01/04/2024 13:57:55

Cover - Pyrotechnic - HV Battery (Remove and Replace)

Correction code 16300052 3.00 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
  1. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
  2. Open all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closing when vehicle is powered down
  3. Lower all windows
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. Remove 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Lift front edge of seat cushion upward to release foam from frame
  7. Partially remove LH rear door seal
  8. Remove LH rear sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
  9. Partially remove RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Pillar and sill trim have tabs seated underneath seal
  10. Remove RH rear sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of RH rear sill trim working your way back towards rear of sill trim
  11. Remove clips securing rear main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  12. Remove fasteners securing 40 seat frame to body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
  13. Fold the 40 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
  14. Disconnect 40 frame connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  15. Remove 2R 40 seat assembly from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  16. Remove fasteners securing 60 seat frame to body
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
  17. Fold the 60 seat in down position
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat back upholstery if necessary, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
  18. Disconnect logic connector at LH seat frame
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  19. Remove 2nd row 60 seat assembly from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  20. Open hood
  21. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  22. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  23. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
  24. Remove all items from pockets and ensure not wearing metal items
  25. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1
  26. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  27. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  28. Remove the ancillary bay probe lid cover from the ancillary bay cover
  29. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  30. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm no visual damage present, Replace gasket if damage is found
  31. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
  32. Remove HV insulating gloves
  33. Disconnect the HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  34. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  35. Remove fasteners securing ancillary bay cover to high voltage controller (HVC)
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10, 5 Nm + 30 degrees, Discard after removal, Newer vehicles may be equipped with 3x bolts
  36. Remove bolts securing ancillary bay cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
  37. Remove ancillary bay cover from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
  38. Install fuses access insulator
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  39. Install the battery pyro and shunt insulators
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators
  40. Install the HV joint insulators onto positive pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators
  41. Install the HV joint insulators to negative pack contactor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators
  42. Install the insulator for DC input assembly to both fastcharge busbars inlet side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  43. Install the negative AC inlet terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 3x clips, Use caution as the clips are very easy to damage
  44. Install the positive AC inlet terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 3x clips, Use caution as the clips are very easy to damage
  45. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  46. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    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
  47. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm
  48. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  49. Release LH side hose clip from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  50. Release RH side hose clips from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  51. Remove lower bolts securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm
  52. Remove upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  53. Remove upper bolts securing rear battery enclosure skid plate from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  54. Remove rear battery enclosure skid plate from HV battery pack
  55. Position coolant drain container underneath LH rear of HV battery
  56. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  57. Attach coolant drain hose adapter to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    90 degree angle, Make sure the locking tab is fully seated
  58. Attach coolant drain hose adapter to coolant hose extension
  59. Attach coolant hose extension to coolant drain hose
  60. Position coolant drain underneath RH rear of HV battery
  61. Disconnect rear PT supply hose from rear of HV battery and plug hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  62. Attach coolant pressure tester to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
  63. Attach coolant pressure tester to pressure fitting adapter
  64. Attach coolant pressure tester to compressed air line
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valves are closed on pressure regulator
  65. Open the regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  66. Open the 2nd valve slowly
  67. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  68. Close the regulator valve
  69. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  70. Open the regulator valve slowly
  71. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  72. Close both valves
  73. Remove coolant pressure tester from pressure fitting adapter
  74. Remove coolant pressure tester from PCS inlet hose coupling
  75. Position coolant drain container underneath LH rear of HV battery
  76. Disconnect coolant drain hose adapter from coolant hose extension
  77. Remove coolant drain hose adapter from PCS outlet hose coupling
  78. Position coolant drain underneath RH rear of HV battery
  79. Attach coolant drain hose adapter to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Hose connects to coolant cart drain hose, Make sure the locking tab is fully seated
  80. Attach coolant drain hose adapter to coolant hose extension
  81. Position coolant drain container underneath LH rear of HV battery
  82. Attach coolant pressure tester to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    This adapter connected to regulated air line adapter, Rotate lower hose for more access, Make sure the locking tab is fully seated
  83. Attach coolant pressure tester to pressure fitting adapter
  84. Open the regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  85. Open the 2nd valve slowly
  86. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  87. Close the regulator valve
  88. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  89. Open the regulator valve slowly
  90. Set timer for 1 minute and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  91. Close the regulator valve
  92. Disconnect compressed air from coolant pressure tester
  93. Remove coolant pressure tester from pressure fitting adapter
  94. Remove coolant pressure tester from PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Install plug to coupling
  95. Close the 2nd valve
  96. Position coolant drain underneath RH rear of HV battery
  97. Disconnect coolant hose extension from coolant drain hose
  98. Disconnect coolant drain hose adapter from coolant hose extension
  99. Remove coolant drain hose adapter from PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Install plug to coupling
  100. Remove coolant drain container from underneath vehicle
  101. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  102. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1
  103. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  104. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  105. Disconnect HV controller connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    7x connectors
  106. Remove the megaharness clips from HV controller hinge tray
    Informational PurposesAn informational icon, calling your attention
    Note
    5x harness clips
  107. Remove screws securing HVC tray assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 2 Nm, 3x wires routed through RH hinge, Pull slightly forward on HVC at ~45 degree angle to access fastener between hinge and tray
  108. Remove the HVC and tray assembly from ancillary bay
  109. Position absorbent sheets below and around the PCS coolant inlet hose to avoid excess coolant dripping
  110. Disconnect PCS coolant inlet hose from PCS and install plugs
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, 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
  111. Position absorbent sheets below and around the PCS coolant outlet hose to avoid excess coolant dripping
  112. Disconnect PCS coolant outlet hose from PCS and install plugs
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, Use the special tool to release the 2x clips
  113. Disconnect PCS to DC bus HV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  114. Disconnect PCS logic connector from PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  115. Disconnect PCS LV connector from PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  116. Disconnect PCS to fastcharge contactor HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  117. Remove bolts securing PCS to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners
  118. Secure suction cups to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss
  119. Lift PCS up and out of ancillary bay area and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Slightly tilt front 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
  120. Install HV joint insulator for negative busbar module 3 to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  121. Install HV joint insulator for positive DC link to module 4
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  122. Install HV joint insulator for positive busbar module 2 to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  123. Remove HV joint insulator for positive busbar module 2 to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  124. Remove Pyro Cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4xclips
  125. Install Pyro Cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4xclips
  126. Install HV joint insulator for positive busbar module 2 to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  127. Position the PCS into ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS downward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary
  128. Remove suction cups from PCS
  129. Install bolts securing PCS to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 8mm, 18 Nm
  130. Connect PCS to fastcharge contactor HV harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  131. Connect PCS LV connector to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  132. Connect PCS logic connector to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  133. Connect PCS to DC bus HV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  134. Remove plug from PCS inlet hose
  135. Replace o-rings on PCS inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    2x o-rings, Apply light amount of Krytox 203
  136. Secure inlet hose to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, 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
  137. Remove plug from PCS outlet hose
  138. Replace o-rings on PCS outlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    2x o-rings, Apply light amount of Krytox 203
  139. Secure PCS outlet hose to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, Place absorbent sheet under hose to catch excess coolant, 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, Visually inspect area for any coolant residue, Clean with shop towel if necessary
  140. Remove HV insulating gloves
  141. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    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
  142. Position coolant drain container underneath LH rear of HV battery
  143. Install coolant pressure test plug adapter to PCS outlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plug from coupling, Make sure the locking tab is fully seated
  144. Position coolant drain underneath RH rear of HV battery
  145. Install coolant pressure adapter to PCS inlet hose coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plug from coupling, Make sure the locking tab is fully seated
  146. Attach coolant pressure tester to pressure fitting adapter
  147. Attach coolant pressure tester to compressed air line
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valves are closed on pressure regulator
  148. Set pressure regulator to specified pressure value
    Informational PurposesAn informational icon, calling your attention
    Note
    Set pressure to 50 psi
  149. Slowly open valve on pressure regulator and allow pressure to reach specification
  150. Close the valve and let pressure settle
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait 2 minutes for pressure to settle, Record the reading
  151. Perform the coolant pressure leak test
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
  152. Disconnect compressed air from coolant pressure tester
  153. Remove pressure fitting adapter from coolant pressure tester
  154. Remove coolant pressure tester from PCS inlet hose coupling
  155. Connect rear PT supply hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated, Perform push-pull-push test
  156. Remove coolant pressure test plug adapter from PCS outlet hose coupling
  157. Connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated, , Perform push-pull-push test
  158. Remove coolant drain container from underneath vehicle
  159. Position rear battery enclosure skid plate to HV battery for installation
  160. Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  161. Install upper nut securing rear battery enclosure skid plate hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  162. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  163. Torque bolts securing HV battery and rear skid plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  164. Torque upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  165. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
  166. Install RH side hose clips to rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  167. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  168. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  169. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm
  170. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  171. Install 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, DO NOT install FRL, You will be performing a toolbox routines with the ancillary bay lid removed, HV power will be connected at a later step
  172. Hook up 12V charger to 12V battery
  173. Connect to vehicle using Toolbox 3.0
  174. Remove coolant bottle cap
  175. Fill coolant to the proper level
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level filled to the Max line
  176. Select "Actions/Autodiag" tab and search for "vcfront"
  177. Select TEST-RESET_VCFRONTSearch for routine in ToolboxLow Voltage / Power Distribution - Reset VCFRONTMid Voltage / Power Distribution - Reset VCFRONT, click 'Run', and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 'X' at top right window to close once complete
  178. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
  179. Fill coolant to the proper level
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level filled to the Max line
  180. Install coolant bottle cap
  181. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  182. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    via Controls > Safety & Security > Vehicle Power > Power Off
  183. Remove 12V charger from 12V battery
  184. Disconnect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, Ensure the climate control system is off and vehicle is not charging before disconnecting 12V
  185. Drill marked points for access to hinge fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    Step up drill bit size, Use 2mm bit first, Use 4mm bit second, Use 6mm bit last, Use caution
  186. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1
  187. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  188. Position HVC tray assembly in ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locating pins, 3x wires routed through RH hinge
  189. Secure HVC tray assembly to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 2 Nm
  190. Connect HV controller connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    7x connectors
  191. Install the megharness clips to HV controller hinge tray
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  192. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  193. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
    Informational PurposesAn informational icon, calling your attention
    Note
    4x studs
  194. Inspect ancillary bay walls for damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, 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
  195. Inspect ancillary bay cover seal to confirm it has no visual damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Image up close for clarity, Delaminated and torn seals cannot be reused
  196. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  197. Position the ancillary bay cover to HV battery for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
  198. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  199. Install bolts securing ancillary bay cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
  200. Install fasteners securing ancillary bay cover to high voltage controller (HVC)
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10, 5 Nm + 30 degrees, Install new bolts, Newer vehicles may be equipped with 3x bolts
  201. Remove HV insulating gloves
  202. Remove logic cap and connect the HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
  203. Install 2R 40 seat assembly into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  204. Connect 40 seat frame connector to body harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  205. Fold the 40 seat into vertical position
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection
  206. Secure 40 seat frame to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
  207. Install RH rear sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips
  208. Reseat RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  209. Install 2nd row 60 seat assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  210. Connect logic connector at LH seat frame
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  211. Fold the 60 seat into vertical position
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat back protection if necessary
  212. Install fasteners securing 60 seat frame to body
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
  213. Install LH rear sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of LH rear sill trim into trunk side trim and work your way forward securing clips
  214. Reseat LH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  215. Install clips securing rear main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  216. Install 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
  217. Connect first responder loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
  218. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  219. Close hood
  220. Move LH front seat to original position
  221. Move RH front seat to original position
  222. Raise all windows
  223. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing
  224. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped