PCS1 to PCS2 Lite (Retrofit)

Raise and support vehicle

Note

Ensure vehicle is not charging, Remove charging cable if it's plugged in

Open all four doors

Lower all four windows

Open hood

Remove rear apron

Note

16x trim clips, 3x location pins, 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

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

Run ODIN routine

Access thermal system routines via UI

Note

Select Service mode > Thermal

Run ODIN routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)

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

Power off vehicle from center display

Note

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

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

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 rear aero shield clips

Note

2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

Remove rear aero shield

Note

11x bolts, 2x tabs, 10mm, 5 Nm

Release clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Release clips securing coolant hose to LH side of HV battery rear skid plate

Note

1x fir tree clip

Release clips securing coolant hose to RH side of HV battery rear skid plate

Note

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate

Note

2x bolts, EP10, 13 Nm

Remove upper bolts securing HV battery rear skid plate

Note

4x bolts, 13mm, 64 Nm

Remove upper nut securing HV battery rear skid plate

Note

1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles, *part number for nut not provided in catalog

Remove rear skid plate from HV battery

Install amp clamp to RDU HV harness

Note

Verify meter is zeroed out before performing measurement, Measure single cable. If current > 0.5A do not proceed with disconnecting HV connector, In this case, Start vehicle electrical isolation again to make sure that all was properly shut down. If the current is within the range of -0.5 A to 0.5 A, Continue to the next step, Disconnect and check voltage at HV plug on the battery side If the measurement is still outside the range of -0.5 A to 0.5 A, Do not disconnect any HV harness, Escalate for assistance

Remove nut securing RDU HV cable bracket from HV battery

Note

1x nut, 10mm, 10 Nm, Number of fasteners may vary

Remove all items from pockets and ensure not wearing metal items

Note

This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones

Inspect HV insulating gloves

Note

Check gloves for damage prior to use, Refer to service document TN-15-92-003 R5, 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 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

Verify no high voltage at RDU HV header

Note

Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, 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

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

Remove leather over gloves and HV insulating gloves

Install RDU HV cable bracket to HV battery

Note

1x nut, 10mm, 10 Nm, Number of fasteners may vary

Position coolant drain container underneath LH rear of vehicle

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 waste coolant container to drain and fill adaptor

Note

Connect hose to drain and fill adaptor, Push until audible click, Perform Push-pull-push test to verify fully seated

Position coolant drain container underneath RH rear of vehicle

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

Remove coolant drain container from underneath vehicle

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 outlet hose to Leak Test Adapter

Note

Hand tighten hose connection, No tool required to tighten

Connect outlet hose to the Leak Test Fixture tool

Note

Hand tighten hose connection, No tool required to tighten

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Connect compressed air to coolant Leak Test Fixture tool

Note

Air supply source should be above 50 psi

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 2 minutes

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Start 2 minute timer

Note

Once timer is complete, select Stop Reset

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

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 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

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 2 minutes

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Start 2 minute timer

Note

Once timer is complete, select Stop Reset

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Disconnect compressed air from Leak Test Fixture tool

Disconnect Waste Coolant Container from drain and fill adaptor

Note

Disconnect hose from drain and fill adaptor, Press grey button to release hose fitting,

Disconnect coolant drain and fill 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

Lower vehicle until tires are touching ground

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Remove 2nd row seat cushion

Note

1x connector, Lift front edge of seat cushion upward to release foam from frame, Adjust the backrest to the appropriate position as needed

Partially remove lower portion of LH rear door seal

Remove LH C-pillar lower trim

Note

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

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,Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly later

Remove clips securing rear main cabin carpet to vehicle

Note

3x push clips

Remove fasteners securing 2nd row 40 seat frame to body

Note

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

Remove fasteners securing 2nd row 60 seat frame to body

Note

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

Disconnect 2nd row 60 seat connector

Note

1x connector, Disengage locking tab

Remove 2nd row 60 seat assembly from vehicle

Note

Set 60 seat assembly onto rear load floor, Then remove the seat assembly from the rear side of the vehicle, Use fender cover to avoid damaging trims, Recommend assistance

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 LV output cable cover

Note

1x cover

Release positive LV output cable from HV battery

Note

1x nut, 13mm, 9 Nm, Discard nut after removal, Place cable to the side out of the way

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, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover, The number of bolts on later vehicles may vary, Later production vehicles may have 18x bolts, EP10 5-Lobe, 8 Nm, 11x bolts, 8mm, 10.5 Nm

Remove all items from pockets and ensure not wearing metal items

Note

This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones

Inspect HV insulating gloves

Note

Check gloves for damage prior to use, Refer to service document TN-15-92-003 R5, 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 HVC logic cap

Note

1x logic cap

Remove ancillary bay cover from HV battery

Install HVC logic cap

Note

1x logic cap

Remove bolts securing pyro disconnect to ancillary bay

Note

1x insulator, 2x bolts, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard fasteners 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

Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X480 – Shunt at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X484 – Pyro disconnect at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X479 –Main HVC connector from HV Controller

Note

1x connector

Release ancillary bay harness from HVC hinge tray

Note

5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife

Remove screws securing HVC tray assembly to ancillary bay

Note

2x screws, T25, 2 Nm, 3x wires routed through RH hinge

Remove HV controller and hinge tray from penthouse assembly

Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping

Disconnect PCS coolant inlet hose from PCS

Note

2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose

Position absorbent sheets below and around PCS coolant outlet hose to avoid excess coolant dripping

Disconnect PCS coolant outlet hose from PCS

Note

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS and hose, Discard O-ring

Disconnect PCS to DC bus HV connector

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS logic connector from PCS

Note

1x connector

Disconnect PCS LV connector from PCS

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove AC Filter harness

Note

1x connector, 1x clip, 2x bolts, 8mm, 4.5 Nm, Pass harness under PCS hose, Release red locking tab, Discard bolts after removal

Remove bolts securing PCS to HV battery

Note

5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners

Secure suction cups to PCS

Note

Continue pressing plunger until red line is no longer visible

Lift PCS up and out of ancillary bay area and remove from vehicle

Note

Slightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Disconnect ancillary bay harness connectors from positive pack contactor

Note

2x connectors

Remove HV PCS to DC Bus harness clip from positive pack contactor

Note

1x clip

Remove HV joint insulators from positive HV switch

Note

2x insulators

Remove bolt securing positive pack contactor to positive busbar

Note

1x bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard fastener

Remove nut securing positive pack contactor to module 4 rear terminal

Note

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

Remove nuts securing positive pack contactor to ancillary bay

Note

3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

Remove positive pack contactor from ancillary bay

Note

2x guide pins

Cut cable ties securing the megaharness to charger output to DC bus harness

Note

2x cable ties

Remove ancillary bay harness clips from positive DC link

Note

3x clips

Reposition ancillary bay harness to access PCS logic pigtail exiting harness bundle

Note

Follow PCS pigtail to first harness clip to locate area

Remove ancillary bay harness clip closest to X420 harness pigtail

Note

Clip is located where X420 pigtail meets the harness bundle, Cut cable tie to remove harness clip

Cut slit in harness wrap tape where X420 pigtail exits harness bundle

Note

Use seam ripper tool from wire harness repair kit to cut tape, Cut about 40mm slit in harness wrap, do not damage or cut wires

Pull PCS logic pigtail away from ancillary bay harness bundle to lengthen pigtail

Note

Position pigtail in a 90 degree angle to the harness bundle for rework steps

Install new harness clip on ancillary bay harness where PCS logic pigtail exits bundle

Note

Install new cable tie harness clip, Cut off excess cable tie length, *Note: Leave PCS logic pigtail out of cable tie for harness clip

Cut and remove tape from Ancillary Bay harness connector X420 pigtail

Note

X420 is Ancillary Bay harness connection to PCS, Use seam ripper tool from wire harness repair kit to cut tape, End of cut should be 80mm from back edge of connector housing

Unlock contact retainer at Ancillary Bay harness connector X420

Note

Pop up contact retainer with HV pick from access points on each side and bottom of connector housing, Note: Retainer only pops up a small amount in the unlocked position

Figure 1. Push pick into this location to release the connector retainer

Figure 2. Push pick into this location to release the connector retainer

Figure 3. Push pick into this location to release the connector retainer

Figure 4. Connector retainer (circled red) is released when it is overflush to the connector housing

Extract both "IPC-CAN" wires at Ancillary Bay harness connector X420

Note

Use HV pick to separate wires from harness bundle if needed, Extract pins at connector cavities 2 and 3, Insert pin extraction tool into hole on connector face above contact cavity, pull on wire from back of connector housing to remove terminal pigtail from connector, repeat for both pins

Note

Wire colors may vary

Note

The service de-pinning toolkit can be used. The pictured pin extraction tool is under development.

Lock contact retainer at Ancillary Bay harness connector X420

Note

Press down contact retainer into fully locked position, retainer will be flush with connector housing when locked

Secure extracted wires to X420 pigtail with tape

Note

Loop extracted wires back onto X420 pigtail and wrap with anti-abrasion tape, Leave some space between tape wrap and back of connector to allow pigtail to flex properly, harness tape end should be 15 mm from back edge of connector housing

Note

There is no need to cut or heatshrink these wires, as the other ends of these wires will also be removed from their connector.

Move Ancillary Bay harness connector X479 lever mechanism to locked position

Note

Use HV pick tool to manually release lever locks on each side of connector housing, Swing lever into locked position

Remove TPA connector faceplate insert from Ancillary Bay harness connector X479

Note

Press TPA insert locking feet from back of connector housing with HV pick, Further release sides of TPA insert with pick if needed, Remove white TPA insert from face of connector

Extract both "IPC-CAN" wires at Ancillary Bay harness connector X479

Note

Extract pins at connector cavities 5 and 6, Insert pin extraction tool to release locking tab on top of terminal, Use HV pick to separate wire from harness bundle if needed, Pull on wire from back of connector housing to remove terminal pigtail from connector, Repeat for both pins, Note: wire colors may vary

Install TPA insert into Ancillary Bay harness connector X479

Note

Install white TPA insert at face of connector, Press insert into connector until audible click and flush with connector face

Secure extracted wires to X479 pigtail with tape

Note

Loop extracted wires back onto X479 pigtail and wrap with anti-abrasion tape, Start wrapping at original tape line, Wrap in direction away from X479 connector housing until extracted wires have been covered, Do not wrap any closer to back of connector than original tape line

Move Ancillary Bay harness connector X479 lever mechanism to unlocked position

Note

Use HV pick tool to manually release lever lock on top of connector housing, Swing lever into unlocked position

Figure 5. Push the green locking tab (circled) to release the connector lever locking arm

Remove protrusion on the ancillary bay harness base

Note

1x tab, If equipped break off tab with insulated needle nose pliers, Remove tab to allow rotation of the coolant inlet hose, Discard tab

Release PCS coolant inlet hose from hose clip

Note

2x hose clips, Use plastic trim tool to remove hose from the card slot, And then rotate 90 degrees counterclockwise

Disconnect PCS coolant inlet hose from penthouse and discard hose

Note

2x clips, Bend or break hose clips with HV insulated pick, Pull hose end upwards to release, Place absorbent sheet under hose to catch residual coolant inside hose

Install PCS Lite coolant inlet hose to penthouse

Note

1x hose, 2x clips, Install lower end of hose to penthouse, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Visually verify clips are fully seated

Release 700VDC 63A compressor fuse

Note

2x patch nuts, 8mm, 4.5 Nm, Discard after removal

Remove 700VDC 63A compressor fuse from AWD bus and dist assembly

Note

1x fuse

Remove nuts securing 700VDC 63A PCS output fuse

Note

2x patch nuts, 8mm, 4.5 Nm, Discard after removal

Remove 700VDC 63A PCS output fuse from AWD bus and dist assembly

Note

1x fuse

Remove the nut securing the negative terminal of the HV PCS to DC Bus harness

Note

1x nut, 8mm, 4.5Nm

Remove the nut securing the HV battery ancillary positive busbar

Note

1x nut, 10mm, 14Nm

Remove the HV battery ancillary positive busbar

Remove screw securing the RH penthouse bus cover

Note

1x screw, T20, 3Nm

Release DC link busbar cover clips and lift up on cover

Note

2x clips, Do not damage the casing when lifting it, it is recommended to assist

Remove HV PCS to DC Bus harness

Note

1x harness, Remove positive cable ring terminal from HV fuse mounting stud, Remove negative cable ring terminal from mounting stud on DC Link negative busbar, Lift up on busbar cover while routing negative cable out from under cover, Do not damage the plastic cover when lifting, it is recommended to assist

Install HVDC PCS Lite harness

Note

1x harness, Lift up on busbar cover while routing negative cable under cover, Do not damage the plastic cover when lifting, Assistance is recommended, Position negative cable ring terminal on DC Link negative busbar stud, Position positive cable ring terminal on HV fuse mounting stud

Secure DC link busbar cover clips

Note

2x clips

Install the screw securing the RH penthouse bus cover

Note

1x screw, T20, 3Nm

Install the HV battery ancillary positive busbar

Note

position busbar in place

Install the nut securing the HV battery ancillary positive busbar

Note

1x nut, 10mm, 14Nm

Install nut securing the HVDC PCS Lite harness negative terminal

Note

1x nut, 8mm, 4.5Nm

Perform Hioki resistance test at HVDC PCS Lite harness negative terminal joint

Note

55μΩ or less, Perform zero adjust to Hioki meter prior to testing

Install 700VDC 63A PCS output fuse to AWD bus and dist assembly

Note

1x fuse

Install nuts securing the 700VDC 63A PCS output fuse

Note

2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque

Perform Hioki resistance test at 63A PCS fuse input joint

Note

1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

Perform Hioki resistance test at 63A PCS fuse output joint

Note

1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

Install the 700VDC 63A compressor fuse to AWD bus and dist assembly

Note

1x fuse

Install the nuts securing the 700VDC 63A compressor fuse

Note

2x patch nuts, 8mm, 2.5 Nm, Install new patch nuts, Mark after torque

Perform Hioki resistance test at 63A fuse output joint

Note

1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

Perform Hioki resistance test at 63A fuse input joint

Note

1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

Install ancillary bay harness clips to positive DC link

Note

3x clips

Position positive pack contactor to ancillary bay for installation

Note

2x guide pins

Install nuts securing positive pack contactor to ancillary bay

Note

3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary

Install bolt securing positive pack contactor to positive busbar

Note

1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque

Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal

Note

1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

Measure resistance from HV joint between HV battery positive contactor and center of HV battery positive terminal

Note

1x HV joint, 110μΩ or less

Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar

Note

1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

Install HV joint insulators onto positive pack contactor

Note

2x insulators

Connect ancillary bay harness connectors to positive pack contactor

Note

2x connectors

Remove bolt securing DCDC ground strap to body

Note

1x bolt, 13mm, 30 Nm, Discard after removal, If reusable E18 service bolt (1056534-00-C) is installed do not discard

Remove DCDC ground strap from HV battery

Note

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

Remove DCDC ground strap from vehicle

Remove bolts securing DCDC pass through to ancillary bay

Note

2x bolts, E10 5-Lobe, 10 Nm

Remove DCDC pass through harness

Note

Electrical Protective Gloves

Install PCS2 Lite 12V DC harness

Install bolts securing PCS2 Lite 12V DC harness to ancillary bay

Note

2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque

Install DCDC ground strap from vehicle

Note

1x alignment tab, Route under RH body harness

Install nut securing DCDC ground strap to HV battery

Note

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

Install bolt securing DCDC ground strap to body

Note

1x bolt, E18, 30 Nm, Install new bolt if original was a self tapping tri-lobular bolt, New bolt (1056534-00-C) can be reused

Remove harness clip from FC contactor cover

Note

1x clip

Disconnect ancillary bay harness connectors from negative pack contactor

Note

2x connectors

Remove HV joint insulators from negative pack contactor

Note

2x insulators

Remove bolt securing negative pack contactor to DC link busbar joint

Note

1x patch bolt, 13mm, 9 Nm, Discard after removal

Remove nut securing negative pack contactor to HV battery tall silicon terminal

Note

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

Remove nuts securing negative pack contactor to penthouse

Note

3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

Remove negative pack contactor from penthouse

Note

2x guide pins

Disconnect PCS coolant outlet hose from penthouse

Note

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to penthouse and hose

Connect PCS2 Lite coolant outlet hose to penthouse

Note

2x clips, The lower end of hose connects to penthouse, Perform push pull push test to make sure coolant hose is fully latched, Visually verify clips are fully seated, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Position negative pack contactor to penthouse for installation

Note

Align the 2x guide pins

Install nuts securing negative pack contactor to penthouse

Note

3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary, Mark after torque

Install bolt securing negative pack contactor to DC link busbar joint

Note

1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque

Install nut securing negative pack contactor to HV battery tall terminal

Note

1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

Perform Hioki impedance test at HV joint of negative pack contactor to negative DC link busbar

Note

1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

Perform Hioki impedance test at negative pack contactor to module 1 rear terminal

Note

1x HV joint, 110μΩ or less

Install HV joint insulators to negative pack contactor

Note

2x insulators

Connect ancillary bay harness connectors to negative pack contactor

Note

2x connectors

Install ancillary bay harness clip around negative pack contactor area

Note

1x clip

Install PCS2 AC Filter harness

Note

1x connector, 1x clip, 2x bolts, 8mm, 4.5 Nm, Install new bolts, Engage locking tab

Remove Module 2 to Pyro disconnect busbar cover

Note

1x orange plastic insulator cover, 1x rubber insulator bolt cover, 3x mounting clips, Remove rubber insulator first if needed, Carefully release each mounting clip and pull cover off busbar, Use plastic trim tool or insulated pick tool

Apply anti-abrasion tape to Module 2 to Pryo disconnect busbar cover

Note

1x orange plastic insulator cover, Only use Orange anti-abrasion tape for rework on busbar cover) Cut Anti-abrasion tape piece ~3cm to 3.5cm long (Figure 1)b) Stick tape laterally on the central section of insulator, It should not cover the cutout sections and should end before the curved edge section (Figure 2)c) Cut anti-abrasion tape piece 4.0 cm long (Figure 3)d) Position tape longitudinally on right-side curved surface, Ensure the inner edge of the tape is precisely aligned with the insulator cutout, Make small lateral cut on one half of tape, positioned near the center. This cut allows the tape to wrap smoothly around the curved geometry without wrinkling (Figure 4)e) Carefully wrap remaining tape around the edge of cover ensuring full contact and no air bubbles or creases. Make sure left edge of tape overlaps first layer of tape (Figure 5)

Install Module 2 to Pryo disconnect busbar cover

Note

1x plastic cover, 1x rubber insulator cover, Verify all 3 cover clips are secure, install rubber insulator bolt cover if removed during rework

Apply anti-abrasion tape to PCS

Note

Use anti-abrasion orange or black tape for rework on PCS) Cut anti-abrasion tape piece 5.0 cm long) Cut square notch out of top right corner, Notch is to clear PCS fastener hole) Install tape piece to bottom side of PCS as shown

Secure vacuum cups to new PCS2 lite

Note

2x vacuum cups

Position PCS2 into ancillary bay

Note

Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datums into PCS holes

Remove suction cups from PCS2

Install bolts securing PCS2 to HV battery

Note

5x bolts, 8mm, 18 Nm

Connect PCS2 AC Filter harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 Lite 12V DC harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS logic pigtail on ancillary bay harness to PCS2

Note

1x connector

Secure PCS logic pigtail to HV positive Contactor with harness edge clip

Note

1x clip, Secure edge band clip onto top of contactor assembly, Secure PCS logic pigtail to edge clip with cable tie, Cut off extra cable tie length

Connect PCS2 Lite HVDC harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 Lite coolant inlet hose to PCS2

Note

2x clips, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated

Connect PCS2 Lite coolant outlet hose to PCS2

Note

2x clips, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated

Position HV controller and hinge tray to penthouse assembly

Note

4x locating pins, 3x wires routed through RH hinge

Install screws securing HVC tray assembly to ancillary bay

Note

2x screws, T25, 2 Nm

Install ancillary bay harness to HVC hinge tray

Note

5x harness clips, 1x tape, Wrap harness tape around the hinge tray at marked location to secure harness bundle

Connect HV controller connector X479 –Main HVC connector to HV Controller

Note

1x connector

Connect HV controller connector X484 – Pyro disconnect at HVC to HV Controller

Note

1x connector

Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller

Note

1x connector

Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller

Note

1x connector

Connect HV controller connector X480 – Shunt at HVC to HV Controller

Note

1x connector

Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller

Note

1x connector

Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller

Note

1x connector

Install HVC pedestal or foam blocks

Note

1x pedestal, 2x screws, E6, 2 Nm, 2x foam blocks, Install plastic pedestal to bottom of HVC if newer rev HVC is present, Pedestal aligns with 1 datum and secures with two screws, Stack 2 foam blocks and stick to bottom of HVC if older rev HVC is present without holes for pedestal, Stick two foam blocks together then stick to bottom of HVC in the center location

Remove pyro disconnect dummy

Clean mating surface of pyro

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, If the insulation protective cover is removed

Set multimeter to "LoZ" (low impedance) mode

Measure voltage between busbar and shunt

Note

Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points

Position pyro disconnect to ancillary bay for installation

Note

1x connector, Measure voltage between busbar and shunt for at least 10 seconds, 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, After the second person places the pyro down on the HV bus, the first person should continue to measure the voltage for another 10 seconds

Install bolts securing pyro disconnect to ancillary bay

Note

2x bolts, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Install new fasteners

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

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

Image up close for clarity, Delaminated and torn seals cannot be reused, If installing new parts, Skip this step

Clean ancillary bay cover mounting surfaces

Note

Clean along gasket and contact surface of sealant, Allow to 1 minute dry time, Skip this step if replacing cover

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 leather over gloves and HV insulating gloves

Install HVC logic cap

Note

1x logic cap

Install ancillary bay cover to HV battery

Note

18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover,The number of bolts on later vehicles may vary, Later production vehicles may have 18x bolts, EP10 5-Lobe, 8 Nm, 11x bolts, 8mm, 10.5 Nm Follow torque sequence per image

Install bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Install positive LV output cable to HV battery

Note

1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque

Install positive LV output cable cover

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

Position 2nd row 60 seat assembly into vehicle

Note

Set 60 seat assembly onto rear load floor through the rear side of the vehicle, Then install the seat assembly onto body, Use fender cover to avoid damaging trims, Recommend assistance

Connect 2nd row 60 seat connector

Note

1x connector, Engage the tab

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

Position 2nd row 40 seat assembly into vehicle

Note

Recommend assistance

Connect 2nd row 40 seat connector

Note

1x connector, Engage the tab

Install fasteners securing 2nd row 40 seat frame to body

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

Install clips securing rear main cabin carpet to vehicle

Note

3x push clips, Ensure the carpet edges are properly installed in place

Install RH C-pillar lower 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

Install LH C-Pillar lower trim

Note

5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips, Confirm 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

Reseat LH rear door seal

Note

Seat pillar and sill trim tabs underneath seal

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

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

Connect coolant Leak Test Adapter plug to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove rubber plug from PCS outlet hose coupling if present, Install 90 degree Leak Test Adaptor with NPT plug, Make sure the locking clip is fully seated

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 outlet hose to Leak Test Adapter

Note

Hand tighten hose connection, No tool required to tighten

Connect outlet hose to the Leak Test Fixture tool

Note

Hand tighten hose connection, No tool required to tighten

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Connect compressed air to coolant Leak Test Fixture tool

Note

Air supply source should be above 50 psi

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Allow pressure in PCS coolant loop to stabilize at 50 psi

Note

Pressure should settle around 50 psi

Set timer for 4 minutes

Record the PCS coolant loop leak check starting pressure

Note

Record the value shown on the digital gauge

Close inlet valve on Leak Test Fixture tool

Note

The valve knob should be perpendicular to the air line when closed

Start 4 minute timer

Note

Once timer is complete, select Stop Reset

Record the PCS coolant loop leak check end pressure

Note

Record the value shown on the digital gauge after 4 minute timer is complete, Max delta between start and end pressures is 0.35 psi, Check coolant hose to see if it is fully seated if pressure test fails

Disconnect compressed air from Leak Test Fixture tool

Open inlet valve on Leak Test Fixture to discharge air from coolant system

Note

1x valve, Turn valve slowly to release air

Disconnect coolant Leak Test Fixture hose from Leak Test Adapter

Disconnect Leak Test Adaptor from PCS inlet hose coupling

Note

1x spring clip

Position coolant drain container underneath RH rear of vehicle

Connect rear PT supply hose to PCS inlet hose coupling

Note

1x spring clip, 1x plug, Remove plug, Perform push-pull-push test to make sure hose is fully seated, Connection is located at RH rear of HV Battery, Vacuum fill required if > 1L lost during repair

Disconnect Leak Test Adaptor plug from PCS outlet hose coupling

Note

1x spring clip, Connection located at LH rear of HV Battery

Position coolant drain container underneath LH rear of vehicle

Connect RDU inverter inlet tube to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged, Connection is located at LH rear of HV Battery, Vacuum fill required if > 1L lost during repair

Remove coolant drain container from underneath vehicle

Position rear battery enclosure skid plate to HV battery for installation

Note

Recommend assistance if needed

Install upper nut securing HV battery rear skid plate hand tight

Note

1x nut, 10mm, 13 Nm, Torque at later step

Install upper bolts securing HV battery rear skid plate hand tight

Note

4x bolts, 13mm, 64 Nm

Install lower bolts securing HV battery rear skid plate hand tight

Note

2x bolts, EP10, 13 Nm

Torque upper nut securing HV battery rear skid plate

Note

1x nut, 10mm, 13 Nm

Torque upper bolts securing HV battery rear skid plate and HV battery to vehicle

Note

4x bolts, 13mm, 64 Nm

Torque lower bolts securing HV battery rear skid plate

Note

2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts

Install clips securing coolant hose to RH side of HV battery rear skid plate

Note

2x fir tree clips

Install clips securing coolant hose to LH side of HV battery rear skid plate

Note

1x fir tree clip

Install clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Install rear aero shield

Note

2x tabs, 11x bolts, 10mm, 5 Nm, Position rear datums first, Apply Loctite 222 onto rear aero shield bolts

Install rear aero shield clips

Note

2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

Lower vehicle fully

Note

Raise lift off locks, Then hold lock release lever to keep locks free while vehicle is lowered

Remove coolant bottle cap

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

Place empty coolant container into front storage area

Fill container with at least 15L of coolant

Place filled coolant container into front storage area

Note

(*Use step for Model Y vehicles)

Setup coolant Vacuum Refill Tool

Note

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

Connect vacuum refill hose to reservoir adaptor cap on coolant bottle

Note

Perform push-pull-push test to verify hose is fully engaged

Place refill hose inside filled coolant container

Note

Make sure hose end is fully submerged into coolant

Place overflow hose into empty container

Connect shop air supply to vacuum refill tool

Note

If not already done, Verify refill valve is set to off

Open shop air supply valve on vacuum refill tool

Note

Air flow will be present when valve is open

Open air inlet valve on vacuum refill tool to draw a vacuum on vehicle coolant system

Note

Vacuum gauge reading should change once valve is open, Gauge should stabilize around 60-70 cmHg

Close air inlet valve on Vacuum Refill Tool once gauge stabilizes

Note

Vacuum gauge reading should not drop after the valve is closed

Monitor gauge for 30 seconds to verify vacuum is maintained in cooling system

Note

If vacuum is not maintained there may be a leak in the cooling system, Verify no loose connections or fittings on vacuum refill tool causing vacuum leak

Continue evacuating cooling system

Note

Open air inlet valve for 3 minutes then close air inlet valve

Close shop air supply valve on refill tool

Note

Air flow noise should stop

Slowly open refill valve to draw coolant into system

Note

Valve lever is inline with hose when fully open, Make sure end of refill hose is fully submerged in container during entire process, Coolant will be transferred through hose from container to vehicle coolant reservoir, Vacuum gauge needle will move towards zero as it fills

When gauge reaches zero, close coolant refill valve

Disconnect shop air from Vacuum Refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from waste coolant container

Disconnect vacuum refill hose from reservoir adaptor cap on coolant bottle

Remove coolant reservoir adaptor cap from coolant bottle assembly

Remove vacuum refill tool from vehicle

Remove both coolant containers from inside underhood area

Note

(*Use this step for Model Y vehicles)

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

Move RH front seat to original position

Move LH front seat to original position

Run ODIN routine UPDATE_CAN-REDEPLOYvia Service Mode Plus:

Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
Thermal ➜ HVAC ➜ CAN Redeploy
chassis ➜ DPB Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Post Replacement ➜ CAN Redeploy
chassis ➜ IDB Post Replacement ➜ CAN Redeploy
chassis ➜ RCU Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
chassis ➜ IBST Replacement Panel ➜ CAN Redeploy

via Toolbox:(link)

Verify software update is complete

Note

Verify on center display release notes are present, If the redeploy fails you may receive an error message on UI

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)

Coolant air purge run time

Note

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

Inspect coolant level and adjust as needed

Note

Ensure that the fluid level filled to the Max line, top off or remove coolant as needed

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, Do not pinch washer hose in between HEPA filter assembly and body

Install rear apron

Note

16x trim clips, 3x location pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron