2026-05-27

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

Korrekturcode 16010232 5.58 HINWEIS: Sofern im Verfahren nicht ausdrücklich anders angegeben, spiegeln der obige Korrekturcode und die FRT den gesamten für die Durchführung dieses Verfahrens erforderlichen Aufwand wider, einschließlich der damit verbundenen Verfahren. Schichten Sie keine Korrekturcodes, wenn Sie nicht ausdrücklich dazu aufgefordert werden. HINWEIS: Weitere Informationen über FRTs und darüber, wie sie erstellt werden, finden Sie unter Richtzeiten. HINWEIS: Siehe Persönlicher Schutz, um sicherzustellen, dass Sie die richtige persönliche Schutzausrüstung tragen, wenn Sie das folgende Verfahren durchführen. HINWEIS: Siehe Maßnahmen zur Ergonomie für sichere und gesunde Arbeitsmethoden.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warnung
Dieses Verfahren ist ein ENTWURF. Es wurde zwar validiert, jedoch können Sicherheitshinweise und Vorsichtsmaßnahmen fehlen. Befolgen Sie die Sicherheitshinweise, und gehen Sie beim Arbeiten an oder in der Nähe von Hochspannungssystemen und -bauteilen äußerst vorsichtig vor.
  • 2026-05-21: Added warnings to never move the gantry with a suspended load or put any part of the body underneath a suspended load. Changed wording to clarify that crates are positioned under gantries rather than gantries moved over crates.
  • 2026-04-01: Released new procedure.

Entfernen

  1. Remove the LH rocker carrier. See
  2. Remove the RH rocker carrier. See
  3. Remove butyl patches covering LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x butyl patches, Clean excess butyl from area
  4. Install Universal Lift Pad Adapters onto LH lift arms
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x Universal Lift Pad Adapters, Remove original lift pads from lift arms then install respective adapter, Align pins with lift point holes on body
  5. Remove butyl patches covering RH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x butyl patches, Clean excess butyl from area
  6. Install Universal Lift Pad Adapters onto RH lift arms
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x Universal Lift Pad Adapters, Remove original lift pads from lift arms then install respective adapter, Align pins with lift point holes on body
  7. Open all four doors
  8. Lower all four windows
  9. Chock LH rear wheel
  10. Place the vehicle in Service Mode. See .
  11. Access thermal system routines via UI
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Select quick controls > Service mode > Thermal
  12. Open the hood.
  13. Remove the rear apron.
  14. Remove the LH lower A-pillar trim. See .
  15. Move LH front seat backward
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Ensure profile is saved to allow seat position to be restored
  16. Remove screw and clips securing LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x push clips, 1x screw, T20, 2.5 Nm
  17. Remove connectors from LH footwell cover and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles an additional ODII connector will have to be connected
  18. Remove LH front floor mat
  19. Remove LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    10x clips, 1x guide pin, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  20. Remove clip securing LH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x push clip
  21. Fold LH front cabin carpet rearward
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Maneuver carpet below brake pedal and accelerator pedal, Newer Vins may be equipped with additional foam installed below carpet
  22. Remove foam plugs to access LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
  23. Remove both LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm
  24. Raise LH front seat cushion to maximum height
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    This will allow access to HV battery bolts at LH front foot well and below LH front seat
  25. Remove the RH lower A-pillar trim. See .
  26. Move the RH front seat back.
  27. Remove clips securing RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x push clips, Clip count may vary depending on region
  28. Remove RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x connectors
  29. Remove RH front floor mat
  30. Remove RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    11x clips, 1x guide pin, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  31. Remove clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x clip
  32. Fold RH front cabin carpet rearward
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Newer Vins may be equipped with additional foam installed below carpet
  33. Remove foam plugs to access RH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
  34. Remove both RH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm
  35. Raise RH front seat cushion to maximum height
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    This will allow access to HV battery bolts at RH front foot well and below RH front seat
  36. Remove 2nd row floor mat from vehicle
  37. Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Located below rear of RH front seat
  38. Remove RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm
  39. Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Located below rear of LH front seat
  40. Remove LH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm
  41. Partially remove lower portion of LH rear door seal
  42. Remove the 2nd row 60 seat. See Sitzbaugruppe – 2. Sitzreihe – LH (7-Sitzer) (Ausbauen und Ersetzen)
  43. Partially remove RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Pillar and sill trim have tabs seated underneath seal
  44. Remove the 2nd row 40 seat. See Sitzbaugruppe – 2. Sitzreihe – RH (7-Sitzer) (Ausbauen und Ersetzen).
  45. Position object beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use shop towel or similar
  46. Remove RH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
  47. Remove LH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  48. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
  49. Disconnect the LV battery connector and First Responder Loop.
  50. Make a slit in 3rd row carpet around LH seat belt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
  51. Make a slit in 3rd row carpet around RH seat belt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
  52. Move 3rd row carpet aside
  53. Move 3rd row NVH insulation aside
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use seatbelt or bungee strap as needed
  54. Remove all items from pockets and ensure not wearing metal items
  55. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  56. Put on the HV insulating gloves and leather over gloves.
  57. Release ancillary bay probe lid cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  58. Remove ancillary bay probe lid cover from ancillary bay cover
  59. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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
  60. Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time
  61. Install ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP10 5-Lobe, 6 Nm, Install new bolts
  62. Remove leather over gloves and HV insulating gloves
  63. Remove bolt securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 10mm, 9 Nm
  64. Remove bolts securing charge port busbar kit to HV header
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 10mm, 9 Nm
  65. Lift busbar kit connector to remove from HV header
  66. Disconnect 3PH chargeport inlet harness from HV header
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, Release red locking tab and rotate lever arm to release
  67. Disconnect HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  68. Remove DCDC ground strap from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 13mm, 15 Nm, Discard after removal
  69. Release the cover on the positive 12V output cable at the DCDC passthrough
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cover
  70. Release the positive 12V output cable from the DCDC passthrough
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 13mm, 9 Nm, Discard nut after removal
  71. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  72. Check the HV battery vitals. Refer to Toolbox article #41977.
  73. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  74. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Latch rear doors to prevent accidental closure
  75. Remove wheel chocks and push vehicle onto lift
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, close all doors enough as needed to fit between the lift and latch rear doors to prevent accidental closure, Replace wheel chocks once vehicle in correct position
  76. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x Universal Lift Adapters, Verify jack locations prior to lifting vehicle,
    Warning IconA warning icon, calling your attention to a possibly risky situation
    ACHTUNG
    ONLY place on lifting points at front and rear of rocker panels
  77. Remove the front skid plate. See Rutschplatte – HV-Batterie – Vorn (Ausbauen und Ersetzen)
  78. Remove bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt,10mm, 10 Nm
  79. Release FDU HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x locking connector. Release red locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
  80. Release FDU HV harness from casting and move aside
  81. Remove FDU ground strap bolt from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 10mm, 10 Nm
  82. Release bracket securing HV connectors to bulk head
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bracket
  83. Release connector from bracket then disconnect PTC HV connector
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, 1x Red locking tab, 2 stage push release, Unlock by pulling back red tab, Push orange lip and pull back ''stage 1'', Push green lip and pull back to disconnect
  84. Disconnect AC compressor HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, Release locking tab, 2 stage push release
  85. Secure LH front wheel liner away from HV battery
  86. Secure RH front wheel liner away from HV battery
  87. Position coolant drain container underneath RH front of HV battery
  88. Disconnect PT return hose at RH side of vehicle and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip
  89. Attach PT drain fitting adapter to male PT return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Verify tooling on white color of fitting adapter, Perform push-pull test to ensure connection is made, Set adapter to locked position
  90. Attach hose extension to coolant drain hose for extra length
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Perform push-pull test to ensure connection is made
  91. Attach PT drain fitting adapter to coolant cart drain hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Perform push-pull test to ensure connection is made
  92. Disconnect rear PT supply hose at RH side of vehicle and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip
  93. Attach PT flush fitting adapter to female side of PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Verify tooling on white color of fitting adapter, Perform push-pull test to verify adapter is fully connected to hose, Set adapter to locked position
  94. Attach PT flush fitting adapter to coolant pressure tester with cart flush hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Pressure regulator is not adjustable (set at 20 psi)
  95. Attach compressed air line to coolant pressure tester
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Make sure valve is closed on pressure regulator
  96. Open valve on PT drain fitting adapter
  97. Slowly open valve on pressure regulator and allow coolant to completely drain
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Keep an eye on all hose connections to verify no leaks from tooling
  98. Close valve on pressure regulator once no coolant is draining from PT return hose
  99. Disconnect compressed air from coolant pressure tester
  100. Remove PT flush fitting adapter from female side of PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 1x plug
  101. Remove PT drain fitting adapter from male side of PT return hose and plug
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 1x plug
  102. Remove PT drain fitting adapter from cart drain hose
  103. Remove PT flush fitting adapter from cart pressure hose
  104. Position coolant drain container underneath LH front of HV battery
  105. Disconnect HV battery return hose at LH side of vehicle and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 2x plugs
  106. Attach battery drain fitting adapter to female battery return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Make sure valve is closed
  107. Attach battery drain fitting adapter to coolant cart drain hose
  108. Disconnect HV battery front manifold hose and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 2x plugs
  109. Remove HV battery front manifold hose clips from body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x clips, Newer vehicles may be equipped with 1x clip
  110. Attach Battery flush fitting adapter to male side of HV battery supply hose
  111. Attach battery flush fitting adapter to coolant cart pressure hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Pre-set pressure regulator valve
  112. Attach compressed air line to coolant pressure tester
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Make sure valve is closed on pressure regulator
  113. Open valve on battery drain fitting
  114. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Close valve on pressure regulator once no coolant is draining from HV battery return hose
  115. Disconnect compressed air from coolant pressure tester
  116. Remove battery drain fitting adapter from female side of HV battery return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Plug HV battery return hose
  117. Remove battery flush fitting adapter from male side of HV battery front manifold hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Plug HV battery front manifold hose
  118. Remove coolant drain container from underneath vehicle
  119. Remove battery drain fitting adapter from cart drain hose
  120. Remove battery flush fitting adapter from cart pressure hose
  121. Remove rear aero shield
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt
  122. Position support stand to support front portion of rear subframe
  123. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x fir tree clips
  124. Remove smaller fasteners for LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  125. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm, Discard after removal
  126. Hand tighten bolt securing LH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 130 Nm
  127. Release clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x fir tree clips
  128. Remove smaller fasteners for RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  129. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm, Discard after removal
  130. Hand tighten bolt securing RH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 130 Nm
  131. Remove support stand from under vehicle
  132. Remove the rear skid plate. See Rutschplatte – HV-Batterie – Hinten (Ausbauen und Ersetzen).
  133. Position coolant drain container underneath LH rear of HV battery
  134. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 2x plugs
  135. Position coolant drain underneath RH rear of HV battery
  136. Disconnect coolant outlet hose to rear PT return hose and plug hoses
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary
  137. Remove coolant drain container from underneath vehicle
  138. Remove nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 10mm, 10 Nm
  139. Disconnect RDU HV cable from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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
  140. Place battery table into position and lower vehicle to support battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
  141. Remove central bolts securing HV battery through center ski cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, EP14, 34 Nm
  142. Remove bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm
  143. Remove bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm
  144. Remove LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  145. Remove RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  146. Raise vehicle to free from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  147. Remove battery from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  148. Disconnect LH inner coolant hose from front of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Use shop towel to clean any residue coolant if necessary
  149. Disconnect LH outer coolant hose from front of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Use shop towel to clean any residue coolant if necessary
  150. Disconnect RH inner coolant hose from front of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Use shop towel to clean any residue coolant if necessary
  151. Disconnect RH front outer coolant hose and remove hose assembly from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Use shop towel to clean any residue coolant if necessary
  152. Remove PT return hose from RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    5x clips, Lower coolant hose
  153. Release PT supply hose from RH rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant if necessary
  154. Remove PT supply hose from RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    5x clips, Upper coolant hose
  155. Attach HV battery H-frame to gantry and raise into position
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warnung
    Stehen Sie niemals unter einer hängenden Last, und halten Sie niemals einen Teil Ihres Körpers darunter.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warnung
    Versuchen Sie niemals, einen Kran zu bewegen, während er eine hängende Last trägt.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warnung
    Informationen zur Sicherheit und zum Betrieb finden Sie in der Anleitung des Kranherstellers.
  156. Position HV battery under gantry
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  157. Lower H-frame onto HV battery and secure H-frame to battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Firmly install bolts hand tight
  158. Raise HV battery off of battery table
  159. Position the pallet under the gantry.
  160. Lower HV battery onto pallet
  161. Remove H-frame from old HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Bolts are firmly hand tight
  162. Raise gantry and H-frame from old HV battery
  163. Remove logic cap from old battery pack
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  164. Open crate top housing new HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  165. Remove fasteners securing ancillary bay cover to high voltage controller (HVC)
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, E10, 5 Nm + 30 degrees, Newer vehicles will be equipped with 3x bolts
  166. Release ancillary bay cover from old HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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
  167. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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
  168. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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.
  169. Remove ancillary bay cover from HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
  170. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  171. Inspect ancillary bay for any missing insulators
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary
  172. Remove battery pyro and shunt insulators
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x insulators, Make sure to wear proper PPE from this step onward until the ancillary bay cover has been secured
  173. Remove bolts securing pyro disconnect to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x patch bolts, 13mm, 9 Nm, Discard after removal
  174. Remove pyro disconnect from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
  175. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  176. Remove from ancillary bay any insulators previously installed
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Remove only the insulators that are part of the kit
  177. Position ancillary cover to HV battery for installation
  178. Install ancillary cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
  179. Install fasteners securing ancillary cover to HVC
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    3x bolts, E10, 5 Nm + 30 degrees, Some vehicles will be equipped with 4x bolts
  180. Remove HV insulating gloves
  181. Install old Pyro Disconnect onto old HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Attach pyro to ancillary bay cover volcano brackets with zip ties, If ancillary bay cover is not equipped with volcano brackets then attach pyro to RH rear corner of HV Battery with zip ties and add tape as notification as shown in illustration, Install a piece of paper roll under pyro
  182. Remove nuts securing new HV battery to crate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x nuts, 15mm
  183. Position the new HV battery crate under the gantry and secure the H-frame to battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Firmly secure hand tight
  184. Lift new HV battery out of crate
  185. Move the HV battery crate from under the gantry, then position the HV battery table under the gantry.
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  186. Lower HV battery onto battery table
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Make sure to align HV battery onto center ski
  187. Release H-frame from HV battery and raise gantry
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Bolts are secured firmly hand tight
  188. Remove HV battery from under gantry
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  189. Position the old HV battery under the gantry.
  190. Lower H-frame onto old HV battery and secure H-frame to battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Firmly secure hand tight
  191. Raise old HV battery above height of HV battery crate
  192. Position crate underneath old HV battery pack
  193. Lower old HV battery into crate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use caution to align the 4 studs and not damage the battery
  194. Remove H-frame from old HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 8mm Allen, Bolts are firmly secured hand tight
  195. Raise gantry and H-frame from old HV battery
  196. Lower gantry and remove HV battery H-frame from gantry
  197. Install nuts securing HV battery to crate hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x nuts, 15mm, Hand tight
  198. Close crate top housing old HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance

Montieren

  1. Install logic cap onto the new battery pack
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cap
  2. Install PT supply hose to RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    5x clips, Upper hose location
  3. Connect PT supply to RH rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  4. Install PT return hose to RH side of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    5x clips, Lower hose location
  5. Verify front HV battery coolant passthru fittings on new HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x passthru hoses, If the passthru are female fittings, Refer to HV battery coolant passthru hoses (Retrofit) procedure to install new 1734606-00-D (TUBE (BATT), FRONT MANIFOLD)
  6. Install front hose assembly onto HV battery and secure RH outer coolant hose connection
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  7. Connect RH inner coolant hose to front of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  8. ODIN-Routine ausführen
  9. Connect LH inner coolant hose to front of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  10. Install penthouse perimeter seal to HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Install new perimeter seal every time the HV battery is removed and reinstalled
  11. Install HV battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x rods, Located on body at front of vehicle, 2x rods, Located at rear of HV battery near penthouse
  12. Position HV battery under vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  13. Lower vehicle onto HV battery and align holes
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
  14. Install bolts securing HV battery to body at LH shear plate area hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm, Torque at later step
  15. Install bolts securing HV battery to body at RH shear plate area hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm, Torque at later step
  16. Loosely install RH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  17. Loosely install LH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  18. Remove HV battery front alignment rods
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x rods
  19. Install bolts securing RH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm, Torque at later step
  20. Install bolts securing LH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm, Torque at later step
  21. Install central bolts securing HV battery through center ski cover hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, EP14, 34 Nm, Torque at later step
  22. Open LH rear door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use caution while working around this area not to damage any components
  23. Remove HV battery alignment rod from LH rear inner bolt location
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x rod
  24. Install LH rear inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
  25. Install LH middle inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Torque at later step
  26. Close LH rear door
  27. Open LH front door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use caution while working around this area not to damage any components
  28. Install both LH front inner HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm, Torque at later step
  29. Close the LH front door.
  30. Open RH rear door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use caution while working around this area not to damage any components
  31. Remove HV battery alignment rod from RH rear inner bolt location
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x rod
  32. Install RH rear inner battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
  33. Install RH inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Torque at later step
  34. Close RH rear door
  35. Open RH front door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Use caution while working around this area not to damage any components
  36. Install both RH front inner HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm, Torque at later step
  37. Close RH front door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Do not latch
  38. Lower vehicle onto pack completely
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance
  39. Torque RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  40. Torque LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    8x bolts, 13mm, 35 Nm
  41. Torque bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm
  42. Torque bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, 16mm, 110 Nm
  43. Torque central bolts securing HV battery through center ski cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x bolts, EP14, 34 Nm
  44. Raise vehicle and lower onto locks, then remove battery table from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  45. Position support stand to support front section of rear subframe
  46. Remove smaller fasteners securing LH rear of HV battery to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  47. Remove bolt securing LH side of rear subframe to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 130 Nm, Discard after removal
  48. Install bolt and shear plate to LH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm, Install new fasteners, Torque at later step
  49. Install bolts securing LH rear shear plate to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm, Torque at later step
  50. Torque bolt securing subframe and LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm, Mark bolt after torque
  51. Torque small fasteners securing LR rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  52. Remove smaller fasteners securing RH rear of HV battery to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  53. Remove bolt securing RH side of rear subframe to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 130 Nm, Discard after removal
  54. Install bolt and shear plate to RH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm, Install new fasteners, Torque at later step
  55. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm, Torque at later step
  56. Torque bolt securing subframe and RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 21mm, 125 Nm
  57. Torque small fasteners securing RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 13mm, 35 Nm
  58. Remove support stand from under vehicle
  59. Install clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x fir tree clips
  60. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x fir tree clips
  61. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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
  62. Install nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 10mm, 10 Nm
  63. Position coolant drain underneath RH rear of HV battery
  64. Remove hose plugs and connect coolant outlet hose to rear PT return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary.Loss of coolant greater than 1L requires coolant vacuum fill
  65. Position coolant drain container underneath LH rear of HV battery
  66. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated,Loss of coolant greater than 1L requires coolant vacuum fill
  67. Remove coolant drain container from underneath vehicle
  68. Install the rear skid plate. See Rutschplatte – HV-Batterie – Hinten (Ausbauen und Ersetzen).
  69. Install RH side hose clips to rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x fir tree clips
  70. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x clips, Clip quantity may vary on older vehicles
  71. Apply Loctite 222 onto rear aero shield bolts and install rear aero shield
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack has one less bolt and one extra clip
  72. Position coolant drain container underneath LH front of HV battery
  73. Install HV battery front manifold hose clips to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x clips, Newer vehicles may be equipped with 1x clip
  74. Remove plug then connect HV battery front manifold coolant hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 1x plugs, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill
  75. Remove plugs then connect HV battery coolant return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip,1x plug
  76. Position coolant drain container underneath RH front of HV battery
  77. Remove plugs then connect PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
  78. Remove plugs and connect PT return hose
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
  79. Remove coolant drain container from underneath vehicle
  80. Remove plastic bracket securing HV connectors to battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    3x clips
  81. Connect A/C compressor HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present
  82. Connect PTC HV connector to HV cable then reinstall bracket
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present
  83. Secure connector bracket onto bulk head studs
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bracket
  84. Install FDU ground strap and bolt to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 10mm, 10 Nm
  85. Connect FDU HV harness connector and lock release lever
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
  86. Install bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 10mm, 10 Nm
  87. Install the front skid plate. See Rutschplatte – HV-Batterie – Vorn (Ausbauen und Ersetzen)
  88. Lower vehicle fully and move rack arms away from vehicle
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  89. Push vehicle away from lift
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
  90. Open all four doors
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Latch rear doors to prevent accidental closure
  91. Install positive 12V output
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 13mm, 9 Nm, Install new nut, Make sure rubber boot is not pinched between cable terminal and pass through
  92. Install positive 12V output cover to PCS cable
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x cover
  93. Install nut securing DCDC ground strap to HV battery
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x nut, 13mm, 15 Nm, Install new nut
  94. Remove logic cap and connect HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
  95. Connect 3PH chargeport inlet harness to HV header
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x connector, Rotate lever arm and secure locking tab
  96. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  97. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  98. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  99. Position busbar kit connector and lower onto HV header
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Hold busbar firmly as there is tension on, caution not to damaged busbar connectors
  100. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, 10mm, 9 Nm
  101. Inspect the HV insulating gloves for any damage.
  102. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    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.
  103. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  104. Remove HV insulating gloves
  105. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 10mm, 9 Nm
  106. Torque LH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  107. Torque RH rear inner battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet for access
  108. Move 3rd row NVH insulation back into position
  109. Move 3rd row carpet back into position
  110. Install the 2nd row 60 seat. See Sitzbaugruppe – 2. Sitzreihe – LH (7-Sitzer) (Ausbauen und Ersetzen).
  111. Install the 2nd row 40 seat. See Sitzbaugruppe – 2. Sitzreihe – RH (7-Sitzer) (Ausbauen und Ersetzen).
  112. Reseat RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Seat pillar and sill trim tabs underneath seal
  113. Reseat LH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Seat pillar and sill trim tabs underneath seal
  114. Install LH middle inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm, Torque at later step
  115. Fold LH side of rear main carpet to its original position
  116. Torque RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x bolt, 16mm, 66 Nm
  117. Fold RH side of rear main carpet to its original position
  118. Install 2nd row floor mat into vehicle
  119. Torque both RH forward HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm
  120. Install RH front cabin carpet support access plugs
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x plugs, Newer Vins may be equipped with 1x foam plug
  121. Fold RH front main cabin carpet back to original position
  122. Install clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x push clip
  123. Install clip securing RH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x push clip
  124. Install the RH lower A-pillar trim. See .
  125. Install RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    11x clips, 1x guide pin, Position side panel and align the locator, then the rear locator, Push side panel towards console to install
  126. Install RH front floor mat
  127. Install RH footwell lighting and speaker connectors
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x connectors
  128. Install clips securing RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    4x push clips, 2x connectors, Puddle lamp and speaker
  129. Torque both LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x bolts, EP20, 136 Nm
  130. Install LH front cabin carpet support access plugs
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x plugs, Newer vins may be equipped with 1x foam plug
  131. Fold LH front main cabin carpet back to original position
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Move front edge down and slide back section up to ease positioning
  132. Install LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    10x clips, 1x guide pin, Position side panel and align the locator, then the rear locator, Push side panel towards console to install
  133. Install LH front floor mat
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x velcro patches, Ensure mat does not interfere with pedal operation
  134. Install LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    5x clips, 1x push clip, 1x Ethernet connector, 1x connector, 1x OBD, T20, 2.5 Nm
  135. Install screw and clips securing LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    1x screw, T20, 2.5 Nm, 2x push clips
  136. Install the LH lower A-pillar trim. See .
  137. Vacuum refill the coolant. See Kühlsystem (Vakuumbefüllung).
  138. Connect the First Responder Loop and LV battery connector.
  139. ODIN-Routine ausführen PROC_EPBR_STOP-SERVICE-MODEvia Toolbox:(link)
  140. ODIN-Routine ausführen 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)
  141. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Ensure that fluid level is at Max line
  142. Install coolant bottle cap
  143. ODIN-Routine ausführen TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)
  144. Reinstall software via UI
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Via Controls > Service Mode > Software Reinstall, Select Reinstall button at Software Reinstall dialogue box, Reinstall will begin immediately, Once firmware redeploy is complete, Verify release notes are present via UI
  145. Verify firmware update is complete
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    Verify on center display release notes are present, If the redeploy fails you may receive an error message on UI
  146. Install the rear apron.
  147. Close the hood.
  148. Raise all four windows
  149. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    If LV is powered up, Unlatch rear doors before closing
  150. Remove Universal Lift Pad Adapters from RH lift arms
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x Universal Lift Pad Adapters, Install original lift pads
  151. Install butyl patches onto RH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  152. Install the RH rocker carrier. See
  153. Remove Universal Lift Pad Adapters from LH lift arms
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x Universal Lift Pad Adapters, Install original lift pads
  154. Install butyl patches onto LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Anmerkung
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  155. Install the LH rocker carrier. See