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.
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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
  2. Open all doors and lower all windows.
  3. Connect to vehicle using Toolbox 3.0
  4. Select ‘Actions/Autodiag’ and search for ‘Thermal’
  5. Select "Thermal Fluid Fill/Drain", click Run and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    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
  6. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  7. Move the LH and RH front seats forward.
  8. Release 2nd row seat cushion
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    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
  9. Move the LH front seat backward.
  10. Set steering wheel straight ahead
  11. Lock steering wheel into position
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    Note
    Protect seat from damage
  12. Open hood
  13. Remove rear apron
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    Note
    14x clips
  14. Remove access panel
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    Note
    3x clips, 1x connector
  15. Remove fasteners securing the frunk assembly
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    Note
    5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck
  16. Remove frunk assembly from vehicle
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    Note
    6x clips, Replace any clips if broken or missing
  17. Remove fasteners holding upper portion of front fascia to vehicle
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    Note
    5x bolts, 10mm, 4 Nm
  18. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off
  19. Disconnect 12V negative terminal and first responders loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
  20. Remove vent tube hose from LH side of 12V battery
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    Note
    1x hose
  21. Release terminal cover and remove positive terminal
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    Note
    2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut
  22. Remove bolt securing 12V battery upper tie down strap to AC compressor bracket
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    Note
    1x bolt, 10mm, 5 Nm
  23. Remove battery upper tie down strap
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    Note
    Lift battery tie down strap up and remove it from the rear tie down hook strap
  24. Remove 12V battery from vehicle
  25. Disconnect the steering gear assembly connectors
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    Note
    2x connectors, Two stage connectors, Slide red locking tab to unlock, then depress the connector release to disconnect
  26. Remove all items from pockets and ensure not wearing metal items
  27. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, 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
  28. Put on HV insulating gloves and leather over gloves
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    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  29. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  30. Remove the ancillary bay probe lid cover from the ancillary bay cover
  31. Verify no high voltage
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  32. Position the ancillary bay probe lid cover to the ancillary bay cover
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    Note
    Inspect gasket to confirm it has no visual damage
  33. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
  34. Remove HV insulating gloves
  35. Remove fasteners for LH side of shock tower brace
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    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
  36. Loosen bolts securing shock tower brace to RH shock tower
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    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
  37. Shift shock tower brace assembly to gain clearance for removal of battery bracket
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    Note
    Shift shock tower brace forward, but do not fully remove
  38. Remove bolt securing the steering gear assembly to intermediate shaft assembly
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    Note
    1x bolt, 13mm, 18 Nm
  39. Slide the electric steering column upward to remove it from the steering gear assembly
  40. Remove LH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  41. Remove RH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  42. Remove RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  43. Remove LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  44. Loosen LH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  45. Loosen LH front halfshaft nut
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    Note
    1x nut, 32mm, 300 Nm
  46. Loosen RH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  47. Loosen RH front halfshaft nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 300 Nm
  48. Loosen RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  49. Loosen LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  50. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  51. Remove outer fasteners from front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  52. Remove remaining nuts and remove front aero shield from vehicle
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    Note
    2x nuts, 15mm, 5 Nm
  53. Release LH front wheel liner from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  54. Release RH front wheel liner from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  55. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  56. Remove LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  57. Remove LH front halfshaft nut and washers
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
  58. Remove LH front fender garnish
    Informational PurposesAn informational icon, calling your attention
    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
  59. Remove clips securing LH front wheel liner to vehicle
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    Note
    14x clips
  60. Remove LH front wheel liner from vehicle
  61. Remove bolt securing LH front wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm, Discard fastener after removal
  62. Remove LH front wheel speed sensor harness from knuckle and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    2x harness clips
  63. Remove nut securing the LH tie rod end to the knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 22mm, 180 Nm, Discard after removal
  64. Remove LH tie rod end from knuckle
  65. Remove RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  66. Remove RH front halfshaft nut and washers
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 300 Nm, The washers are attached to the nut, Discard after removal
  67. Remove RH front fender garnish
    Informational PurposesAn informational icon, calling your attention
    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
  68. Remove clips securing RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  69. Remove RH front wheel liner from vehicle
  70. Remove bolt securing RH front wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  71. Remove RH front wheel speed sensor harness from knuckle and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    2x harness clips
  72. Remove nut securing the RH tie rod end to the knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 22mm, 180 Nm, Discard after removal
  73. Remove RH tie rod end from knuckle
  74. Remove RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  75. Remove LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  76. Disconnect 12V harness for front fascia
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Release the locking tab by sliding it away from the connector, Then depress the grey lock to release the connector
  77. Release pedestrian warning harness
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    Note
    1x connector, 1x clip, Pull tab to disengage lock, Pull again release from connector, Speaker is located behind RH wheel liner
  78. Release both front corners then release front of front fascia by pulling upward and away from vehicle and place onto padded surface
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Recommend assistance, Use caution not to damage headlamp or fender during removal
  79. Remove bolts securing front end carrier to LH front subframe crash can assembly
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    Note
    2x bolts, 13mm, 16 Nm
  80. Remove bolts securing front end carrier to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 16 Nm
  81. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  82. Remove nut securing front stabar link to LH front stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
  83. Move LH front stabar link assembly aside
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    Note
    May need to move the stabilizer bar up/down to get the correct angle needed to remove end link
  84. Remove nut securing front stabar to RH front stabar link assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
  85. Move RH front stabar link assembly aside
    Informational PurposesAn informational icon, calling your attention
    Note
    May be necessary to pull down on the sway bar to allow the end link to disengage
  86. Remove bolt and nut securing LH front lower comp link to front subframe
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    Note
    1x bolt, 21mm, 1x nut, 21mm, 115 Nm
  87. Move the LH front lower comp link aside
  88. Remove bolts securing LH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm
  89. Remove bolt and nut securing LH strut to LH front lower lateral link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  90. Remove bolt and nut securing RH front lower comp link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 115 Nm
  91. Move the RH front lower comp link aside
  92. Remove bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm
  93. Remove bolt and nut securing RH strut to lower control arm and move the RH front lower lateral link aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  94. Loosen the bolts securing securing front subframe to LH front subframe crash can assembly
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    Note
    2x bolts, 15mm, 53 Nm, This will help when installing the subframe
  95. Loosen the bolts securing securing front subframe to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm, This will help when installing the subframe
  96. Position coolant drain container underneath RH front of HV battery
  97. Disconnect FDU coolant inlet hose at RH front of HV battery and plug both hose ends
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    Note
    1x spring clip
  98. Place coolant drain container below RH side of FDU
  99. Disconnect coolant hose from the FDU oil cooler to the coolant bottle and allow coolant to drain
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  100. Install plugs to both open coolant hose connections
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  101. Position coolant drain container below LH side of radiator
  102. Disconnect coolant hose from radiator inlet and plug both ends
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    Note
    1x spring clip, 2x plugs
  103. Remove coolant drain container from underneath vehicle
  104. Disconnect connectors from horn assembly
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    Note
    2x connectors
  105. Disconnect the logic connectors below steering gear
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    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
  106. Release harness clip from subframe assembly
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    Note
    1x clip, Image zoomed out for location reference
  107. Release harness clip from lower clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  108. Disconnect harness from LH front rail bracket
    Informational PurposesAn informational icon, calling your attention
    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
  109. Remove bolt securing FDU HV harness to the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 10 Nm
  110. Disconnect the FDU HV harness connector
    Informational PurposesAn informational icon, calling your attention
    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
  111. Remove the FDU HV harness connector from the FDU and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  112. Remove bolt securing FDU ground strap to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  113. Remove FDU ground strap harness clip from FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  114. Loosen bolt securing FDU ground strap to HV battery and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  115. Disconnect FDU oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  116. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  117. Install hydraulic hub puller onto LH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  118. Separate the LH axle from the hub assembly and move axle aside
    Informational PurposesAn informational icon, calling your attention
    Note
    Turn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
  119. Remove the hydraulic hub puller from the LH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  120. Install hydraulic hub puller onto RH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  121. Separate the axle from the hub assembly and move axle aside
    Informational PurposesAn informational icon, calling your attention
    Note
    Turn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
  122. Remove the hydraulic hub puller from the RH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  123. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  124. Move the subframe lifting tool underneath the front subframe area
  125. Connect air supply to subframe lifting tool
  126. Position and support the front subframe with subframe lifting tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Latch the subframe to subframe lifting tool, Make sure to align the two guides
  127. Position the rear FDU support posts to the FDU
    Informational PurposesAn informational icon, calling your attention
    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
  128. Remove bolt securing the LH motor mount to the LH motor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 105 Nm
  129. Remove bolt securing the RH motor mount to the RH motor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 105 Nm
  130. Remove bolt securing LH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  131. Remove bolt securing RH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  132. Remove LH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm, Discard after removal
  133. Remove RH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm, Discard after removal
  134. Remove LH smaller bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  135. Remove RH smaller bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  136. Remove LH larger bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm, Discard after removal
  137. Remove RH larger bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm, Discard after removal
  138. Lower the subframe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  139. Disconnect air supply from subframe lifting tool
  140. Remove subframe lifting tool from under vehicle
  141. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  142. Position the oil drain container under hydraulic control unit area
  143. Disconnect the hydraulic control unit connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Disengage locking tab and pull up on connector to release
  144. Remove the RH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  145. Remove the LH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  146. Remove the RH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  147. Remove the LH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  148. Remove the front brake line bundle clip around the LH front rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  149. Remove the master cylinder brake lines from the 4 tube bundle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  150. Remove RH front brake line from front brake line bundle clip around the LH front rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x brake line
  151. Move brake lines away from hydraulic control unit
  152. Remove the oil drain container from underneath vehicle
  153. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  154. Remove the thermal beam hose clips from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  155. Position the oil drain under front brake line junction area
  156. Release bottom side brake pipe from coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
  157. Release top side brake pipe from coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
  158. Release top side brake pipe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Slide brake pipe back and release from clip
  159. Release bottom side brake pipe from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Slide brake pipe back and release from clip
  160. Position the oil drain under LH front brake hose area
  161. Remove the nut securing LH front brake line to LH front brake hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  162. Remove the LH front brake line clip from body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  163. Position the oil drain under front RH front brake hose
  164. Remove the RH front brake line tube nut from RH front brake hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  165. Remove the RH front brake line clips from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  166. Remove the oil drain from underneath vehicle
  167. Release coolant hose clip on the LH fender
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  168. Remove the front brake line bundle clip from LH body rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  169. Remove the LH front side 3 bundle brake lines from the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the front brake line bundle out of steering column area, then route it through LH front wheel liner and front subframe area
  170. Release clips securing HV cables to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x barrel clips
  171. Remove HV battery front manifold hose clips from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Newer vehicles may be equipped with 1x clip
  172. Release coolant hose from the right side subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  173. Release coolant hose from the right side body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  174. Remove the clips securing RH front brake line to body
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  175. Remove the RH front brake line from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the brake line out of steering column area, then move toward RH side, and remove it out between the front subframe area
  176. Remove the RH front brake line from new front brake line bundle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips

Install

  1. Position the RH front brake line to vehicle for installation
    Informational PurposesAn informational icon, calling your attention
    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.
  2. Install the clips securing RH front brake line to body
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  3. Secure the right side coolant hose to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  4. Secure the right side coolant hose to the subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  5. Secure coolant hoses to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x barrel clips
  6. Install HV battery front manifold hose clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Newer vehicles may be equipped with 1x clip
  7. Secure the HV cables to the body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x barrel clips
  8. Install the left side 3 bundle brake line into the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the front brake line bundle through LH front wheel liner and front subframe area, then route it to LH frame rail area.
  9. Install coolant hose to the LH fender
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  10. Install the front brake line bundle clip to LH body rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  11. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  12. Install the RH front brake line tube nut to RH front brake hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  13. Install the RH front brake line clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  14. Install the nut securing LH front brake line to LH front brake hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  15. Install the LH front brake line clip to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  16. Install top side brake pipe to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Insert brake pipe into coupling and secure to clip
  17. Install bottom side brake pipe to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Insert brake pipe into coupling and secure to clip
  18. Install top side brake pipe to coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
  19. Install bottom side brake pipe to coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm, 1x coupling, 13mm, 16 Nm
  20. Install the thermal beam hose clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  21. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  22. Install RH front brake line to front brake line bundle clip around the LH front rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x brake line
  23. Install the master cylinder brake lines to 4 tube bundle clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  24. Install the front brake line bundle clip around the LH front rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  25. Move master cylinder lines into position for installation
  26. Install the LH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  27. Install the RH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  28. Install the LH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  29. Install the RH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  30. Connect the hydraulic control unit connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Gently push connector downward, Engage locking tab
  31. Position shock tower brace assembly back for installation
  32. Install fasteners for LH side of shock tower brace
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
  33. Torque fasteners for RH side of shock tower brace
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
  34. Install 12V battery into vehicle
  35. Position battery tie down strap onto the battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Hook the upper tie down strap into the rear tie down hook strap and position for installation
  36. Install bolt securing upper tie down strap to the AC compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 5 Nm
  37. Install vent tube hose in 12V battery
  38. Install positive terminal and terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 2x clips
  39. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  40. Position lifting tool and subframe under vehicle for installation
  41. Connect air supply to subframe lifting tool
  42. Install bolt securing the RH motor mount to the RH motor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 105 Nm, May need adjust subfame jig to align mount with bolt hole
  43. Install bolt securing the LH motor mount to the LH motor mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E18, 105 Nm, May need adjust subfame jig to align mount with bolt hole
  44. Raise support tool until the front subframe and body meet
    Informational PurposesAn informational icon, calling your attention
    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
  45. Loosely install the RH larger bolt securing rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm, Install new bolt
  46. Loosely install the LH larger bolt securing rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm, Install new bolt
  47. Loosely install the RH smaller bolt securing rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Install new bolt
  48. Loosely install the LH smaller bolt securing rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Install new bolt
  49. Loosely install RH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
  50. Loosely install LH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm, Install new bolt, Adjust subframe lifting tool if necessary
  51. Loosely install bolt securing the RH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Install new bolt
  52. Loosely install bolt securing the LH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm, Install new bolt
  53. Loosely install the bolts securing front end carrier to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 16 Nm
  54. Loosely install the bolts securing front front end carrier to LH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 16 Nm
  55. Torque the RH larger bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm
  56. Torque the LH larger bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 125 Nm
  57. Torque the RH smaller bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  58. Torque the LH smaller bolt securing the rear portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  59. Torque the RH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm
  60. Torque the LH bolt securing the front portion of the front subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 72 Nm
  61. Torque the bolt securing the RH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  62. Torque the bolt securing the LH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  63. Torque the bolts securing securing front subframe to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  64. Torque the bolts securing LH front subframe crash can assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  65. Torque the bolts securing front end carrier to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 16 Nm
  66. Torque the bolts securing front end carrier to LH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 16 Nm
  67. Lower the subframe lifting tool from the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Unlatch the subframe lifting tool from front subframe
  68. Disconnect air supply from subframe lifting tool
  69. Remove the subframe lifting tool from vehicle
  70. Apply Molykote M-77 to outboard side of RH front halfshaft assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary, Apply no more than 1 gram to axle only
  71. Loosely install RH front halfshaft into RH front hub assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, Install new nut and washer, Torqued at later step
  72. Apply Molykote M-77 to outboard side of LH front halfshaft assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean if necessary, Apply no more than 1 gram to halfshaft only
  73. Loosely install LH front halfshaft into the LH front hub assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, Install new nut and washer, Torqued at later step
  74. Install the RH front lower lateral link and loosely install bolt and nut securing RH strut to lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  75. Loosely install bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  76. Install the RH front lower comp link to front subframe
  77. Install bolt and nut securing RH front lower comp link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
  78. Torque bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  79. Install LH front lower lateral link and loosely install bolt and nut securing LH strut to lower lateral link
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  80. Loosely install bolts securing LH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  81. Install LH front lower comp link to front subframe
  82. Install bolt and nut securing LH front lower comp link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 115 Nm, Recommend assistance if necessary
  83. Torque bolts securing LH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 115 Nm
  84. Connect the FDU oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  85. Place FDU ground strap to original position and install bolt to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  86. Install FDU ground strap harness clip to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Make sure to properly route the ground strap
  87. Install bolt securing FDU ground strap to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  88. Install FDU HV harness connector to FDU
    Informational PurposesAn informational icon, calling your attention
    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
  89. Connect the FDU HV harness connector and lock the release lever
    Informational PurposesAn informational icon, calling your attention
    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
  90. Install bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  91. Connect harness located at LH front rail bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket, Image zoomed in for clarity
  92. Install upper harness clip onto lower harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  93. Install lower harness clip into subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  94. Connect the logic connectors below steering gear
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Engage locking tabs
  95. Connect horn assembly connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  96. Position coolant drain container below LH side of radiator
  97. Remove plugs and connect coolant inlet hose to LH side of radiator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  98. Position coolant drain container under RH side of FDU
  99. Remove plugs and connect coolant hose from coolant bottle to oil cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  100. Position coolant drain container underneath RH front of HV battery
  101. Remove plugs and connect FDU coolant inlet hose at the RH side of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  102. Remove coolant drain container from underneath vehicle
  103. Position the RH front stabar link assembly to front stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    May be necessary to pull down on the sway bar to allow the end link to engage
  104. Install nut securing front stabar to RH front stabar link assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
  105. Position LH front stabar link assembly to front stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    May be necessary to pull down on the sway bar to allow the end link to engage
  106. Install nut securing front stabar link to LH front stabar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 18mm, 98 Nm, Install new nyloc nut, Counter hold ball joint with T40, Mark with paint pen
  107. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  108. Position RH front tie rod end to RH front knuckle
  109. Install nut securing RH front tie rod end to RH front knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
  110. Position LH tie rod end to LH front knuckle
  111. Install nut securing LH front tie rod end to LH front knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 22mm, 180 Nm, Install new nyloc nut
  112. Install front fascia onto vehicle and secure front clips and both front corners
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Recommend assistance, Use caution not to damage headlamp or fender during installation
  113. Connect 12V harness for front fascia
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab
  114. Connect pedestrian warning harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip, Engage locking tab
  115. Install LH front wheel liner to vehicle
  116. Install LH front wheel liner clips securing LH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  117. Install LH front fender garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 3x tabs, Start at rear and maneuver into rocker panel, Be cautious not to bend front tabs going into front fascia
  118. Install RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  119. Install clips securing RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  120. Install RH front fender garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel
  121. Lower vehicle until tires are just above the ground
    Informational PurposesAn informational icon, calling your attention
    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
  122. Slide the intermediate shaft assembly downward to install it to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
  123. Install bolt securing the intermediate shaft assembly to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 18 Nm
  124. Connect the steering gear assembly connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Engage locking tab
  125. Fill brake bleeder reservoir to full level
  126. Clean area around brake fluid reservoir and remove brake reservoir cap
  127. Top off brake fluid reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    Top off brake fluid as needed
  128. Install pressure bleeder adapter onto reservoir
  129. Set brake bleed reservoir pressure to 30 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
  130. Connect to vehicle using Toolbox 3.0
  131. Select Actions/Autodiag and search for "bleed"
  132. Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  133. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  134. Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  135. Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  136. Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  137. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  138. Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  139. Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  140. Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  141. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  142. Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  143. Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  144. Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  145. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  146. Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  147. Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  148. Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
  149. Remove pressure bleeder adapter from reservoir
  150. Check fluid level
    Informational PurposesAn informational icon, calling your attention
    Note
    Top off if necessary
  151. Install brake reservoir cap
  152. Pump the brake pedal a few times to ensure the brake pedal feels normal
  153. Using Toolbox 3:
    1. Select the Actions tab and search for "Stiffness".
    2. Select the ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICESearch for routine in ToolboxChassis / Brakes - Brake Stiffness Test, 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.
      Informational PurposesAn informational icon, calling your attention
      Note
      Do not press the brake pedal during the test.
  154. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  155. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  156. Install LH front wheel liner to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  157. Install RH front wheel liner to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  158. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  159. Position the front aero shield to vehicle and install nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  160. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  161. Install LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  162. Install LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  163. Install RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  164. Install RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  165. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  166. Torque LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  167. Torque LH front halfshaft nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 300 Nm
  168. Torque RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  169. Torque RH front halfshaft nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 300 Nm
  170. Torque RH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  171. Torque LH rear wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  172. Install LH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  173. Install RH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  174. Install RH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  175. Install LH rear wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  176. Remove coolant bottle cap
  177. Place empty coolant container into front storage area
  178. Fill container with at least 15L of coolant
  179. Place filled coolant container into front storage area
  180. Place coolant refill hose inside filled coolant container and make sure end is fully submerged
  181. Install vacuum refill cap onto coolant bottle assembly
  182. Close air inlet and coolant refill valves
  183. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  184. Place end of overflow hose into empty container
  185. Place coolant refill hose inside filled coolant container and make sure end is fully submerged
  186. Connect shop air supply to vacuum tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Minimum pressure 5.5 bar (80 psi)
  187. Open air inlet valve for 10 seconds to create a vacuum, then fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    The vacuum should stabilize at approximately -27 to -24 inHg or -70 to -60 cmHg.
  188. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    This purges trapped air from the hose
  189. Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
  190. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  191. Slowly open the coolant refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure end of coolant refill hose is fully submerged during entire process
  192. Once the gauge reads zero, close the coolant refill valve
  193. Disconnect shop air supply from coolant refill tool
  194. Remove coolant refill hose from coolant container
  195. Remove coolant overflow hose from coolant container
  196. Remove vacuum refill hose from refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Push down on black ring to release hose and pull hose up to remove
  197. Lift the coolant refill tool above coolant container to allow excess coolant to drain from hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    May need to reopen valves to remove all coolant
  198. Remove both coolant containers from inside underhood area
  199. Connect first responder loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
  200. Remove the steering wheel holder
  201. Connect to vehicle using Toolbox 3.0
  202. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
  203. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  204. Install coolant bottle cap
  205. Select ‘Actions/Autodiag’ and search for ‘Thermal Performance’
  206. Select ‘TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCESearch for routine in Toolbox’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete.
  207. Install frunk assembly into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, Replace any clips if broken or missing
  208. Install fasteners securing the frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck
  209. Install access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x connector
  210. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  211. Close hood
  212. Reposition 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide cushion rearward then align with buckles and foam with seat rail, Make sure cushion is fully seated with push & pull test
  213. Move RH front seat to original position
  214. Move LH front seat to original position
  215. Raise all windows
  216. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing
  217. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  218. Lower the alignment rack partially and set onto locks
  219. Latch the driver seat belt to buckle
  220. Latch LH front door and place vehicle into neutral
    Informational PurposesAn informational icon, calling your attention
    Note
    Careful not to slam the door while latch is engaged
  221. Install alignment heads onto wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  222. Enter vehicle information to alignment machine
  223. Perform rolling compensation
    Informational PurposesAn informational icon, calling your attention
    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
  224. Unlock alignment slip/turn plates
  225. Verify chassis height measurement tool is calibrated
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust if necessary, Measure height of tool and adjust reading to match
  226. Perform ride height measurement
    Informational PurposesAn informational icon, calling your attention
    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
  227. Apply brake pedal depressor
  228. Perform caster sweep and install steering wheel holder and level tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If camber and caster are out of specification, perform necessary camber and caster adjustment
  229. Verify alignment reading is within specification and print vehicle summary
  230. Remove alignment heads from wheels
    Informational PurposesAn informational icon, calling your attention
    Note
    4x alignment heads
  231. Remove brake pedal depressor
  232. Lock alignment slip/turn plates
  233. Lower the alignment rack to ground
  234. Unlatch the driver door, place vehicle in park and remove steering wheel leveler and steering wheel holder
  235. Unlatch LH front seat belt
  236. Remove wheel chocks
  237. Remove vehicle from alignment rack
  238. Perform test drive
    Informational PurposesAn informational icon, calling your attention
    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