Subframe Assembly - Front (Dual Motor) (Remove and Replace)

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 four doors

Note

Latch rear doors to prevent accidental closing when power is down

Lower all windows

Connect to vehicle using Toolbox 3.0

Note

Vehicle connection is integrated into drivers footwell cover. Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)

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 LH front seat forward

Move RH front seat 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 LH front seat backward

Set steering wheel straight ahead

Lock steering wheel into position

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

Remove frunk assembly from vehicle

Note

4x clips, Replace any clips if broken or missing

Remove fasteners holding upper portion of front fascia to vehicle

Note

5x bolts, 10mm, 4 Nm

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

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

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.

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, E10 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, E10 5-Lobe, 6 Nm, Install new rubber washer bolts

Remove HV insulating gloves

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

Loosen RH front wheel

Note

5x nuts, 21mm, 175 Nm

Loosen LH front wheel

Note

5x nuts, 21mm, 175 Nm

Loosen LH front halfshaft nut

Note

1x nut, 32mm, 245 Nm

Loosen RH front halfshaft nut

Note

1x nut, 32mm, 245 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, 245 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 front clip first and work around to the end of the garnish

Remove bolt securing LH side of fascia to fender

Note

1x bolt, 10mm, 4 Nm

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, 245 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 front clip first and work around to the end of the garnish

Remove bolt securing RH side of fascia to fender

Note

1x bolt, 10mm, 4 Nm

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

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 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 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 FDU coolant inlet hose at LH side of radiator and plug both ends

Note

1x spring clip

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, 10mm, 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

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

Remove outer bolts securing steering gear assembly to front subframe

Note

2x bolts, 15mm, 27 Nm

Remove inner bolts securing steering gear assembly to front subframe

Note

2x bolts, 18mm, 75 Nm

Remove the steering gear assembly from front subframe

Remove the LH front axle shaft from the FDU

Note

1x axle, Position cable around axle and use slide hammer to release from DU

Remove the RH front axle shaft from the FDU

Note

1x axle, Position cable around axle and use slide hammer to release from DU

Disconnect the FDU inverter logic connector

Note

1x connector, Release locking tab then push the handle downward to release connector

Remove the FDU harness clips from the inverter

Note

2x clips

Remove FDU harness clips from LH side of front subframe

Note

3x clips

Remove FDU harness clips in front of front subframe

Note

2x clips

Remove FDU harness clips from RH side of front subframe

Note

3x clips

Remove the FDU harness clip from the motor

Note

1x clip

Disconnect the resolver logic connector

Note

1x connector, Release red locking tab, Press down on locking tab then release connector

Disconnect oil pump connector

Note

1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector

Remove FDU harness from front subframe

Remove LH nuts securing front stabar to front subframe

Note

2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance

Remove RH nuts securing front stabar to front subframe and remove from vehicle

Note

2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance

Remove bolts securing front subframe to LH front subframe crash can assembly

Note

2x bolts, 15mm, 53 Nm

Remove bolts securing front subframe to RH front subframe crash can assembly

Note

2x bolts, 15mm, 53 Nm

Remove bolt securing horn assembly to front subframe

Note

1x bolt, 10mm, 12 Nm

Release clip securing inverter hose to subframe

Note

1x clip

Position the front subframe assembly under gantry

Install the drive unit sling onto the gantry hook

Install the drive unit sling onto the FDU

Note

3x FDU connections

Raise gantry hook to put tension onto the sling

Remove the front FDU mount bolt

Note

1x bolt, 18mm, 80 Nm

Lift the FDU up and away from the front subframe

Note

Ensure the rear FDU support posts are not moved out of their current position

Remove the straps securing the front subframe to the subframe jig

Note

3x straps

Remove the front subframe from subframe lifting tool

Note

Recommend assistance

Position the front subframe to subframe lifting tool

Note

Recommend assistance, Make sure the 2x guides align

Install straps securing the front subframe to subframe lifting tool

Note

3x straps

Lower the FDU into the front subframe

Note

Ensure the rear FDU support posts are in the same location when the FDU was lifted

Install the FDU mount bolt

Note

1x bolt, 18mm, 80 Nm, May need to adjust gantry to ease install

Lower gantry hook to relieve tension on the drive unit sling

Remove the drive unit sling from the FDU

Note

3x FDU connections

Remove the drive unit sling from the gantry hook

Remove the front subframe assembly from the gantry area

Note

Return subframe and lifting tool to the vehicle work area

Secure inverter hose to subframe

Note

1x clip

Install FDU harness to front subframe

Install the FDU harness clip to the motor

Note

1x clip

Connect the resolver logic connector

Note

1x connector, Engage locking tab

Connect the oil pump connector

Note

1x connector, Install locking tab after the connector is fully seated, Perform push-pull test after locking tab is seated

Install FDU harness clips to RH side of front subframe

Note

3x clips

Install FDU harness clips to front of front subframe

Note

2x clips

Install FDU harness clips to LH side of front subframe

Note

3x clips

Install the FDU harness clips to the inverter

Note

2x clips

Connect the FDU inverter logic connector

Note

1x connector, Engage locking tab

Install bolt securing horn assembly to front subframe

Note

1x bolt, 10mm, 12 Nm

Loosely install the bolts securing LH front subframe crash can assembly to front subframe

Note

2x bolts, 15mm, 53 Nm

Loosely install the bolts securing front subframe to RH front subframe crash can assembly

Note

2x bolts, 15mm, 53 Nm

Position the front stabar to front subframe and install the RH nuts securing it to subframe

Note

2x nyloc nuts, 15mm, 35 Nm, Recommend assistance, Install new nyloc nuts, Mark with paint pen

Install the LH nuts securing the front stabar to the front subframe

Note

2x nyloc nuts, 15mm, 35 Nm, Install new nyloc nuts, Mark with paint pen

Install the RH front axle shaft into the FDU

Note

1x axle

Install the LH front axle shaft into the FDU

Note

1x axle

Position the steering gear assembly to front subframe for installation

Loosely install inner bolts securing the steering gear assembly to front subframe

Note

2x bolts, 18mm, 75 Nm

Install outer bolts securing the steering gear assembly to front subframe

Note

2x bolts, 15mm, 27 Nm

Torque inner bolts securing the steering gear assembly to front subframe

Note

1x bolt, 18mm, 75 Nm

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 subframe 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 subframe 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 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 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

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 connectors to horn assembly

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 bolt securing RH side of fascia to fender

Note

1x bolt, 10mm, 4 Nm

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

Install RH front wheel

Note

5x nuts, 21mm, 175 Nm, Torque at later step

Install bolt securing LH side of fascia to fender

Note

1x bolt, 10mm, 4 Nm

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

11x clips, 1x push clip, 3x tabs, Start at rear and maneuver into rocker panel

Install LH front wheel

Note

5x nuts, 21mm, 175 Nm, Torque at later step

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

Position the front aero shield to vehicle and install nuts

Note

2x nuts, 15mm, 5 Nm

Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note

7x bolts, 10mm, 5 Nm

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

Install fasteners holding upper portion of front fascia to vehicle

Note

5x bolts, 10mm, 4 Nm

Connect the steering gear assembly connectors

Note

2x locking connectors, Engage locking tab

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

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 RH front wheel

Note

5x nuts, 21mm, 175 Nm

Torque LH front wheel

Note

5x nuts, 21mm, 175 Nm

Torque LH front halfshaft nut

Note

1x nut, 32mm, 245 Nm

Torque RH front halfshaft nut

Note

1x nut, 32mm, 245 Nm

Install RH front wheel cap

Note

1x cap, Align valve stem with wheel cap cavity

Install LH front 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

Gauge stabilizes roughly (24-27Hg)

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, Connect FRL first before connecting 12V to avoid damage to car computer

Remove the steering wheel holder

Connect to vehicle using Toolbox 3.0

Note

Vehicle connection is integrated into drivers footwell cover. Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)

Select "TEST_VCFRONT_x005F_X_THERMAL-COOLANT-AIR-PURGE ", 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. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. 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 "[NS]STRKEY.TASKS.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.

Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle

Install frunk assembly into vehicle

Note

4x clips, Replace any clips if broken or missing

Install fasteners securing the frunk assembly

Note

5x bolts, 10mm, 5 Nm

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

Move RH front seat to original position

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 LH front seat to original position

Raise all windows

Close all four doors

Note

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

Check tire pressures

Note

4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar

Verify the alignment slip/turn plates are locked

Drive vehicle onto alignment rack

Torque bolt and nut securing LH strut to lower control arm

Note

1x bolt, 21mm, 1x nut, 21mm, 106 Nm

Torque bolt and nut securing RH strut to lower control arm

Note

1x bolt, 21mm, 1x nut, 21mm, 106 Nm

Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.