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Open all four doors.

Lower all four windows.

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link) .

Remove clips securing LH rocker cover and rocker carrier to LH front wheel liner.

Remove clips securing LH rocker cover and rocker carrier to LH rear wheel liner.

Remove LH rocker cover from rocker carrier.

Remove bolts securing LH rocker carrier to body.

Note

2x bolts, 10mm, 9 Nm

Remove LH rocker carrier from body.

Note

10x clips, 1x location pin

Remove clips securing RH rocker cover and rocker carrier to RH front wheel liner.

Remove clips securing RH rocker cover and rocker carrier to RH rear wheel liner.

Remove RH rocker cover from rocker carrier.

Note

Work a plastic trim tool between door panel and rocker cover to release tabs.

Remove bolts securing RH rocker carrier to body.

Note

2x bolts, 10mm, 9 Nm

Remove RH rocker carrier from body.

Remove butyl patches covering LH rocker access holes.

Install lift pad adapters onto LH lift.

Remove butyl patches covering RH rocker access holes.

Chock LH rear wheel.

Unlock vehicle gateway.

Access Thermal System routines using UI.

Run ODIN routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:

Thermal ➜ Actions ➜ Start Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain

via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain

Move LH front seat forward

Move RH front seat forward

Note

Adjust seat back if needed to avoid contacting headliner

Remove 2nd row seat cushion

Remove LH lower C pillar trim

Remove RH lower C pillar trim

Note

7x clips, 2x guide tabs, pull the trim upward to release all clips

Remove clips securing rear main cabin carpet to vehicle

Note

3x push clips

Remove fasteners securing 2nd row 60 seat frame to body

Note

5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Discard after removal

Disconnect 2nd row 60 seat connector

Note

1x connector, Disengage the tab

Remove 2nd row 60 seat assembly from vehicle

Note

Recommend assistance

Remove fasteners securing 2nd row 40 seat frame to body

Note

4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Discard after removal

Disconnect 2nd row 40 seat connector

Note

1x connector, Disengage the tab

Remove 2nd row 40 seat assembly from vehicle

Note

Recommend assistance

Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt

Note

Located below rear of LH front seat, Expand the hole if necessary

Remove LH middle inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm

Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt

Note

Located below rear of RH front seat, Expand the hole if necessary

Remove RH middle inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm

Position air bag beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts

Remove LH rear inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm, Located below LH rear main carpet

Remove RH rear inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm, Located below RH rear main carpet

Partially release LH front primary door seal

Note

For remove LH IP end cap, LH lower A pillar trim, LH front B pillar trim

Remove LH IP end cap

Note

5x clips, 2x guide tabs

Remove LH lower A pillar trim

Note

7x clips, 3x guide tabs, 1x push clip, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet

Move LH front seat backward

Release front LH cabin carpet cover from driver footwell hush panel

Note

2x magnets, 2x datums

Release OBD port from footwell cover

Note

2x tabs, Press black tabs to unlock then push upwards out of footwell cover

Remove driver footwell hush panel

Note

1x connector, 8x tabs, 2x location pins

Remove console LH front side panel

Note

14x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged

Fold LH front cabin carpet rearward

Note

Maneuver carpet below brake pedal and accelerator pedal, Different regions may stick the carpet and foam together and tear them apart

Remove foam plugs to access LH front inner HV battery bolts

Note

1x foam plug

Remove both LH front inner HV battery bolts

Note

2x bolts, EP20, 136 Nm

Partially release RH front primary door seal

Note

For remove RH IP end cap, RH lower A pillar trim, RH front B pillar trim

Remove RH IP end cap

Note

5x clips, 2x guide tabs

Remove RH lower A pillar trim

Note

8x clips, 2x guide tabs, 1x push clip, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet

Move RH front seat backward

Release front RH cabin carpet cover from RH knee air bag cover

Note

1x connector, 2x magnets, 2x datums

Remove RH knee air bag cover from IP carrier

Note

1x connector, 5x tabs, 1x location pin

Remove console RH front side panel

Note

14x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged

Fold RH front cabin carpet rearward

Note

Maneuver carpet below brake pedal and accelerator pedal, Different regions may stick the carpet and foam together and tear them apart

Remove foam plugs to access RH front inner HV battery bolts

Note

1x foam plug

Remove both RH front inner HV battery bolts

Note

2x bolts, EP20, 136 Nm

Open hood

Power off vehicle from center display

Remove rear apron

Note

16x trim clips, 3x datums, 2x clips

Remove HEPA filter assembly

Note

2x bolts, 10mm, 10 Nm, Pivot rear edge up past brake reservoir then lift up to clear frunk assembly

Disconnect LV battery and First Responder Loop

Note

2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

Verify operation of multimeter

Note

Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

Release LH body harness from rear body and move aside

Note

1x clip

Partially remove LH B-pillar lower trim

Note

1x push clip

Partially pull out LH rear body harness

Remove all items from pockets and ensure not wearing metal items

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

Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover from ancillary bay cover

Verify no high voltage

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

Wipe ancillary bay cover with IPA to clean surface

Note

Allow to 1 minute dry time

Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover

Note

Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners

Remove fastener securing busbar cover access door

Note

1x bolt, 10mm, 9 Nm

Remove bolts securing charge port busbar kit to HV header

Note

2x bolts, 10mm, 9 Nm

Lift busbar kit connector to remove from HV header

Note

Use inflatable air bag to suspend busbar away from HV header during removal and installation, hold busbar firmly as there is tension on, Avoid damaging the harness bracket

Disconnect AC chargeport inlet harness from HV header

Note

1x connector, Release red locking tab and rotate lever arm to release

Disconnect HVC logic connector and install logic cap

Note

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Release positive 12V output cover from PCS cable

Note

1x cover

Remove PCS cable from 12V passthrough output

Note

1x nut, 13mm, 9 Nm, Discard nut after removal

Link to procedure: 60631a60269fe10017633be3

Remove bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Remove bolts securing ancillary bay cover to HV battery

Note

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

Remove HVC logic cap

Note

1x logic cap

Remove ancillary bay cover from HV battery

Install HVC logic cap

Note

1x logic cap

Inspect ancillary bay for any missing insulators

Note

Install service insulator kit before continuing to next step

Remove bolts securing pyro disconnect to ancillary bay

Note

1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal

Remove pyro disconnect from ancillary bay

Note

1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay

Install pyro disconnect dummy

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

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

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

Raise vehicle fully and lower lift onto locks

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 bolt securing LH front wheel liner to skid plate

Note

1x bolt, 10mm, 5 Nm

Remove clip securing LH wheel liner to body

Note

1x push clip

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 LH front wheel liner

Note

Secure to subframe

Use bungee strap to pull back RH front wheel liner

Note

Secure to subframe

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 HV insulating gloves

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 powertrain return hose from powertrain return tube 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 smaller fasteners for LH shear plate

Note

2x bolts, 13mm, 64 Nm

Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 125 Nm

Hand tighten bolt securing LH side of subframe to body

Note

1x bolt, 21mm, 125 Nm

Remove smaller fasteners for RH shear plate

Note

2x bolts, 13mm, 64 Nm

Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 125 Nm

Hand tighten bolt securing RH side of subframe to body

Note

1x bolt, 21mm, 125 Nm

Remove support stand from under vehicle

Place HV battery table into position and lower vehicle to support HV battery

Note

Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table

Remove central bolts securing HV battery center ski cover

Note

4x bolts, EP14, 34 Nm

Remove bolts securing LH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove bolts securing RH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove LH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Remove RH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Raise vehicle free of HV battery

Remove battery from under vehicle

Note

Recommend assistance

Remove penthouse engagement seal from HV battery pack

Note

Discard anytime HV battery is removed from vehicle

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

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

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

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

1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary.Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container under LH rear of vehicle

Remove plugs and connect RDU inverter inlet hose to rear of HV battery

Note

1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.

Connect LH coolant hose to rear of HV battery

Note

1x spring clip, 2x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

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 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

Remove HV insulating gloves

Install front skid plate

Note

4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation

Release LH front wheel liner from bungee strap

Note

Remove strap from vehicle

Install bolt securing LH front wheel liner to skid plate

Note

1x bolt, 10mm, 5 Nm

Install clip securing LH wheel liner to body

Note

1x push clip

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

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 fully

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

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

Access Thermal System routines using UI

Unlock vehicle gateway

Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)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

Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:

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

via Service Mode Plus:

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

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

Fasten 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

Fasten 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

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