29/05/2024 18:08:17
Brake Lines - Front Bundle (Remove and Replace)
Correction code 33035002 4.92 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.
- 2023-12-08: Updated brake stiffness routine.
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.
Remove
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Raise and support vehicle
NoteEnsure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
- Open all doors and lower all windows.
- Connect to vehicle using Toolbox 3.0
- Select ‘Actions/Autodiag’ and search for ‘Thermal’
-
Select "Thermal Fluid Fill/Drain", click Run and allow routine to complete
NoteSelect ‘X’ at top right of window to close once complete, For AC related repairs verify all EXV's are in proper position, For all coolant related repairs verify vehicle is in Series, Thermal Fluid Fill/Drain routine has a 5 hour timeout, Routine will continuously run and not end
- Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
- Move the LH and RH front seats forward.
-
Release 2nd row seat cushion
NoteLift front edge of seat cushion upward to release foam from frame, Pull towards front of vehicle then tilt bench against 40/60 back
- Move the LH front seat backward.
- Set steering wheel straight ahead
-
Lock steering wheel into position
NoteProtect seat from damage
- Open hood
-
Remove rear apron
Note14x clips
-
Remove access panel
Note3x clips, 1x connector
-
Remove fasteners securing the frunk assembly
Note5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
-
Remove frunk assembly from vehicle
Note6x clips, Replace any clips if broken or missing
-
Remove fasteners holding upper portion of front fascia to vehicle
Note5x bolts, 10mm, 4 Nm
-
Power off vehicle from center display
NoteVia Controls > Safety & Security > Vehicle Power > Power Off
-
Disconnect 12V negative terminal and first responders loop
Note1x 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
-
Remove vent tube hose from LH side of 12V battery
Note1x hose
-
Release terminal cover and remove positive terminal
Note2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut
-
Remove bolt securing 12V battery upper tie down strap to AC compressor bracket
Note1x bolt, 10mm, 5 Nm
-
Remove battery upper tie down strap
NoteLift battery tie down strap up and remove it from the rear tie down hook strap
-
Remove 12V battery from vehicle
-
Disconnect the steering gear assembly connectors
Note2x connectors, Two stage connectors, Slide red locking tab to unlock, then depress the connector release to disconnect
-
Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
-
Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
-
Remove the ancillary bay probe lid cover from the ancillary bay cover
-
Verify no high voltage
NoteMake 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
-
Position the ancillary bay probe lid cover to the ancillary bay cover
NoteInspect gasket to confirm it has no visual damage
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Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
- Remove HV insulating gloves
-
Remove fasteners for LH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
-
Loosen bolts securing shock tower brace to RH shock tower
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
-
Shift shock tower brace assembly to gain clearance for removal of battery bracket
NoteShift shock tower brace forward, but do not fully remove
-
Remove bolt securing the steering gear assembly to intermediate shaft assembly
Note1x bolt, 13mm, 18 Nm
-
Slide the electric steering column upward to remove it from the steering gear assembly
-
Remove LH front wheel cap
Note1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
-
Remove RH front wheel cap
Note1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
-
Remove RH rear wheel cap
Note1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
-
Remove LH rear wheel cap
Note1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
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Loosen LH front wheel
Note5x nuts, 21mm, 175 Nm
-
Loosen LH front halfshaft nut
Note1x nut, 32mm, 300 Nm
-
Loosen RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Loosen RH front halfshaft nut
Note1x nut, 32mm, 300 Nm
-
Loosen RH rear wheel
Note5x nuts, 21mm, 175 Nm
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Loosen LH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Remove outer fasteners from front aero shield
Note7x bolts, 10mm, 5 Nm
-
Remove remaining nuts and remove front aero shield from vehicle
Note2x nuts, 15mm, 5 Nm
-
Release LH front wheel liner from HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
-
Release RH front wheel liner from HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
-
Lower vehicle partially and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Remove LH front wheel
Note5x nuts, 21mm, 175 Nm
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Remove LH front halfshaft nut and washers
Note1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
-
Remove LH front fender garnish
Note11x clips,1x push clip, 3x tabs, Release from center of garnish and work your way outward towards both ends, Be cautious not to bend front tabs going into front fascia
-
Remove clips securing LH front wheel liner to vehicle
Note14x clips
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Remove LH front wheel liner from vehicle
-
Remove bolt securing LH front wheel speed sensor to knuckle
Note1x bolt, 10mm, 5 Nm, Discard fastener after removal
-
Remove LH front wheel speed sensor harness from knuckle and move aside
Note2x harness clips
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Remove nut securing the LH tie rod end to the knuckle
Note1x nyloc nut, 22mm, 180 Nm, Discard after removal
-
Remove LH tie rod end from knuckle
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Remove RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Remove RH front halfshaft nut and washers
Note1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
-
Remove RH front fender garnish
Note11x clips,1x push clip, 3x tabs, Release from center of garnish and work your way outward towards both ends, Be cautious not to bend front tabs going into front fascia
-
Remove clips securing RH front wheel liner to vehicle
Note14x clips
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Remove RH front wheel liner from vehicle
-
Remove bolt securing RH front wheel speed sensor to knuckle
Note1x bolt, 10mm, 5 Nm
-
Remove RH front wheel speed sensor harness from knuckle and move aside
Note2x harness clips
-
Remove nut securing the RH tie rod end to the knuckle
Note1x nyloc nut, 22mm, 180 Nm, Discard after removal
-
Remove RH tie rod end from knuckle
-
Remove RH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Remove LH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Disconnect 12V harness for front fascia
Note1x locking connector, Release the locking tab by sliding it away from the connector, Then depress the grey lock to release the connector
-
Release pedestrian warning harness
Note1x connector, 1x clip, Pull tab to disengage lock, Pull again release from connector, Speaker is located behind RH wheel liner
-
Release both front corners then release front of front fascia by pulling upward and away from vehicle and place onto padded surface
Note8x clips, Recommend assistance, Use caution not to damage headlamp or fender during removal
-
Remove bolts securing front end carrier to LH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Remove bolts securing front end carrier to RH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Remove nut securing front stabar link to LH front stabar
Note1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
-
Move LH front stabar link assembly aside
NoteMay need to move the stabilizer bar up/down to get the correct angle needed to remove end link
-
Remove nut securing front stabar to RH front stabar link assembly
Note1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
-
Move RH front stabar link assembly aside
NoteMay be necessary to pull down on the sway bar to allow the end link to disengage
-
Remove bolt and nut securing LH front lower comp link to front subframe
Note1x bolt, 21mm, 1x nut, 21mm, 115 Nm
-
Move the LH front lower comp link aside
-
Remove bolts securing LH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm
-
Remove bolt and nut securing LH strut to LH front lower lateral link
Note1x bolt, 21mm, 1x nut, 21mm, 106 Nm
-
Remove bolt and nut securing RH front lower comp link to front subframe
Note1x bolt, 21mm, 1x nut, 21mm, 115 Nm
-
Move the RH front lower comp link aside
-
Remove bolts securing RH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm
-
Remove bolt and nut securing RH strut to lower control arm and move the RH front lower lateral link aside
Note1x bolt, 21mm, 1x nut, 21mm, 106 Nm
-
Loosen the bolts securing securing front subframe to LH front subframe crash can assembly
Note2x bolts, 15mm, 53 Nm, This will help when installing the subframe
-
Loosen the bolts securing securing front subframe to RH front subframe crash can assembly
Note2x bolts, 15mm, 53 Nm, This will help when installing the subframe
-
Position coolant drain container underneath RH front of HV battery
-
Disconnect FDU coolant inlet hose at RH front of HV battery and plug both hose ends
Note1x spring clip
-
Place coolant drain container below RH side of FDU
-
Disconnect coolant hose from the FDU oil cooler to the coolant bottle and allow coolant to drain
Note1x spring clip
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Install plugs to both open coolant hose connections
Note1x spring clip
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Position coolant drain container below LH side of radiator
-
Disconnect coolant hose from radiator inlet and plug both ends
Note1x spring clip, 2x plugs
-
Remove coolant drain container from underneath vehicle
-
Disconnect connectors from horn assembly
Note2x connectors
-
Disconnect the logic connectors below steering gear
Note2x connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Image zoomed out for location reference
-
Release harness clip from subframe assembly
Note1x clip, Image zoomed out for location reference
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Release harness clip from lower clip
Note1x clip
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Disconnect harness from LH front rail bracket
Note1x connector, Red locking tab, Release lock from opposite side of bracket then release connector towards front of vehicle, Image zoomed in for clarity
-
Remove bolt securing FDU HV harness to the FDU
Note1x bolt, EP10, 10 Nm
-
Disconnect the FDU HV harness connector
Note1x clip, 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 FDU header are not damaged
-
Remove the FDU HV harness connector from the FDU and move aside
Note1x connector
-
Remove bolt securing FDU ground strap to FDU
Note1x bolt, 10mm, 6 Nm
-
Remove FDU ground strap harness clip from FDU
Note1x clip
-
Loosen bolt securing FDU ground strap to HV battery and move aside
Note1x bolt, 10mm, 10 Nm
-
Disconnect FDU oil pump connector
Note1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
-
Lower vehicle partially and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install hydraulic hub puller onto LH wheel studs
Note5x nuts, 21mm, Hand tight
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Separate the LH axle from the hub assembly and move axle aside
NoteTurn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
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Remove the hydraulic hub puller from the LH wheel studs
Note5x nuts, 21mm, Hand tight
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Install hydraulic hub puller onto RH wheel studs
Note5x nuts, 21mm, Hand tight
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Separate the axle from the hub assembly and move axle aside
NoteTurn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
-
Remove the hydraulic hub puller from the RH wheel studs
Note5x nuts, 21mm, Hand tight
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Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Move the subframe lifting tool underneath the front subframe area
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Connect air supply to subframe lifting tool
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Position and support the front subframe with subframe lifting tool
NoteRecommend assistance, Latch the subframe to subframe lifting tool, Make sure to align the two guides
-
Position the rear FDU support posts to the FDU
NoteBoth FDU supports need to engage the FDU, The left side post is dimpled and fits into a recess on the FDU and the right side post has a teflon block that sits against the FDU, Both posts are threaded and the handle should be turned until the posts are tight
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Remove bolt securing the LH motor mount to the LH motor mount bracket
Note1x bolt, E18, 105 Nm
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Remove bolt securing the RH motor mount to the RH motor mount bracket
Note1x bolt, E18, 105 Nm
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Remove bolt securing LH mid mount to body
Note1x bolt, 15mm, 50 Nm, Discard after removal
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Remove bolt securing RH mid mount to body
Note1x bolt, 15mm, 50 Nm, Discard after removal
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Remove LH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm, Discard after removal
-
Remove RH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm, Discard after removal
-
Remove LH smaller bolt securing the rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm, Discard after removal
-
Remove RH smaller bolt securing the rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm, Discard after removal
-
Remove LH larger bolt securing the rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm, Discard after removal
-
Remove RH larger bolt securing the rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm, Discard after removal
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Lower the subframe from vehicle
NoteRecommend assistance
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Disconnect air supply from subframe lifting tool
-
Remove subframe lifting tool from under vehicle
-
Lower vehicle partially and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Position the oil drain container under hydraulic control unit area
-
Disconnect the hydraulic control unit connector
Note1x connector, Disengage locking tab and pull up on connector to release
-
Remove the RH front brake line tube nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
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Remove the LH rear brake line tube nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the RH rear brake line tube nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
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Remove the LH front brake line tube nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
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Remove the front brake line bundle clip around the LH front rail area
Note1x clip
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Remove the master cylinder brake lines from the 4 tube bundle
Note1x clip
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Remove RH front brake line from front brake line bundle clip around the LH front rail area
Note1x brake line
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Move brake lines away from hydraulic control unit
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Remove the oil drain container from underneath vehicle
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Remove the thermal beam hose clips from body
Note2x clips
-
Position the oil drain under front brake line junction area
-
Release bottom side brake pipe from coupling
Note1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
-
Release top side brake pipe from coupling
Note1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
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Release top side brake pipe from vehicle
Note1x clip, Slide brake pipe back and release from clip
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Release bottom side brake pipe from vehicle
Note1x clip, Slide brake pipe back and release from clip
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Position the oil drain under LH front brake hose area
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Remove the nut securing LH front brake line to LH front brake hose
Note1x nut, 12mm, 16 Nm
-
Remove the LH front brake line clip from body
Note1x clip
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Position the oil drain under front RH front brake hose
-
Remove the RH front brake line tube nut from RH front brake hose
Note1x nut, 12mm, 16 Nm
-
Remove the RH front brake line clips from body
Note2x clips
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Remove the oil drain from underneath vehicle
-
Release coolant hose clip on the LH fender
Note1x harness clip
-
Remove the front brake line bundle clip from LH body rail area
Note1x clip
-
Remove the LH front side 3 bundle brake lines from the vehicle
NoteRoute the front brake line bundle out of steering column area, then route it through LH front wheel liner and front subframe area
-
Release clips securing HV cables to the body
Note2x barrel clips
-
Remove HV battery front manifold hose clips from body
Note2x clips, Newer vehicles may be equipped with 1x clip
-
Release coolant hose from the right side subframe
Note1x harness clip
-
Release coolant hose from the right side body
Note1x harness clip
-
Remove the clips securing RH front brake line to body
Note5x clips
-
Remove the RH front brake line from vehicle
NoteRoute the brake line out of steering column area, then move toward RH side, and remove it out between the front subframe area
-
Remove the RH front brake line from new front brake line bundle
Note2x clips
Install
-
Position the RH front brake line to vehicle for installation
NoteRoute the RH front brake line through front subframe area out toward the RH front wheel liner area, then route it to LH frame rail area.
-
Install the clips securing RH front brake line to body
Note5x clips
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Secure the right side coolant hose to the body
Note1x harness clip
-
Secure the right side coolant hose to the subframe
Note1x harness clip
-
Secure coolant hoses to the body
Note4x barrel clips
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Install HV battery front manifold hose clips to body
Note2x clips, Newer vehicles may be equipped with 1x clip
-
Secure the HV cables to the body
Note2x barrel clips
-
Install the left side 3 bundle brake line into the vehicle
NoteRoute the front brake line bundle through LH front wheel liner and front subframe area, then route it to LH frame rail area.
-
Install coolant hose to the LH fender
Note1x harness clip
-
Install the front brake line bundle clip to LH body rail area
Note1x clip
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Lower vehicle partially and set onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install the RH front brake line tube nut to RH front brake hose
Note1x nut, 12mm, 16 Nm
-
Install the RH front brake line clips to body
Note2x clips
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Install the nut securing LH front brake line to LH front brake hose
Note1x nut, 12mm, 16 Nm
-
Install the LH front brake line clip to body
Note1x clip
-
Install top side brake pipe to vehicle
Note1x clip, Insert brake pipe into coupling and secure to clip
-
Install bottom side brake pipe to vehicle
Note1x clip, Insert brake pipe into coupling and secure to clip
-
Install top side brake pipe to coupling
Note1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
-
Install bottom side brake pipe to coupling
Note1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
-
Install the thermal beam hose clips to body
Note2x clips
-
Lower vehicle partially and set onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install RH front brake line to front brake line bundle clip around the LH front rail area
Note1x brake line
-
Install the master cylinder brake lines to 4 tube bundle clip
Note1x clip
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Install the front brake line bundle clip around the LH front rail area
Note1x clip
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Move master cylinder lines into position for installation
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Install the LH front brake line tube nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH rear brake line tube nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the LH rear brake line tube nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH front brake line tube nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Connect the hydraulic control unit connector
Note1x connector, Gently push connector downward, Engage locking tab
-
Position shock tower brace assembly back for installation
-
Install fasteners for LH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
-
Torque fasteners for RH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
-
Install 12V battery into vehicle
-
Position battery tie down strap onto the battery
NoteHook the upper tie down strap into the rear tie down hook strap and position for installation
-
Install bolt securing upper tie down strap to the AC compressor bracket
Note1x nut, 10mm, 5 Nm
-
Install vent tube hose in 12V battery
-
Install positive terminal and terminal cover
Note1x nut, 10mm, 6 Nm, 2x clips
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Position lifting tool and subframe under vehicle for installation
-
Connect air supply to subframe lifting tool
-
Install bolt securing the RH motor mount to the RH motor mount bracket
Note1x bolt, E18, 105 Nm, May need adjust subfame jig to align mount with bolt hole
-
Install bolt securing the LH motor mount to the LH motor mount bracket
Note1x bolt, E18, 105 Nm, May need adjust subfame jig to align mount with bolt hole
-
Raise support tool until the front subframe and body meet
NoteRecommend assistance, Guide the motor mount bushings into the motor mount isolators as the lift is being raised into position, Make sure to line up the rear locating pins on the subframe
-
Loosely install the RH larger bolt securing rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm, Install new bolt
-
Loosely install the LH larger bolt securing rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm, Install new bolt
-
Loosely install the RH smaller bolt securing rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm, Install new bolt
-
Loosely install the LH smaller bolt securing rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm, Install new bolt
-
Loosely install RH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
-
Loosely install LH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
-
Loosely install bolt securing the RH mid mount to body
Note1x bolt, 15mm, 50 Nm, Install new bolt
-
Loosely install bolt securing the LH mid mount to body
Note1x bolt, 15mm, 50 Nm, Install new bolt
-
Loosely install the bolts securing front end carrier to RH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Loosely install the bolts securing front front end carrier to LH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Torque the RH larger bolt securing the rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm
-
Torque the LH larger bolt securing the rear portion of the front subframe to body
Note1x bolt, 21mm, 125 Nm
-
Torque the RH smaller bolt securing the rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm
-
Torque the LH smaller bolt securing the rear portion of the front subframe to body
Note1x bolt, 15mm, 50 Nm
-
Torque the RH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm
-
Torque the LH bolt securing the front portion of the front subframe to body
Note1x bolt, 18mm, 72 Nm
-
Torque the bolt securing the RH mid mount to body
Note1x bolt, 15mm, 50 Nm
-
Torque the bolt securing the LH mid mount to body
Note1x bolt, 15mm, 50 Nm
-
Torque the bolts securing securing front subframe to RH front subframe crash can assembly
Note2x bolts, 15mm, 53 Nm
-
Torque the bolts securing LH front subframe crash can assembly to front subframe
Note2x bolts, 15mm, 53 Nm
-
Torque the bolts securing front end carrier to RH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Torque the bolts securing front end carrier to LH front subframe crash can assembly
Note2x bolts, 13mm, 16 Nm
-
Lower the subframe lifting tool from the vehicle
NoteUnlatch the subframe lifting tool from front subframe
-
Disconnect air supply from subframe lifting tool
-
Remove the subframe lifting tool from vehicle
-
Apply Molykote M-77 to outboard side of RH front halfshaft assembly
NoteClean if necessary, Apply no more than 1 gram to axle only
-
Loosely install RH front halfshaft into RH front hub assembly
Note1x nut, Install new nut and washer, Torqued at later step
-
Apply Molykote M-77 to outboard side of LH front halfshaft assembly
NoteClean if necessary, Apply no more than 1 gram to halfshaft only
-
Loosely install LH front halfshaft into the LH front hub assembly
Note1x nut, Install new nut and washer, Torqued at later step
-
Install the RH front lower lateral link and loosely install bolt and nut securing RH strut to lower control arm
Note1x bolt, 21mm, 1x nut, 21mm, 106 Nm
-
Loosely install bolts securing RH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
-
Install the RH front lower comp link to front subframe
-
Install bolt and nut securing RH front lower comp link to front subframe
Note1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
-
Torque bolts securing RH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
-
Install LH front lower lateral link and loosely install bolt and nut securing LH strut to lower lateral link
Note1x bolt, 21mm, 1x nut, 21mm, 106 Nm
-
Loosely install bolts securing LH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
-
Install LH front lower comp link to front subframe
-
Install bolt and nut securing LH front lower comp link to front subframe
Note1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
-
Torque bolts securing LH front lower lateral link to front subframe
Note2x bolts, 21mm, 115 Nm
-
Connect the FDU oil pump connector
Note1x connector, Engage locking tab
-
Place FDU ground strap to original position and install bolt to HV battery
Note1x bolt, 10mm, 10 Nm
-
Install FDU ground strap harness clip to FDU
Note1x clip, Make sure to properly route the ground strap
-
Install bolt securing FDU ground strap to FDU
Note1x bolt, 10mm, 6 Nm
-
Install FDU HV harness connector to FDU
Note1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
-
Connect the FDU HV harness connector and lock the release lever
Note1x clip, 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
-
Install bolt securing FDU HV harness to FDU
Note1x bolt, 10mm, 10 Nm
-
Connect harness located at LH front rail bracket
Note1x connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket, Image zoomed in for clarity
-
Install upper harness clip onto lower harness clip
Note1x clip
-
Install lower harness clip into subframe
Note1x clip
-
Connect the logic connectors below steering gear
Note2x connectors, Engage locking tabs
-
Connect horn assembly connectors
Note2x connectors
-
Position coolant drain container below LH side of radiator
-
Remove plugs and connect coolant inlet hose to LH side of radiator
Note1x spring clip
-
Position coolant drain container under RH side of FDU
-
Remove plugs and connect coolant hose from coolant bottle to oil cooler
Note1x spring clip
-
Position coolant drain container underneath RH front of HV battery
-
Remove plugs and connect FDU coolant inlet hose at the RH side of vehicle
Note1x spring clip
- Remove coolant drain container from underneath vehicle
-
Position the RH front stabar link assembly to front stabar
NoteMay be necessary to pull down on the sway bar to allow the end link to engage
-
Install nut securing front stabar to RH front stabar link assembly
Note1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
-
Position LH front stabar link assembly to front stabar
NoteMay be necessary to pull down on the sway bar to allow the end link to engage
-
Install nut securing front stabar link to LH front stabar
Note1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
-
Lower vehicle partially and set onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Position RH front tie rod end to RH front knuckle
-
Install nut securing RH front tie rod end to RH front knuckle
Note1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
-
Position LH tie rod end to LH front knuckle
-
Install nut securing LH front tie rod end to LH front knuckle
Note1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
-
Install front fascia onto vehicle and secure front clips and both front corners
Note8x clips, Recommend assistance, Use caution not to damage headlamp or fender during installation
-
Connect 12V harness for front fascia
Note1x locking connector, Engage locking tab
-
Connect pedestrian warning harness
Note1x connector, 1x clip, Engage locking tab
-
Install LH front wheel liner to vehicle
-
Install LH front wheel liner clips securing LH front wheel liner to vehicle
Note14x clips
-
Install LH front fender garnish
Note12x clips, 3x tabs, Start at rear and maneuver into rocker panel, Be cautious not to bend front tabs going into front fascia
-
Install RH front wheel liner to vehicle
Note14x clips
-
Install clips securing RH front wheel liner to vehicle
Note14x clips
-
Install RH front fender garnish
Note11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
-
Lower vehicle until tires are just above the ground
NoteThe front wheels should still move freely for aligning the intermediate shaft, Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Slide the intermediate shaft assembly downward to install it to the steering gear assembly
NoteEnsure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
-
Install bolt securing the intermediate shaft assembly to the steering gear assembly
Note1x bolt, 13mm, 18 Nm
-
Connect the steering gear assembly connectors
Note2x locking connectors, Engage locking tab
-
Fill brake bleeder reservoir to full level
-
Clean area around brake fluid reservoir and remove brake reservoir cap
-
Top off brake fluid reservoir
NoteTop off brake fluid as needed
-
Install pressure bleeder adapter onto reservoir
-
Set brake bleed reservoir pressure to 30 psi
NoteConnect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
- Connect to vehicle using Toolbox 3.0
- Select Actions/Autodiag and search for "bleed"
-
Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP
Note2x covers
-
Open LH front brake caliper outer
bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDSearch for routine in ToolboxChassis / Brakes - Brake Bleed FL-RRChassis / Brakes - Brake Bleed FL-RR and select Run to start the ESP, then close
the bleeding valve once the pump stop running, then repeat the process for inner bleeding
valve, and then lastly repeat the process for outer bleeding valve again
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP
Note2x covers
-
Open RH front brake caliper outer
bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDSearch for routine in ToolboxChassis / Brakes - Brake Bleed FR-RLChassis / Brakes - Brake Bleed FR-RL and select Run to start the ESP, then close
the bleeding valve once the pump stop running, then repeat the process for inner bleeding
valve, and then lastly repeat the process for outer bleeding valve again
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP
Note1x cover
-
Open RH rear brake caliper bleeding
valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDSearch for routine in ToolboxChassis / Brakes - Brake Bleed FL-RRChassis / Brakes - Brake Bleed FL-RR and select Run to start the ESP, then close
the bleeding valve once the pump stop running
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover
Note1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP
Note1x cover
-
Open LH rear brake caliper bleeding
valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDSearch for routine in ToolboxChassis / Brakes - Brake Bleed FR-RLChassis / Brakes - Brake Bleed FR-RL and select Run to start the ESP, then close
the bleeding valve once the pump stop running
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover
Note1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
-
Remove pressure bleeder adapter from reservoir
-
Check fluid level
NoteTop off if necessary
-
Install brake reservoir cap
- Pump the brake pedal a few times to ensure the brake pedal feels normal
-
Using Toolbox 3:
- Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
-
Raise vehicle fully and lower lift onto locks
NoteSet 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
-
Install LH front wheel liner to HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
-
Install RH front wheel liner to HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
-
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
Note7x bolts, 10mm, 5 Nm
-
Position the front aero shield to vehicle and install nuts
Note2x nuts, 15mm, 5 Nm
-
Lower vehicle partially and set onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install LH front wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Install LH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Install RH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Install RH front wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Lower vehicle until tires are touching the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Torque LH front wheel
Note5x nuts, 21mm, 175 Nm
-
Torque LH front halfshaft nut
Note1x nut, 32mm, 300 Nm
-
Torque RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Torque RH front halfshaft nut
Note1x nut, 32mm, 300 Nm
-
Torque RH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Torque LH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Install LH front wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Install RH front wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Install RH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Install LH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Remove coolant bottle cap
-
Place empty coolant container into front storage area
-
Fill container with at least 15L of coolant
-
Place filled coolant container into front storage area
-
Place coolant refill hose inside filled coolant container and make sure end is fully submerged
-
Install vacuum refill cap onto coolant bottle assembly
-
Close air inlet and coolant refill valves
-
Install vacuum refill hose into refill cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully installed
-
Place end of overflow hose into empty container
-
Place coolant refill hose inside filled coolant container and make sure end is fully submerged
-
Connect shop air supply to vacuum tool
NoteMinimum pressure 5.5 bar (80 psi)
-
Open air inlet valve for 10 seconds to create a vacuum, then fully close valve
NoteThe vacuum should stabilize at approximately -27 to -24 inHg or -70 to -60 cmHg.
-
Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose, Close the valve when the hose is full of coolant
NoteThis purges trapped air from the hose
-
Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
-
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
-
Slowly open the coolant refill valve to allow coolant to be drawn into the system
NoteMake sure end of coolant refill hose is fully submerged during entire process
-
Once the gauge reads zero, close the coolant refill valve
-
Disconnect shop air supply from coolant refill tool
-
Remove coolant refill hose from coolant container
-
Remove coolant overflow hose from coolant container
-
Remove vacuum refill hose from refill cap on coolant bottle
NotePush down on black ring to release hose and pull hose up to remove
-
Lift the coolant refill tool above coolant container to allow excess coolant to drain from hoses
NoteMay need to reopen valves to remove all coolant
-
Remove both coolant containers from inside underhood area
-
Connect first responder loop and 12V negative terminal
Note1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
-
Remove the steering wheel holder
- Connect to vehicle using Toolbox 3.0
-
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
NoteMake 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
-
Inspect coolant level and top off as necessary
NoteEnsure that the fluid level is at the Max line
-
Install coolant bottle cap
-
Select ‘Actions/Autodiag’ and search for ‘Thermal Performance’
-
Select ‘TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCESearch for routine in Toolbox’, click ‘Run’, and allow routine to complete
NoteSelect ‘X’ at top right of window to close once complete.
-
Install frunk assembly into vehicle
Note6x clips, Replace any clips if broken or missing
-
Install fasteners securing the frunk assembly
Note5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
-
Install access panel
Note3x clips, 1x connector
-
Install rear apron
Note14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
- Close hood
-
Reposition 2nd row seat cushion
NoteSlide cushion rearward then align with buckles and foam with seat rail, Make sure cushion is fully seated with push & pull test
- Move RH front seat to original position
- Move LH front seat to original position
- Raise all windows
-
Close all four doors
NoteIf 12V is powered up, Unlatch rear doors before closing
-
Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
-
Lower the alignment rack partially and set onto locks
-
Latch the driver seat belt to buckle
-
Latch LH front door and place vehicle into neutral
NoteCareful not to slam the door while latch is engaged
-
Install alignment heads onto wheels
Note4x alignment heads
- Enter vehicle information to alignment machine
-
Perform rolling compensation
NoteRemove the wheel chocks from the LH rear tire and push the back of the tire to roll vehicle forward. Reinstall wheel chocks once vehicle is in position
-
Unlock alignment slip/turn plates
-
Verify chassis height measurement tool is calibrated
NoteAdjust if necessary, Measure height of tool and adjust reading to match
-
Perform ride height measurement
NoteMeasure the ride height 75mm inward of the HV battery ski hole at each corner, If using ballast bags, move the front seats as necessary to achieve ride height spec, See Service Manual for ride height specifications
-
Apply brake pedal depressor
-
Perform caster sweep and install steering wheel holder and level tool
NoteIf camber and caster are out of specification, perform necessary camber and caster adjustment
-
Verify alignment reading is within specification and print vehicle summary
-
Remove alignment heads from wheels
Note4x alignment heads
-
Remove brake pedal depressor
-
Lock alignment slip/turn plates
-
Lower the alignment rack to ground
-
Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
-
Unlatch LH front seat belt
-
Remove wheel chocks
-
Remove vehicle from alignment rack
-
Perform test drive
NotePer current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing