

Note
7x clips, 2x guide tabs, Align guide tabs, then press down to securing all clips
Install LH rear primary door seal near LH lower C pillar trim
Install RH lower C pillar trim

Note
7x clips, 2x guide tabs, Align guide tabs, then press down to securing all clips
Partially install RH rear primary door seal

Note
Verify seal is seated properly on all trim panels
Install 2nd row seat cushion

Note
1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test, and ensure the buckles get stuck under the 2nd row cushion
Move RH front seat to original position
Move LH front seat to original position
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair
Install coolant bottle cap
Coolant air purge run time

Note
Run time: 00:10:00, Subtract overlap time spent on other operations while waiting for coolant purge run
Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
Install HEPA filter assembly

Note
2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct
Install rear apron

Note
16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron
Close hood
Move RH front seat to original position
Move LH front seat to original position
Raise all windows
Close all four doors