2025-04-08

High Voltage Battery - RWD - 3 Phase (Remove and Install)

Correction code 1601010701 FRT 3.66 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Warning

This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Open all four doors.
Lower all four windows.
Enable Service Mode. See Service Mode.
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-DRAIN
via 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
If the HV battery is being shipped, secure the old pyrotechnic battery disconnect to the brackets on the ancillary bay cover of the old HV battery using cable ties.

Note
Install a piece of paper roll under the pyrotechnic battery disconnect. Use masking tape if necessary to prevent movement.

Install

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-DRAIN
via 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-PURGE
via 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
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

High Voltage Battery - RWD - 3 Phase (Remove and Install)

Remove

Install

Figure 1

Figure 2

Figure 3