01/04/2024 13:56:45

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

Raise and support vehicle

Note
Ensure 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

Note
Select ‘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

Note
Lift 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

Note
Protect seat from damage
Open hood
Remove rear apron

Note
14x clips
Remove access panel

Note
3x clips, 1x connector
Remove fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
Remove frunk assembly from vehicle

Note
6x clips, Replace any clips if broken or missing
Remove fasteners holding upper portion of front fascia to vehicle

Note
5x bolts, 10mm, 4 Nm
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off
Disconnect 12V negative terminal and first responders loop

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
Remove vent tube hose from LH side of 12V battery

Note
1x hose
Release terminal cover and remove positive terminal

Note
2x 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

Note
1x bolt, 10mm, 5 Nm
Remove battery upper tie down strap

Note
Lift 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

Note
2x 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

Note
Check 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

Note
Make 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

Note
2x 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

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
Position the ancillary bay probe lid cover to the ancillary bay cover

Note
Inspect gasket to confirm it has no visual damage
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
Remove HV insulating gloves
Remove fasteners for LH side of shock tower brace

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
Loosen bolts securing shock tower brace to RH shock tower

Note
2x 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

Note
Shift shock tower brace forward, but do not fully remove
Remove bolt securing the steering gear assembly to intermediate shaft assembly

Note
1x bolt, 13mm, 18 Nm
Slide the electric steering column upward to remove it from the steering gear assembly
Remove LH front wheel cap

Note
1x 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

Note
1x 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

Note
1x 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

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Loosen LH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH front halfshaft nut

Note
1x nut, 32mm, 300 Nm
Loosen RH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen RH front halfshaft nut

Note
1x nut, 32mm, 300 Nm
Loosen RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle fully and lower lift onto locks

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
Remove outer fasteners from front aero shield

Note
7x bolts, 10mm, 5 Nm
Remove remaining nuts and remove front aero shield from vehicle

Note
2x nuts, 15mm, 5 Nm
Release LH front wheel liner from HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Release RH front wheel liner from HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Lower vehicle partially and set lift onto locks

Note
Raise 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

Note
5x nuts, 21mm, 175 Nm
Remove LH front halfshaft nut and washers

Note
1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
Remove LH front fender garnish

Note
11x 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

Note
14x clips
Remove LH front wheel liner from vehicle
Remove bolt securing LH front wheel speed sensor to knuckle

Note
1x bolt, 10mm, 5 Nm, Discard fastener after removal
Remove LH front wheel speed sensor harness from knuckle and move aside

Note
2x harness clips
Remove nut securing the LH tie rod end to the knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Discard after removal
Remove LH tie rod end from knuckle
Remove RH front wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH front halfshaft nut and washers

Note
1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
Remove RH front fender garnish

Note
11x 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

Note
14x clips
Remove RH front wheel liner from vehicle
Remove bolt securing RH front wheel speed sensor to knuckle

Note
1x bolt, 10mm, 5 Nm
Remove RH front wheel speed sensor harness from knuckle and move aside

Note
2x harness clips
Remove nut securing the RH tie rod end to the knuckle

Note
1x nyloc nut, 22mm, 180 Nm, Discard after removal
Remove RH tie rod end from knuckle
Remove RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Disconnect 12V harness for front fascia

Note
1x 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

Note
1x 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

Note
8x 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

Note
2x bolts, 13mm, 16 Nm
Remove bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Raise vehicle fully and lower lift onto locks

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
Remove nut securing front stabar link to LH front stabar

Note
1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
Move LH front stabar link assembly aside

Note
May 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

Note
1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
Move RH front stabar link assembly aside

Note
May 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

Note
1x 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

Note
2x bolts, 21mm, 115 Nm
Remove bolt and nut securing LH strut to LH front lower lateral link

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Remove bolt and nut securing RH front lower comp link to front subframe

Note
1x 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

Note
2x bolts, 21mm, 115 Nm
Remove bolt and nut securing RH strut to lower control arm and move the RH front lower lateral link aside

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosen the bolts securing securing front subframe to LH front subframe crash can assembly

Note
2x 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

Note
2x 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

Note
1x 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

Note
1x spring clip
Install plugs to both open coolant hose connections

Note
1x spring clip
Position coolant drain container below LH side of radiator
Disconnect coolant hose from radiator inlet and plug both ends

Note
1x spring clip, 2x plugs
Remove coolant drain container from underneath vehicle
Disconnect connectors from horn assembly

Note
2x connectors
Disconnect the logic connectors below steering gear

Note
2x 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

Note
1x clip, Image zoomed out for location reference
Release harness clip from lower clip

Note
1x clip
Disconnect harness from LH front rail bracket

Note
1x 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

Note
1x bolt, EP10, 10 Nm
Disconnect the FDU HV harness connector

Note
1x 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

Note
1x connector
Remove bolt securing FDU ground strap to FDU

Note
1x bolt, 10mm, 6 Nm
Remove FDU ground strap harness clip from FDU

Note
1x clip
Loosen bolt securing FDU ground strap to HV battery and move aside

Note
1x bolt, 10mm, 10 Nm
Disconnect FDU oil pump connector

Note
1x 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

Note
Raise 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

Note
5x nuts, 21mm, Hand tight
Separate the LH axle from the hub assembly and move axle aside

Note
Turn 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 LH wheel studs

Note
5x nuts, 21mm, Hand tight
Install hydraulic hub puller onto RH wheel studs

Note
5x nuts, 21mm, Hand tight
Separate the axle from the hub assembly and move axle aside

Note
Turn 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

Note
5x nuts, 21mm, Hand tight
Raise vehicle fully and lower lift onto locks

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
Move the subframe lifting tool underneath the front subframe area
Connect air supply to subframe lifting tool
Position and support the front subframe with subframe lifting tool

Note
Recommend assistance, Latch the subframe to subframe lifting tool, Make sure to align the two guides
Position the rear FDU support posts to the FDU

Note
Both 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
Remove bolt securing the LH motor mount to the LH motor mount bracket

Note
1x bolt, E18, 105 Nm
Remove bolt securing the RH motor mount to the RH motor mount bracket

Note
1x bolt, E18, 105 Nm
Remove bolt securing LH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove bolt securing RH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove LH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Discard after removal
Remove RH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm, Discard after removal
Remove LH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove RH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Discard after removal
Remove LH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Discard after removal
Remove RH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Discard after removal
Lower the subframe from vehicle

Note
Recommend assistance
Disconnect air supply from subframe lifting tool
Remove subframe lifting tool from under vehicle
Lower vehicle partially and set lift onto locks

Note
Raise 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

Note
1x connector, Disengage locking tab and pull up on connector to release
Remove the RH front brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the LH rear brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the RH rear brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the LH front brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the front brake line bundle clip around the LH front rail area

Note
1x clip
Remove the master cylinder brake lines from the 4 tube bundle

Note
1x clip
Remove RH front brake line from front brake line bundle clip around the LH front rail area

Note
1x brake line
Move brake lines away from hydraulic control unit
Remove the oil drain container from underneath vehicle
Raise vehicle fully and lower lift onto locks

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
Remove the thermal beam hose clips from body

Note
2x clips
Position the oil drain under front brake line junction area
Release bottom side brake pipe from coupling

Note
1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
Release top side brake pipe from coupling

Note
1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
Release top side brake pipe from vehicle

Note
1x clip, Slide brake pipe back and release from clip
Release bottom side brake pipe from vehicle

Note
1x clip, Slide brake pipe back and release from clip
Position the oil drain under LH front brake hose area
Remove the nut securing LH front brake line to LH front brake hose

Note
1x nut, 12mm, 16 Nm
Remove the LH front brake line clip from body

Note
1x clip
Position the oil drain under front RH front brake hose
Remove the RH front brake line tube nut from RH front brake hose

Note
1x nut, 12mm, 16 Nm
Remove the RH front brake line clips from body

Note
2x clips
Remove the oil drain from underneath vehicle
Release coolant hose clip on the LH fender

Note
1x harness clip
Remove the front brake line bundle clip from LH body rail area

Note
1x clip
Remove the LH front side 3 bundle brake lines from the vehicle

Note
Route 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

Note
2x barrel clips
Remove HV battery front manifold hose clips from body

Note
2x clips, Newer vehicles may be equipped with 1x clip
Release coolant hose from the right side subframe

Note
1x harness clip
Release coolant hose from the right side body

Note
1x harness clip
Remove the clips securing RH front brake line to body

Note
5x clips
Remove the RH front brake line from vehicle

Note
Route 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

Note
2x clips

Install

Position the RH front brake line to vehicle for installation

Note
Route 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

Note
5x clips
Secure the right side coolant hose to the body

Note
1x harness clip
Secure the right side coolant hose to the subframe

Note
1x harness clip
Secure coolant hoses to the body

Note
4x barrel clips
Install HV battery front manifold hose clips to body

Note
2x clips, Newer vehicles may be equipped with 1x clip
Secure the HV cables to the body

Note
2x barrel clips
Install the left side 3 bundle brake line into the vehicle

Note
Route 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

Note
1x harness clip
Install the front brake line bundle clip to LH body rail area

Note
1x clip
Lower vehicle partially and set onto locks

Note
Raise 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

Note
1x nut, 12mm, 16 Nm
Install the RH front brake line clips to body

Note
2x clips
Install the nut securing LH front brake line to LH front brake hose

Note
1x nut, 12mm, 16 Nm
Install the LH front brake line clip to body

Note
1x clip
Install top side brake pipe to vehicle

Note
1x clip, Insert brake pipe into coupling and secure to clip
Install bottom side brake pipe to vehicle

Note
1x clip, Insert brake pipe into coupling and secure to clip
Install top side brake pipe to coupling

Note
1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
Install bottom side brake pipe to coupling

Note
1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
Install the thermal beam hose clips to body

Note
2x clips
Lower vehicle partially and set onto locks

Note
Raise 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

Note
1x brake line
Install the master cylinder brake lines to 4 tube bundle clip

Note
1x clip
Install the front brake line bundle clip around the LH front rail area

Note
1x clip
Move master cylinder lines into position for installation
Install the LH front brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the RH rear brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the LH rear brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the RH front brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Connect the hydraulic control unit connector

Note
1x 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

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
Torque fasteners for RH side of shock tower brace

Note
2x 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

Note
Hook 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

Note
1x nut, 10mm, 5 Nm
Install vent tube hose in 12V battery
Install positive terminal and terminal cover

Note
1x nut, 10mm, 6 Nm, 2x clips
Raise vehicle fully and lower lift onto locks

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
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

Note
1x 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

Note
1x 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

Note
Recommend 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

Note
1x bolt, 21mm, 125 Nm, Install new bolt
Loosely install the LH larger bolt securing rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm, Install new bolt
Loosely install the RH smaller bolt securing rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install the LH smaller bolt securing rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install RH bolt securing the front portion of the front subframe to body

Note
1x 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

Note
1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
Loosely install bolt securing the RH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install bolt securing the LH mid mount to body

Note
1x bolt, 15mm, 50 Nm, Install new bolt
Loosely install the bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Loosely install the bolts securing front front end carrier to LH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Torque the RH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm
Torque the LH larger bolt securing the rear portion of the front subframe to body

Note
1x bolt, 21mm, 125 Nm
Torque the RH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm
Torque the LH smaller bolt securing the rear portion of the front subframe to body

Note
1x bolt, 15mm, 50 Nm
Torque the RH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm
Torque the LH bolt securing the front portion of the front subframe to body

Note
1x bolt, 18mm, 72 Nm
Torque the bolt securing the RH mid mount to body

Note
1x bolt, 15mm, 50 Nm
Torque the bolt securing the LH mid mount to body

Note
1x bolt, 15mm, 50 Nm
Torque the bolts securing securing front subframe to RH front subframe crash can assembly

Note
2x bolts, 15mm, 53 Nm
Torque the bolts securing LH front subframe crash can assembly to front subframe

Note
2x bolts, 15mm, 53 Nm
Torque the bolts securing front end carrier to RH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Torque the bolts securing front end carrier to LH front subframe crash can assembly

Note
2x bolts, 13mm, 16 Nm
Lower the subframe lifting tool from the vehicle

Note
Unlatch 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

Note
Clean if necessary, Apply no more than 1 gram to axle only
Loosely install RH front halfshaft into RH front hub assembly

Note
1x nut, Install new nut and washer, Torqued at later step
Apply Molykote M-77 to outboard side of LH front halfshaft assembly

Note
Clean if necessary, Apply no more than 1 gram to halfshaft only
Loosely install LH front halfshaft into the LH front hub assembly

Note
1x 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

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosely install bolts securing RH front lower lateral link to front subframe

Note
2x 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

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
Torque bolts securing RH front lower lateral link to front subframe

Note
2x 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

Note
1x bolt, 21mm, 1x nut, 21mm, 106 Nm
Loosely install bolts securing LH front lower lateral link to front subframe

Note
2x 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

Note
1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
Torque bolts securing LH front lower lateral link to front subframe

Note
2x bolts, 21mm, 115 Nm
Connect the FDU oil pump connector

Note
1x connector, Engage locking tab
Place FDU ground strap to original position and install bolt to HV battery

Note
1x bolt, 10mm, 10 Nm
Install FDU ground strap harness clip to FDU

Note
1x clip, Make sure to properly route the ground strap
Install bolt securing FDU ground strap to FDU

Note
1x bolt, 10mm, 6 Nm
Install FDU HV harness connector to FDU

Note
1x 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

Note
1x 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

Note
1x bolt, 10mm, 10 Nm
Connect harness located at LH front rail bracket

Note
1x 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

Note
1x clip
Install lower harness clip into subframe

Note
1x clip
Connect the logic connectors below steering gear

Note
2x connectors, Engage locking tabs
Connect horn assembly connectors

Note
2x connectors
Position coolant drain container below LH side of radiator
Remove plugs and connect coolant inlet hose to LH side of radiator

Note
1x spring clip
Position coolant drain container under RH side of FDU
Remove plugs and connect coolant hose from coolant bottle to oil cooler

Note
1x 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

Note
1x spring clip
Remove coolant drain container from underneath vehicle
Position the RH front stabar link assembly to front stabar

Note
May 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

Note
1x 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

Note
May 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

Note
1x 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

Note
Raise 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

Note
1x 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

Note
1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
Install front fascia onto vehicle and secure front clips and both front corners

Note
8x clips, Recommend assistance, Use caution not to damage headlamp or fender during installation
Connect 12V harness for front fascia

Note
1x locking connector, Engage locking tab
Connect pedestrian warning harness

Note
1x 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

Note
14x clips
Install LH front fender garnish

Note
12x 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

Note
14x clips
Install clips securing RH front wheel liner to vehicle

Note
14x clips
Install RH front fender garnish

Note
11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
Lower vehicle until tires are just above the ground

Note
The 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

Note
Ensure 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

Note
1x bolt, 13mm, 18 Nm
Connect the steering gear assembly connectors

Note
2x 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

Note
Top off brake fluid as needed
Install pressure bleeder adapter onto reservoir
Set brake bleed reservoir pressure to 30 psi

Note
Connect 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

Note
2x covers
Open LH front brake caliper outer bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED 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

Note
2x 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

Note
2x 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

Note
2x 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

Note
2x covers
Open RH front brake caliper outer bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED 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

Note
2x 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

Note
2x 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

Note
2x 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

Note
1x cover
Open RH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x 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

Note
1x 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

Note
1x 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

Note
1x cover
Open LH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x 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

Note
1x 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

Note
1x 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

Note
Top off if necessary
Install brake reservoir cap
Pump the brake pedal a few times to ensure the brake pedal feels normal
Using Toolbox 3:
1. Select the Actions tab and search for "Stiffness".
2. Select the ODIN routine IBST Stiffness Test - Service - BURNISHED/UNBURNISHEDTEST_BRAKE_X_STIFFNESS-TEST-SERVICEGen3/tasks/TEST_BRAKE_X_STIFFNESS-TEST-SERVICEChassisChassis / Brakes - Brake Stiffness TestService Mode Service Plus Factory Mode Developer , and then click the link of the routine.
3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
4. Click RUN, and allow the routine to complete.
  
  Note
  Do not press the brake pedal during the test.
Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Raise vehicle fully and lower lift onto locks

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
Install LH front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Install RH front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
7x bolts, 10mm, 5 Nm
Position the front aero shield to vehicle and install nuts

Note
2x nuts, 15mm, 5 Nm
Lower vehicle partially and set onto locks

Note
Raise 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

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque LH front halfshaft nut

Note
1x nut, 32mm, 300 Nm
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH front halfshaft nut

Note
1x nut, 32mm, 300 Nm
Torque RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Torque LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Install LH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install RH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install RH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install LH rear wheel cap

Note
1x 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

Note
Perform 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

Note
Minimum pressure 5.5 bar (80 psi)
Open air inlet valve for 10 seconds to create a vacuum, then fully close valve

Note
The 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

Note
This 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

Note
Make 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

Note
Push 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

Note
May need to reopen valves to remove all coolant
Remove both coolant containers from inside underhood area
Connect first responder loop and 12V negative terminal

Note
1x 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 ‘Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer ’, click ‘Run’, and allow routine to complete

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
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Select ‘Actions/Autodiag’ and search for ‘Thermal Performance’
Select ‘Heat Pump Thermal System Performance TestTEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCEModelY/tasks/TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCELow Voltage Controllers’, click ‘Run’, and allow routine to complete

Note
Select ‘X’ at top right of window to close once complete.
Install frunk assembly into vehicle

Note
6x clips, Replace any clips if broken or missing
Install fasteners securing the frunk assembly

Note
5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
Install access panel

Note
3x clips, 1x connector
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Reposition 2nd row seat cushion

Note
Slide 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

Note
If 12V is powered up, Unlatch rear doors before closing
Remove vehicle from lift

Note
Lower 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

Note
Careful not to slam the door while latch is engaged
Install alignment heads onto wheels

Note
4x alignment heads
Enter vehicle information to alignment machine
Perform rolling compensation

Note
Remove 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

Note
Adjust if necessary, Measure height of tool and adjust reading to match
Perform ride height measurement

Note
Measure 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

Note
If 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

Note
4x 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

Note
Per 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