Code de correction TBD FRT 2.52 REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire indiqués ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous. REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.

1. Raise and support vehicle
   Remarque

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

   

   

   

2. Open all four doors

   

3. Lower all four windows

   

4. Move LH front seat forward
   Remarque

   Adjust seat back if needed to avoid contacting headliner

   

5. Move RH front seat forward
   Remarque

   Adjust seatback if needed to avoid contacting headliner

   

6. Move 60 seat to easy entry position
   Remarque

   Press shoulder switch then push seat forward

   

   

7. Partially remove lower portion of LH rear door seal

   

8. Remove LH 7s lower C-pillar trim
   Remarque

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

   

   

9. Move 60 seat to original position
   Remarque

   Press shoulder switch then pull seat backward

   

10. Fold 2nd row 60 seatback down
    Remarque

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

    

    

11. Disconnect 2nd row 60 seat connector
    Remarque

    1x connector,

    

    

12. Move 60 seat forward using towel bar
    Remarque

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

    

    

13. Remove 60 seat rear outboard track fastener
    Remarque

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

    

14. Remove 60 seat rear inboard track fasteners
    Remarque

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

    

15. Move 60 seat fully rearward using towel bar
    Remarque

    pull up bar, slide seat forward

    

16. Remove 60 seat outboard track cover
    Remarque

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

    

    

    

17. Remove center track cover from 2nd row seats
    Remarque

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

    

    

    

18. Release cabin carpet from 60 seat
    Remarque

    Pull cabin carpet towards front of vehicle

    

    

19. Remove 60 seat front inboard track fasteners
    Remarque

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

    

20. Remove 2nd row 60 seat frame front outboard track fasteners
    Remarque

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

    

21. Remove 2nd row 60 seat assembly from vehicle
    Remarque

    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

    

    

22. Move RH front seat forward
    Remarque

    Adjust seatback if needed to avoid contacting headliner

    

23. Move 60 seat to easy entry position
    Remarque

    Press shoulder switch then push seat forward

    

    

24. Partially remove RH rear door seal
    Remarque

    Pillar and sill trim have tabs seated underneath seal

    

25. Remove RH C-pillar lower trim
    Remarque

    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

    

    

26. Move 40 seat to original position
    Remarque

    Press shoulder switch then pull seat backward

    

27. Fold 2nd row 40 seatback down
    Remarque

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

    

    

28. Remove 40 seat outboard track cover
    Remarque

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

    

29. Remove bolts securing 40 seat podium to vehicle
    Remarque

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

    

30. Move 40 seat forward using towel bar
    Remarque

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

    

31. Remove bolts securing 40 seat inner and outer tracks to vehicle
    Remarque

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

    

32. Move 40 seat fully rearward using towel bar
    Remarque

    pull bar, slide seat forward

    

33. Disconnect 2nd row 40 seat connector
    Remarque

    1x connector, Newer models may have red locking tab

    

    

34. Remove 40 seat from vehicle
    Remarque

    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

    

    

35. Remove 3rd row seat cushion
    Remarque

    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

    

    

    

    

    

36. Remove 3rd row LH seat cushion bolster
    Remarque

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

    

37. Remove 3rd row RH seat cushion bolster
    Remarque

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

    

    

    

38. Release LH side of 3rd row rear carpet
    Remarque

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

    

    

    

    

39. Release RH side of 3rd row rear carpet
    Remarque

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

    

    

    

    

40. Remove 3rd row rear cabin carpet

    

    

41. Open hood

    

    

42. Exécutez la routine ODIN PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)
43. Unlock the vehicle gateway. See Passerelle (déverrouiller).
44. Access thermal system routines via UI
    Remarque

    Select Service mode > Thermal

    

    

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

    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

    

    

    

46. Power off vehicle from center display
    Remarque

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

    

    

47. Remove rear apron
    Remarque

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

    

    

    

    

48. Remove HEPA filter assembly
    Remarque

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

    

    

    

    

49. Disconnect LV battery and first responder loop
    Remarque

    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

    

    

    

    

    

50. Verify operation of multimeter
    Remarque

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

    

51. Remove 3rd row NVH insulator
    Remarque

    1x connector, Disconnect connector then remove insulator

    

    

    

    

52. Install HVC logic cap
    Remarque

    1x logic cap

    

53. Remove all items from pockets and ensure not wearing metal items

    

54. Inspect HV insulating gloves
    Remarque

    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

    

55. Put on HV insulating gloves and leather over gloves
    Remarque

    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.

    

56. Release positive LV output cover from PCS cable
    Remarque

    1x cover

    

    

57. Remove PCS cable from LV passthrough output
    Remarque

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

    

58. Remove bolts securing ancillary bay probe lid cover
    Remarque

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

    

59. Remove ancillary bay probe lid cover

    

    

60. Verify no high voltage
    Remarque

    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

    

    

    

    

61. Wipe ancillary bay cover with IPA to clean surface
    Remarque

    Allow to 1 minute dry time

    

62. Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
    Remarque

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

    

    

63. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Remarque

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

    

64. Remove leather over gloves and HV insulating gloves

    

65. Raise vehicle fully and lower lift onto locks
    Remarque

    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

    

    

66. Remove LH and RH push clips securing mid aero shield to wheel house liner
    Remarque

    2x clips

    

    

67. Remove mid aero shield
    Remarque

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

    

    

68. Release LH side hose clip from rear battery skid plate
    Remarque

    1x fir tree clip

    

69. Release RH side hose clips from rear battery skid plate
    Remarque

    2x fir tree clips

    

70. Remove lower bolts securing HV battery rear skid plate enclosure
    Remarque

    2x bolts, EP10, 13 Nm

    

71. Remove upper bolts securing HV battery rear skid plate enclosure
    Remarque

    4x bolts, 13mm, 64 Nm

    

72. Remove HV battery rear skid plate enclosure

    

73. Position coolant drain container under LH rear of vehicle

    

74. Disconnect RDU inverter inlet hose from PCS outlet hose coupling
    Remarque

    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

    

    

75. Connect coolant Drain and Fill Adapter to PCS outlet hose coupling
    Remarque

    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

    

    

76. Connect coolant hose extension to Drain and Fill adaptor
    Remarque

    Press hose end onto adaptor until clicked into place

    

77. Connect coolant hose extension to coolant drain hose
    Remarque

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

    

78. Position coolant drain container underneath RH rear of HV battery

    

79. Disconnect rear powertrain supply hose from PCS inlet hose coupling
    Remarque

    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

    

    

80. Remove coolant drain container from underneath vehicle

    

81. Connect coolant Leak Test Adaptor to PCS inlet hose coupling
    Remarque

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

    

    

82. Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter
    Remarque

    Hand tighten hose connection, No tool required to tighten

    

    

83. Connect outlet hose to the Leak Test Fixture tool
    Remarque

    Hand tighten hose connection, No tool required to tighten

    

    

    

84. Close both valves on the coolant Leak Test Fixture tool
    Remarque

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

    

    

    

85. Connect compressed air to coolant Leak Test Fixture tool
    Remarque

    Air supply source should be above 50 psi

    

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

    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

    

    

    

    

    

87. Set timer for 2 minutes

    

88. Open outlet valve on Leak Test Fixture tool.
    Remarque

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

    

    

89. Start 2 minute timer
    Remarque

    Once timer is complete, select Stop Reset

    

90. Close both valves on the coolant Leak Test Fixture tool
    Remarque

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

    

    

    

91. Disconnect coolant Leak Test Adaptor with hose from PCS inlet hose coupling
    Remarque

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

    

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

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

    

93. Connect coolant Leak Test Adaptor with hose to PCS outlet hose coupling
    Remarque

    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

    

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

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

    

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

    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

    

    

    

    

    

96. Set timer for 2 minutes

    

97. Open outlet valve on Leak Test Fixture tool.
    Remarque

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

    

    

98. Start 2 minute timer
    Remarque

    Once timer is complete, select Stop Reset

    

99. Close both valves on the coolant Leak Test Fixture tool
    Remarque

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

    

    

    

100. Disconnect compressed air from Leak Test Fixture tool

     

101. Disconnect coolant hose extension from coolant drain hose
     Remarque

     Press grey button to release hose fitting

     

102. Disconnect coolant hose extension from coolant Drain and Fill adaptor
     Remarque

     Press grey button to release hose fitting

     

103. Disconnect coolant drain hose adapter from PCS inlet hose coupling
     Remarque

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

     

     

104. Disconnect coolant Leak Test Fixture outlet hose from Leak Test Adapter
     Remarque

     1x hose connection

     

105. Disconnect coolant Leak Test Adaptor from PCS outlet hose coupling
     Remarque

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

     

     

     

106. Lower vehicle fully
     Remarque

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

     

     

     

107. Remove bolts securing ancillary bay cover to HVC
     Remarque

     3x bolts, E10, 5 Nm + 30 degrees

     

108. Remove bolts securing ancillary bay cover to HV battery
     Remarque

     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

     

     

109. Remove HVC logic cap
     Remarque

     1x logic cap

     

110. Remove ancillary bay cover from HV battery

     

     

111. Install HVC logic cap
     Remarque

     1x logic cap

     

112. Inspect ancillary bay for any missing insulators
     Remarque

     Install service insulator kit before continuing to next step

     

     

     

     

     

113. Remove bolts securing pyro disconnect to ancillary bay
     Remarque

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

     

     

114. Remove pyro disconnect from ancillary bay
     Remarque

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

     

     

115. Install pyro disconnect dummy

     

116. Disconnect AC harness connector from PCS
     Remarque

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

     

117. Remove AC Filter harness
     Remarque

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

     

     

     

     

     

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

     1x connector

     

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

     1x connector

     

120. Disconnect HV controller connector X480 – Shunt at HVC from HV Controller
     Remarque

     1x connector

     

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

     1x connector

     

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

     1x connector

     

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

     1x connector

     

124. Disconnect HV controller connector X479 –Main HVC connector from HV Controller
     Remarque

     1x connector

     

125. Remove megaharness clips from HV controller hinge tray
     Remarque

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

     

126. Remove screws securing HVC tray assembly to ancillary bay
     Remarque

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

     

     

127. Remove HV controller and hinge tray from penthouse assembly

     

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

     

129. Disconnect PCS coolant inlet hose from PCS
     Remarque

     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

     

     

     

     

130. Disconnect PCS coolant outlet hose from PCS
     Remarque

     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

     

     

     

     

131. Disconnect PCS to DC bus HV connector
     Remarque

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

     

132. Disconnect PCS logic connector from PCS
     Remarque

     1x connector

     

133. Disconnect PCS LV connector from PCS
     Remarque

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

     

134. Disconnect AC harness connector from PCS
     Remarque

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

     

135. Remove bolts securing PCS to HV battery
     Remarque

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

     

136. Secure suction cups to PCS
     Remarque

     Continue pressing plunger until red line is no longer visible

     

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

     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

     

138. Install PCS2 AC Filter harness
     Remarque

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

     

     

     

     

     

139. Position PCS2 into ancillary bay
     Remarque

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

     

     

     

140. Remove suction cups from PCS2

     

     

141. Install bolts securing PCS2 to HV battery
     Remarque

     5x bolts, 8mm, 18 Nm

     

142. Connect PCS2 AC Filter harness connector to PCS2
     Remarque

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

     

     

143. Connect PCS2 Lite 12V DC harness connector to PCS2
     Remarque

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

     

     

144. Connect PCS logic pigtail on ancillary bay harness to PCS2
     Remarque

     1x connector

     

145. Secure PCS logic pigtail to HV Pos Contactor with harness edge clip
     Remarque

     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

     

     

146. Connect PCS2 Lite HVDC harness connector to PCS2
     Remarque

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

     

     

147. Connect PCS2 Lite coolant inlet hose to PCS2
     Remarque

     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

     

     

148. Connect PCS2 Lite coolant outlet hose to PCS2
     Remarque

     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

     

     

149. Position HV controller and hinge tray to penthouse assembly
     Remarque

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

     

     

     

150. Secure HVC tray assembly to ancillary bay
     Remarque

     2x screws, T25, 2 Nm

     

151. Install megharness clips to HV controller hinge tray
     Remarque

     5x harness clips, 1x tape, Wrap harness tape around the hinge tray again

     

152. Connect HV controller connector X479 –Main HVC connector to HV Controller
     Remarque

     1x connector

     

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

     1x connector

     

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

     1x connector

     

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

     1x connector

     

156. Connect HV controller connector X480 – Shunt at HVC to HV Controller
     Remarque

     1x connector

     

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

     1x connector

     

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

     1x connector

     

159. Remove pyro disconnect dummy

     

160. Clean mating surface of pyro
     Remarque

     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

     

     

     

161. Set multimeter to "LoZ" (low impedance) mode

     

162. Measure voltage between busbar and shunt
     Remarque

     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

     

     

163. Position pyro disconnect to ancillary bay for installation
     Remarque

     1x connector, 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, The pyro disconnect can only be installed one way

     

     

     

     

164. Install bolts securing pyro disconnect to ancillary bay
     Remarque

     2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen

     

165. Measure resistance from module 2 busbar to pyro disconnect
     Remarque

     1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

     

     

166. Measure resistance from pyro disconnect to shunt
     Remarque

     1x HV joint, 45μΩ or less, Perform zero adjust to Hioki meter prior to testing

     

     

167. Remove service insulator kit

     

     

     

     

168. Remove HVC logic cap
     Remarque

     1x logic cap

     

169. Inspect ancillary bay walls for damage
     Remarque

     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

     

170. Inspect ancillary bay cover seal to confirm it has no visual damage
     Remarque

     Image up close for clarity, Delaminated and torn seals cannot be reused

     

     

     

     

     

171. Wipe ancillary bay cover with IPA to clean surface
     Remarque

     Allow to 1 minute dry time

     

172. Position ancillary bay cover to HV battery for installation
     Remarque

     Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered.

     

     

173. Remove leather over gloves and HV insulating gloves

     

174. Install bolts securing ancillary bay cover to HV battery
     Remarque

     18x bolts, EP10 5-Lobe, 8 Nm, Fasteners are captive, Follow torque sequence per image

     

     

175. Install bolts securing ancillary bay cover to HVC
     Remarque

     3x bolts, E10, 5 Nm + 30 degrees

     

176. Install positive LV output from PCS cable and torque nut securing it
     Remarque

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

     

177. Install positive LV output cover to PCS cable
     Remarque

     1x cover

     

178. Remove HVC logic cap
     Remarque

     1x logic cap

     

179. Install 3rd row NVH insulator
     Remarque

     1x connector, Install insulator then connect connector

     

     

     

     

180. Position 3rd row rear cabin carpet

     

     

181. Secure RH side of 3rd row rear carpet
     Remarque

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

     

     

     

     

182. Secure LH side of 3rd row rear carpet
     Remarque

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

     

     

     

     

183. Install 3rd row LH seat cushion bolster
     Remarque

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

     

     

184. Install 3rd row RH seat cushion bolster
     Remarque

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

     

     

     

185. Install 3rd row seat cushion and connect harness
     Remarque

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

     

     

186. Raise vehicle fully and lower lift onto locks
     Remarque

     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

     

     

187. Connect coolant Leak Test Adapter plug to PCS outlet hose coupling
     Remarque

     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

     

     

188. Connect coolant Leak Test Adaptor to PCS inlet hose coupling
     Remarque

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

     

     

189. Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter
     Remarque

     Hand tighten hose connection, No tool required to tighten

     

     

190. Close both valves on the coolant Leak Test Fixture tool
     Remarque

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

     

     

     

191. Connect compressed air to coolant Leak Test Fixture tool
     Remarque

     Air supply source should be above 50 psi

     

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

     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

     

     

     

     

     

193. Open outlet valve on Leak Test Fixture tool.
     Remarque

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

     

     

194. Allow pressure in PCS coolant loop to stabilize at 50 psi
     Remarque

     Pressure should settle around 50 psi

     

195. Set timer for 4 minutes

     

196. Record the PCS coolant loop leak check starting pressure
     Remarque

     Record the value shown on the digital gauge

     

197. Start 4 minute timer
     Remarque

     Once timer is complete, select Stop Reset

     

198. Record the PCS coolant loop leak check end pressure
     Remarque

     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

     

199. Disconnect compressed air from Leak Test Fixture tool

     

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

     1x valve, Turn valve slowly to release air

     

201. Disconnect coolant Leak Test Fixture hose from Leak Test Adapter

     

202. Disconnect Leak Test Adaptor from PCS inlet hose coupling
     Remarque

     1x spring clip

     

     

203. Connect rear PT supply hose to PCS inlet hose coupling
     Remarque

     Effectuez un test pousser-tirer-pousser pour vous assurer que le flexible est bien en place. Ne remuez pas le tuyau près de la connexion.

     

     

204. Disconnect Leak Test Adaptor plug from PCS outlet hose coupling
     Remarque

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

     

     

205. Connect RDU inverter inlet tube to PCS outlet hose coupling
     Remarque

     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

     

206. Position HV battery rear skid plate enclosure
     Remarque

     Recommend assistance if needed

     

     

207. Install upper bolts securing HV battery rear skid plate enclosure hand tight
     Remarque

     4x bolts, 13mm, 64 Nm

     

208. Install lower bolts securing HV battery rear skid plate enclosure
     Remarque

     2x bolts, EP10, 13 Nm

     

209. Torque bolts securing HV battery rear skid plate enclosure to vehicle
     Remarque

     4x bolts, 13mm, 64 Nm

     

210. Install RH side hose clips to rear battery skid plate
     Remarque

     2x fir tree clips

     

211. Install LH side hose clip to rear battery skid plate
     Remarque

     1x fir tree clip

     

212. lnstall mid aero shield
     Remarque

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

     

     

     

     

213. Install LH and RH push clips securing mid aero shield to wheel house liner
     Remarque

     2x clips

     

     

214. Lower vehicle fully
     Remarque

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

     

     

     

215. Place towel into front storage area
     Remarque

     Prevent front storage area pollution

     

216. Remove coolant bottle cap
     Remarque

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

     

     

217. Place empty coolant container into front storage area

     

218. Fill container with coolant
     Remarque

     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

     

219. Place filled coolant container into front storage area

     

220. Install coolant reservoir adaptor cap onto coolant bottle assembly
     Remarque

     (*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

     

     

     

221. Setup vacuum refill tool
     Remarque

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

     

     

222. Connect vacuum refill hose to refill cap on coolant bottle
     Remarque

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

     

     

223. Position overflow hose into empty container

     

224. Place refill hose inside filled coolant container
     Remarque

     Make sure hose end is fully submerged into coolant

     

225. Connect shop air supply to coolant refill tool

     

226. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Remarque

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

     

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

     

228. Slowly open refill valve to allow coolant to be drawn into system
     Remarque

     Make sure hose end of refill hose is fully submerged during entire process

     

229. Once gauge reads zero, close refill valve

     

     

230. Disconnect shop air supply from coolant refill tool

     

231. Remove coolant refill hose from coolant container

     

232. Remove coolant overflow hose from coolant container

     

233. Disconnect vacuum refill hose from refill cap on coolant bottle

     

     

234. Remove refill tool cap from coolant bottle assembly

     

235. Remove coolant refill tool from vehicle

     

     

236. Remove both coolant containers from inside underhood area

     

237. Connect first responder loop and LV battery
     Remarque

     2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

     

     

     

     

     

238. Exécutez la routine ODIN 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)
239. Access thermal system routines via UI
     Remarque

     Select service mode > Thermal
240. Exécutez la routine ODIN 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)
241. Exécutez la routine ODIN 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)
242. Coolant air purge run time
     Remarque

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

     

243. Exécutez la routine ODIN PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
244. Inspect coolant level and top off as necessary
     Remarque

     Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair

     

245. Install coolant bottle cap

     

246. Install HEPA filter assembly
     Remarque

     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

     

     

     

     

     

     

247. Install rear apron
     Remarque

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

     

     

     

248. Close hood

     

     

249. Install 40 seat into vehicle
     Remarque

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

     

     

250. Connect 2nd row 40 seat connector
     Remarque

     1x connector,

     

     

251. Install bolts securing 40 seat podium to vehicle hand tight
     Remarque

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

     

252. Move 40 seat forward using towel bar
     Remarque

     pull up bar, slide seat forward

     

253. Install bolts securing 40 seat inner and outer tracks to vehicle
     Remarque

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

     

254. Move 40 seat to original position
     Remarque

     Press shoulder switch then pull seat backward

     

255. Install cabin carpet to 40 seat

     

256. Torque bolts securing 40 seat podium to vehicle
     Remarque

     2x patch bolts, 11mm, 37 Nm

     

257. Install center track cover to 2nd row seats
     Remarque

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

     

     

     

258. Install 40 seat outboard track cover
     Remarque

     1x clip

     

259. Position 40 seat into easy entry mode
     Remarque

     Press shoulder switch and push 40 seat forward

     

     

260. Install RH rear sill trim
     Remarque

     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

     

     

261. Reseat RH rear door seal
     Remarque

     Seat pillar and sill trim tabs underneath seal

     

262. Move 40 seat to original position
     Remarque

     Press shoulder switch then pull seat backward

     

263. Move RH front seat to original position

     

264. Install 2nd row 60 seat assembly
     Remarque

     Recommend assistance

     

     

     

265. Connect 2nd row 60 seat connector
     Remarque

     1x connector,

     

     

266. Install fasteners securing 60 seat frame to body
     Remarque

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

     

     

     

     

267. Secure cabin carpet to 60 seat
     Remarque

     Strap velcro on

     

     

268. Return 2nd row 60 seatback to vertical position
     Remarque

     Via trunk seat switch, Remove seatback protection if necessary

     

     

269. Install 60 seat outboard track cover
     Remarque

     1x clip

     

     

     

270. Position 60 seat into easy entry mode
     Remarque

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

     

     

271. Install LH 7s lower C-pillar trim
     Remarque

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

     

     

272. Reseat LH rear door seal
     Remarque

     Seat pillar and sill trim tabs underneath seal

     

273. Move 60 seat to original position

     

274. Move RH front seat to original position

     

275. Move LH front seat to original position

     

276. Raise all four windows
     Remarque

     Via LH front door switch

     

277. Exécutez la routine ODIN PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)
278. Unlock the vehicle gateway. See Passerelle (déverrouiller).
279. Exécutez la routine ODIN PROC_VCLEFT_X_2R-SEAT-RECLINE-CALIBRATIONvia Service Mode:Low Voltage ➜ Second Row Seats ➜ Calibratevia Toolbox:(link)
280. Exécutez la routine ODIN PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
281. Close all four doors
     Remarque

     If LV is powered up then unlatch rear doors before closing