HV Battery (7-Seat) (Remove and Replace)

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

Note

2x clips

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

Note

2x clips

Remove LH rocker cover from rocker carrier

Note

11x clips, 11x tabs, 1x location pin, Work a plastic trim tool between door panel and rocker cover to release tabs

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

Note

2x clips

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

Note

2x clips

Remove RH rocker cover from rocker carrier

Note

11x clips, 11x tabs, 1x location pin, 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

Note

10x clips, 1x location pin

Remove butyl patches covering LH rocker access holes

Note

2x butyl patches, Clean excess butyl from area, Discard after removal

Install Universal Lift Pad Adapters onto LH lift arms

Note

2x Universal Lift Pad Adapters, Remove original lift pads from lift arms then install respective adapter, Align pins with lift point holes on body

Remove butyl patches covering RH rocker access holes

Note

2x butyl patches, Clean excess butyl from area, Discard after removal

Install Universal Lift Pad Adapters onto RH lift arms

Note

2x Universal Lift Pad Adapters, Remove original lift pads from lift arms then install respective adapter, Align pins with lift point holes on body

Unlock the vehicle gateway. See Gateway (Unlock).

Access thermal system routines via UI

Note

Select Service mode > Thermal

Perform "Start Thermal Fill/Drain (Coolant Only)" through Service UI

Note

Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again

Move LH front seat forward

Note

Adjust seat back if needed to avoid contacting headliner

Move RH front seat forward

Note

Adjust seatback if needed to avoid contacting headliner

Move 60 seat to easy entry position

Note

Press shoulder switch then push seat forward

Partially remove lower portion of LH rear door seal

Remove LH 7s lower C-pillar trim

Note

8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips

Move 60 seat to original position

Note

Press shoulder switch then pull seat backward

Fold 2nd row 60 seatback down

Note

Via seat switch or manual tether, Protect seat back upholstery if necessary

Disconnect 2nd row 60 seat connector

Note

1x connector,

Move 60 seat forward using towel bar

Note

With one hand on towel bar pull up and slide the seat forward with your other hand

Remove 60 seat rear outboard track fastener

Note

1x patch bolt, 11mm, 37 Nm, Discard after removal

Remove 60 seat rear inboard track fasteners

Note

2x patch bolts, 11mm, 37 Nm, Discard after removal

Move 60 seat fully rearward using towel bar

Note

pull up bar, slide seat forward

Remove 60 seat outboard track cover

Note

1x clip, Slide covers forward to release from 60 seat tracks

Remove center track cover from 2nd row seats

Note

2x clips, Slide covers forward to release from 2nd row seat tracks

Release cabin carpet from 60 seat

Note

Pull cabin carpet towards front of vehicle

Remove 60 seat front inboard track fasteners

Note

1x bolts, 11mm, 37 Nm, Discard after removal

Remove 2nd row 60 seat frame front outboard track fasteners

Note

1x bolts, 11mm, 37 Nm, Discard after removal

Remove 2nd row 60 seat assembly from vehicle

Note

Recommend assistance, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

Move RH front seat forward

Note

Adjust seatback if needed to avoid contacting headliner

Move 60 seat to easy entry position

Note

Press shoulder switch then push seat forward

Partially remove RH rear door seal

Note

Pillar and sill trim have tabs seated underneath seal

Remove RH C-pillar lower trim

Note

5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ by vehicle build location, and the number of clips may also varyt, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Fold 2nd row 40 seatback down

Note

Via seat switch or manual tether, Protect seat back upholstery if necessary

Remove 40 seat outboard track cover

Note

1x clip, Slide cover forward to release from 40 seat track

Remove bolts securing 40 seat podium to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

Move 40 seat forward using towel bar

Note

With one hand on towel bar pull up and slide the seat forward with your other hand

Remove bolts securing 40 seat inner and outer tracks to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

Move 40 seat fully rearward using towel bar

Note

pull bar, slide seat forward

Disconnect 2nd row 40 seat connector

Note

1x connector, Newer models may have red locking tab

Remove 40 seat from vehicle

Note

Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

Remove 3rd row seat cushion

Note

2x clips, 1x connector, 2x circular hooks, Press tabs backward then pull front edge up, Press rear seat cushion and lift the front seat cushion

Remove 3rd row LH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster towards front of vehicle to remove

Remove 3rd row RH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster towards front of vehicle to remove

Release LH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

Release RH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

Remove 3rd row rear cabin carpet

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 remove LH front primary door seal from body

Remove LH IP end cap

Note

5x clips, 2x guide tabs

Remove LH lower A pillar trim from body

Note

7x clips,4x 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 LH footwell cover

Note

2x magnets, 2x datums, Cover is attached to carpet

Release OBD port from footwell cover

Note

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

Remove LH knee air bag cover

Note

1x connector, 8x tabs, 2x datums

Remove console LH front side panel

Note

14x clips, 2x datums, 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

7x clips, 4x 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

2x connector, 5x tabs, 1x datum, 4x bolts, E10, 8 Nm, Discard bolts after removal, Remove 4x fasteners before unlatching airbag cover assembly, carefully remove connector for light by pressing tab and pulling, for airbag use pick tool to unlock tabs and release connector.

Remove console RH front side panel

Note

14x clips, 2x datums, Use finger hole to release panel located at top edge of front side panel, Pull bottom to release remaining clips, Use caution and pull panel straight away from console to avoid damage

Fold RH front cabin carpet rearward

Note

Different regions may stick the carpet and foam together and tear them apart

Remove foam plug 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

Note

Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

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, Ensure that one minute has passed after window movement before performing the power-off, 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 3rd row NVH insulator

Note

1x connector, Disconnect connector then remove insulator

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

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

Remove bolts securing ancillary bay probe lid cover

Note

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

Remove ancillary bay probe lid 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 bolts

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

Remove leather over gloves and HV insulating gloves

Install HVC logic cap

Note

1x logic cap

Release positive LV output cover from PCS cable

Note

1x cover

Remove PCS cable from LV passthrough output

Note

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

Remove nut securing DCDC ground busbar to HV battery

Note

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

Close all four doors

Note

If necessary, Fake lock block

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

Note

Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

Remove bolts securing front aero shield

Note

7x bolts, 10mm, 5 Nm

Remove front aero shield

Note

2x nuts, 15mm, 5 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

Secure LH front wheel liner aside

Note

1x bungee strap, Secure to subframe

Secure RH front wheel liner aside

Note

1x bungee strap, 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

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

Disconnect AC compressor HV harness connector from HV Ancillary harness

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

Release FDU HV harness from 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 leather over gloves and 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

Note

1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill

Attach battery drain fitting adapter to female side of HV battery return tube

Note

1x spring clip, Make sure valve is set to closed, Perform push-pull test to verify adapter is fully engaged

Attach hose extension to coolant drain hose for extra length

Connect battery flush fitting adapter to coolant cart drain hose

Release chiller to battery hose from body

Note

1x clip

Disconnect HV battery front manifold hose from chiller to battery hose

Note

1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill

Attach Battery flush fitting adapter to male side of HV battery supply hose

Attach battery flush fitting adapter to coolant cart pressure hose

Attach battery drain fitting adapter to coolant cart pressure hose

Open valve on battery drain fitting adapter

Note

Turn valve knob to vertical position

Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return tube

Note

Close valve on pressure regulator once no coolant is draining from HV battery return hose

Close valve on pressure regulator once no coolant is draining from battery return hose

Disconnect compressed air from coolant cart

Remove battery drain fitting adapter from female side of HV battery return tube

Note

1x spring clip, Set valve knob to closed position, And plug the hose, If the battery is returned to Reman, please remove the special tool plugs

Remove battery flush fitting adapter from male side of HV battery supply tube

Note

1x spring clip, Plug hose once adapter has been removed, If the battery is returned to Reman, please remove the special tool plugs

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, If the battery is returned to Reman, please remove the special tool plugs

Disconnect PT supply hose

Note

1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant 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, If the battery is returned to Reman, Please remove the special tool plugs

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 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

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

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 leather over gloves and 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, If the battery is returned to Reman, please remove the special tool plug

Disconnect RDU inverter inlet hose from PCS outlet hose coupling

Note

1x spring clip, 2x plugs, Connection is located at the LH rear of the HV Battery, Install plugs once disconnected, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plug

Connect coolant Drain and Fill Adapter to PCS outlet hose coupling

Note

Use adapter with 90 degree angle, Make sure locking clip is fully seated, Make sure valve is open, Valve is inline with the adaptor when open, Connection is at LH rear of HV Battery

Connect coolant hose extension to Drain and Fill adaptor

Note

Press hose end onto adaptor until clicked into place

Connect coolant hose extension to coolant drain hose

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Position coolant drain container underneath RH rear of HV battery

Disconnect rear powertrain supply hose from PCS inlet hose coupling

Note

1x spring clip, Plug hose connections as needed, Connection is located at RH rear of HV Battery, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plugs

Connect coolant Leak Test Adaptor to PCS inlet hose coupling

Note

Remove rubber plug from coupler if installed, Make sure the locking clip is fully seated, Connection is at RH rear of HV Battery

Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter

Note

Hand tighten hose connection, No tool required to tighten

Remove coolant drain container from underneath vehicle

Connect compressed air to coolant pressure tester

Note

Make sure valves are closed on pressure regulator

Open regulator valve then slowly adjust regulator to 50 psi

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Close regulator valve

Disconnect compressed air from coolant pressure tester

Disconnect coolant Leak Test Adaptor with hose from PCS inlet hose coupling

Note

1x spring clip, Leave the Leak Test Fixture hose connected to Leak Test Adaptor, Connection is at RH rear of HV Battery

Disconnect coolant Drain and Fill Adapter with extension hose from PCS outlet hose coupling

Note

1x spring clip, leave extension hose attached to drain and fill adaptor, Connection is at LH rear of HV battery

Connect coolant Leak Test Adaptor with hose to PCS outlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Leave the coolant Leak Test Fixture hose attached to the Leak Test Adaptor, Connection is at LH rear of HV Battery

Connect coolant Drain and Fill Adapter with extension hose to PCS inlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Connection is at RH rear of HV battery

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

Note

Once timer is complete, select Stop Reset

Close regulator valve

Disconnect compressed air from Leak Test Fixture tool

Disconnect coolant hose extension from coolant drain hose

Note

Press grey button to release hose fitting

Disconnect coolant hose extension from coolant Drain and Fill adaptor

Note

Press grey button to release hose fitting

Disconnect coolant drain hose adapter from PCS inlet hose coupling

Note

1x spring clip, Install plug to inlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Disconnect coolant Leak Test Fixture outlet hose from Leak Test Adapter

Note

1x hose connection

Disconnect coolant Leak Test Adaptor from PCS outlet hose coupling

Note

1x spring clip, Install plug to outlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Position coolant drain container 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, If the battery is returned to Reman, Please remove the special tool plugs

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, Discard after removal

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, Discard after removal

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, 35 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

Note

Recommend assistance

Remove battery from under vehicle

Note

Recommend assistance

Remove ancillary bay engagement seal from HV battery pack

Note

Discard anytime HV battery is removed from vehicle

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

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 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

Remove service insulator kit

Remove HVC logic cap

Note

1x logic cap

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 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 old Pyro Disconnect onto old HV battery

Note

Attach pyro to ancillary bay cover volcano brackets with zip ties, If ancillary bay cover is not equipped with volcano brackets then attach pyro to RH rear corner of HV Battery with zip ties and add tape as notification as shown in illustration, Install a piece of paper roll under pyro

Attach HV battery H-frame to gantry and raise into position

Position HV battery under gantry

Note

Recommend assistance, If original pack is RWD and supplied pack is DM, Center ski transfer will be needed

Lower H-frame onto HV battery and secure H-frame to battery

Note

6x bolts, 8mm Allen, Hand tight

Raise HV battery off of battery table

Position gantry over pallet

Lower HV battery onto pallet

Remove H-frame from old HV battery

Note

6x bolts, 8mm Allen, Hand tight

Raise gantry and H-frame from old HV battery

Open crate top housing new HV battery pack

Note

Recommend assistance, Confirm part number specific to vehicles configuration https://epcadmin.teslamotors.com/epcadmin

Remove nuts securing new HV battery to crate

Note

4x nuts, 15mm

Position gantry over new HV battery crate and secure H-frame to battery

Note

6x bolts, 8mm Allen, Hand tight

Lift new HV battery out of crate

Move gantry away from HV battery crate and over HV battery table

Note

Recommend assistance

Lower HV battery onto battery table

Note

Recommend assistance, Make sure to align HV battery onto center ski

Release H-frame from HV battery and raise gantry

Note

6x bolts, 8mm Allen, Hand tight

Remove HV battery from under gantry

Note

Recommend assistance

Position gantry over old HV battery

Lower H-frame onto old HV battery and secure H-frame to battery

Note

6x bolts, 8mm Allen, Hand tight

Raise old HV battery above height of HV battery crate

Note

Remove the pallet

Position HV battery crate underneath old HV battery

Lower old HV battery into crate

Note

Use caution to align the 4 studs and not damage the battery

Remove H-frame from old HV battery

Note

6x bolts, 8mm Allen, Hand tight

Raise gantry and H-frame from old HV battery

Lower gantry and remove HV battery H-frame from gantry

Install nuts securing HV battery to crate hand tight

Note

4x nuts, 15mm

Close crate top housing old HV battery

Note

Recommend assistance

Install HVC logic cap onto new HV battery

Note

1x logic cap

Install HV battery alignment rods

Note

2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay

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, 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, 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 ancillary bay

Set up ladder

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

Remove ladder

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

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

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

Set central bolts securing HV battery center ski cover with cordless impact

Note

4x bolts, EP14, 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

Torque central bolts securing HV battery through center ski cover

Note

4x bolts, EP14, 35 Nm

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, Install new bolt, 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, Install new bolt, 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 container 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

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 rear battery skid plate

Note

2x fir tree clips

Install LH side hose clip to rear battery skid plate

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 hose onto chiller to battery hose

Note

1x spring clip, Remove plugs as needed, Perform push-pull test, Loss of coolant greater than 1L requires coolant vacuum fill

Secure chiller to battery hose onto body

Note

1x clip

Connect HV battery return hose

Note

1x spring clip, Remove plugs as needed, Perform push-pull test, 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 PT supply hose

Note

1x spring clip, Remove plugs as needed, Perform push-pull test, 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 A/C compressor HV harness connector to HV Ancillary harness

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 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

Release LH front wheel liner

Note

1x bungee strap, Remove bungee strap as needed

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

Note

1x bungee strap, Remove bungee strap as needed

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, 5 Nm, Hand-tighten the nuts to temporarily hold the panel in place

Install front aero shield onto vehicle

Note

7x bolts, 10mm, 5 Nm, Apply Loctite 222 onto front aero shield bolts and install fasteners to front aero shield

Torque front aero shield nuts

Note

2x nuts, 15mm, 5 Nm

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, Cut to the required size, 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, Cut to the required size, 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

Install DCDC ground busbar to HV battery

Note

Gently press down

Install nut securing DCDC ground busbar to HV battery

Note

1x nut, 13mm, 9 Nm, Install new nut

Install positive LV 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 LV output cover to PCS cable

Note

1x cover

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

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

Remove HVC logic cap

Note

1x logic cap

Install 3rd row NVH insulator

Note

1x connector, Install insulator then connect connector

Position 3rd row rear cabin carpet

Secure RH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

Secure LH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

Install 3rd row LH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster into seat frame complete

Install 3rd row RH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster into seat frame complete

Install 3rd row seat cushion and connect harness

Note

1x connector, Secure 3rd row seat cushion into RH and LH latches

Remove coolant bottle cap

Note

(*Use this step for Model Y vehicles with heat pump)

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 coolant reservoir adaptor cap onto coolant bottle assembly

Note

(*Use step for Model Y & NV36 coolant procedures)1x adaptor cap, Adaptor found in Vacuum Refill kit, turn clockwise to tighten cap onto coolant bottle

Setup vacuum refill tool

Note

Verify all valves on refill tool are in the closed position, See image for clarity

Connect vacuum refill hose to 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

Disconnect 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 leave LV battery disconnected

Note

1x connector, Engage locking tab, Connect FRL but leave LV battery disconnected

Connect LV battery maintenance-charger

Note

Release positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to ground terminal located above the VCfront, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time (apart from during a SW reinstall/CAN redeploy)

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODE-PLUSvia Toolbox:(link)

Access High Voltage System routines using UI

Note

Select Service mode plus > High Voltage

Select "Procedures" through UI

Select "High Voltage Battery Replacement" through UI

Note

Procedures > High Voltage Battery Replacement

Select "Software Reinstall" through UI

Note

Software Reinstall > CAN ECU > Reinstall, Allow routine to complete, ensure routine is successful

Run ODIN routine PROC_HVC_X_PACK-REPLACEMENTvia Service Mode Plus:

High Voltage Battery ➜ High Voltage Battery Replacement ➜ High Voltage Battery Replacement Routine
High Voltage ➜ HV Battery ➜ HV Battery Replacement Routine

via Toolbox:(link)

Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia 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)

Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:

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

via Service Mode Plus:

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

via Toolbox:(link)

Remove diagnostic cable from port to disconnect toolbox from vehicle

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

2x connector, 5x tabs, 1x location pin, 4x bolts, E10, 8 Nm, Install new bolts, After reconnecting 2x harness assure 5x datum's and location pin align prior to re-attaching air bag cover assembly, insert 4x e10 bolts to secure air bag assembly after re-attachment

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

7x clips, 4x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure, Make sure all clips and tabs fully seated

Install RH IP end cap

Note

5x clips, 2x guide tabs, Pull the seal over end cap

Install RH front primary door seal

Note

Verify seal is seated properly on all trim panels

Move RH front seat forward

Note

Adjust seatback 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

Secure OBD port to LH footwell cover

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 LH knee air bag cover

Note

1x connector, 8x tabs, 2x datums

Secure LH footwell cover

Note

2x magnets, 2x datums

Install LH lower A pillar trim

Note

7x clips, 4x guide tabs, 1x push clip, Align guide tabs with body and harness bracket then push downwards to secure

Install LH lower A pillar trim

Note

7x clips, 4x guide tabs, 1x push clip, Align guide tabs with body and harness bracket then push downwards to secure

Install LH IP end cap

Note

5x clips, 2x guide tabs

Partially 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 40 seat into vehicle

Note

Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium

Connect 2nd row 40 seat connector

Note

1x connector,

Install bolts securing 40 seat podium to vehicle hand tight

Note

2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step

Move 40 seat forward using towel bar

Note

pull up bar, slide seat forward

Install bolts securing 40 seat inner and outer tracks to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Install new bolts

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Install cabin carpet to 40 seat

Torque bolts securing 40 seat podium to vehicle

Note

2x patch bolts, 11mm, 37 Nm

Install center track cover to 2nd row seats

Note

2x clip, Slide cover straight on to clip to 2nd row seat tracks

Install 40 seat outboard track cover

Note

1x clip

Position 40 seat into easy entry mode

Note

Press shoulder switch and push 40 seat forward

Install RH rear sill trim

Note

4x tabs, 3x clips, 5x location pins, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips

Reseat RH rear door seal

Note

Seat pillar and sill trim tabs underneath seal

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Move RH front seat to original position

Install 2nd row 60 seat assembly

Note

Recommend assistance

Connect 2nd row 60 seat connector

Note

1x connector,

Install fasteners securing 60 seat frame to body

Note

5x patch bolts, 11mm, 37 Nm, Install new patch bolts, bottom seat bolts located in rear

Secure cabin carpet to 60 seat

Note

Strap velcro on

Return 2nd row 60 seatback to vertical position

Note

Via trunk seat switch, Remove seatback protection if necessary

Install 60 seat outboard track cover

Note

1x clip

Position 60 seat into easy entry mode

Note

Press shoulder switch and push 60 seat forward to position into easy entry mode

Install LH 7s lower C-pillar trim

Note

8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips

Reseat LH rear door seal

Note

Seat pillar and sill trim tabs underneath seal

Move 60 seat to original position

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)

Coolant air purge run time

Note

Run time: 00:10:00, Subtract overlap time spent on other operations while waiting for coolant purge run

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, Do not pinch washer hose inbetween HEPA filter assembly and body