2026-04-01

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

Correction code 30010312 4.14 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. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-03-31: Added the rivet nut check/installation step.
  • 2025-08-21: Updated torque spec for the bolts that attach the steering gear assembly to the front subframe (47 Nm).
  • 2025-05-21: Updated torque spec for the bolts securing LH/RH front lower lateral link to front subframe (135 Nm).
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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.

Remove

  1. Raise and support vehicle
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    Note
    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
  2. Open all four doors and lower all windows
  3. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)
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    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
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. 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
  7. Move LH front seat backward
  8. Set steering wheel straight ahead
  9. Lock steering wheel into position
  10. Open hood
  11. Remove rear apron
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    Note
    14x clips
  12. Remove access panel
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    Note
    3x clips, 1x connector
  13. Remove fasteners securing the frunk assembly
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    Note
    5x bolts, 10mm, 5 Nm
  14. Remove frunk assembly from vehicle
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    Note
    4x clips, Replace any clips if broken or missing
  15. Remove fasteners holding upper portion of front fascia to vehicle
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    Note
    5x bolts, 10mm, 4 Nm
  16. Remove bolt securing the steering gear assembly to intermediate shaft assembly
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    Note
    1x bolt, 13mm, 18 Nm
  17. Slide the electric steering column upward to remove it from the steering gear assembly
  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
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    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. 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
  21. Remove all items from pockets and ensure not wearing metal items
  22. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
  23. 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
  24. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, E10 5-Lobe, 6 Nm, Discard after removal
  25. Remove the ancillary bay probe lid cover from the ancillary bay cover
  26. 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
  27. 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
  28. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
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    Note
    2x bolts, E10 5-Lobe, 6 Nm, Install new rubber washer bolts
  29. Remove HV insulating gloves
  30. Remove LH front wheel cap
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    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  31. Remove RH front wheel cap
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    Note
    1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
  32. Loosen RH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  33. Loosen LH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  34. Loosen LH front halfshaft nut
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    Note
    1x nut, 32mm, 245 Nm
  35. Loosen RH front halfshaft nut
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    Note
    1x nut, 32mm, 245 Nm
  36. Raise vehicle fully and lower lift onto locks
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    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
  37. Remove outer fasteners from front aero shield
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    Note
    7x bolts, 10mm, 5 Nm
  38. Remove remaining nuts and remove front aero shield from vehicle
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    Note
    2x nuts, 15mm, 5 Nm
  39. Release LH front wheel liner from HV battery
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    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  40. Release RH front wheel liner from HV battery
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    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  41. Lower vehicle partially and set lift onto locks
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  42. Remove LH front wheel
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    Note
    5x nuts, 21mm, 175 Nm
  43. Remove LH front halfshaft nut and washers
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    Note
    1x nut, 32mm, 245 Nm, The washers are attached to the nut, Discard after removal
  44. Remove LH front fender garnish
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    Note
    11x clips, 1x push clip, 3x tabs, Release front clip first and work around to the end of the garnish
  45. Remove bolt securing LH side of fascia to fender
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    Note
    1x bolt, 10mm, 4 Nm
  46. Remove clips securing LH front wheel liner to vehicle
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    Note
    14x clips
  47. Remove LH front wheel liner from vehicle
  48. Remove bolt securing LH front wheel speed sensor to knuckle
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    Note
    1x bolt, 10mm, 5 Nm, Discard fastener after removal
  49. Remove LH front wheel speed sensor harness from knuckle and move aside
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    Note
    2x harness clips
  50. Remove nut securing the LH tie rod end to the knuckle
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    Note
    1x nyloc nut, 22mm, 180 Nm, Discard after removal
  51. Remove LH tie rod end from knuckle
  52. Remove RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  53. Remove RH front halfshaft nut and washers
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm, The washers are attached to the nut, Discard after removal
  54. Remove RH front fender garnish
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips,1x push clip, 3x tabs, Release front clip first and work around to the end of the garnish
  55. Remove bolt securing RH side of fascia to fender
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    Note
    1x bolt, 10mm, 4 Nm
  56. Remove clips securing RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  57. Remove RH front wheel liner from vehicle
  58. Remove bolt securing RH front wheel speed sensor to knuckle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  59. Remove RH front wheel speed sensor harness from knuckle and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    2x harness clips
  60. 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
  61. Remove RH tie rod end from knuckle
  62. 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
  63. 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
  64. Release both front corners then release front of front fascia by pulling upward and away from vehicle and place onto padded surface
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    Note
    8x clips, Recommend assistance, Use caution not to damage headlamp or fender during removal
  65. Remove bolts securing front end carrier to LH front subframe crash can assembly
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    Note
    2x bolts, 13mm, 16 Nm
  66. Remove bolts securing front end carrier to RH front subframe crash can assembly
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    Note
    2x bolts, 13mm, 16 Nm
  67. 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
  68. Remove nut securing front stabar link to LH front stabar
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    Note
    1x nyloc nut, 18mm, 98 Nm, Counter hold ball joint with T40, Discard after removal
  69. 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
  70. 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
  71. Move RH front stabar link assembly aside
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    Note
    May be necessary to pull down on the sway bar to allow the end link to disengage
  72. 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
  73. Move the LH front lower comp link aside
  74. Remove bolts securing LH front lower lateral link to front subframe
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    Note
    2x bolts, 21mm, 135 Nm
  75. Remove bolt and nut securing LH strut to LH front lower lateral link
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    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  76. 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
  77. Move the RH front lower comp link aside
  78. Remove bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 135 Nm
  79. 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
  80. Loosen the bolts 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
  81. Loosen the bolts 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
  82. Position coolant drain container underneath RH front of HV battery
  83. Disconnect FDU coolant inlet hose at RH front of HV battery and plug both hose ends
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    Note
    1x spring clip
  84. Place coolant drain container below RH side of FDU
  85. Disconnect coolant hose from the FDU oil cooler to the coolant bottle and allow coolant to drain
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    Note
    1x spring clip
  86. Install plugs to both open coolant hose connections
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    Note
    1x spring clip
  87. Position coolant drain container below LH side of radiator
  88. Disconnect FDU coolant inlet hose at LH side of radiator and plug both ends
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    Note
    1x spring clip
  89. Remove coolant drain container from underneath vehicle
  90. Disconnect connectors from horn assembly
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    Note
    2x connectors
  91. 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
  92. Release harness clip from subframe assembly
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    Note
    1x clip, Image zoomed out for location reference
  93. Release harness clip from lower clip
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    Note
    1x clip
  94. Disconnect harness from LH front rail bracket
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    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
  95. Remove bolt securing FDU HV harness to the FDU
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    Note
    1x bolt, 10mm, 10 Nm
  96. Disconnect the FDU HV harness connector
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    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
  97. Remove the FDU HV harness connector from the FDU and move aside
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    Note
    1x connector
  98. Remove bolt securing FDU ground strap to FDU
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    Note
    1x bolt, 10mm, 6 Nm
  99. Remove FDU ground strap harness clip from FDU
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    Note
    1x clip
  100. Loosen bolt securing FDU ground strap to HV battery and move aside
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    Note
    1x bolt, 10mm, 10 Nm
  101. 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
  102. Install hydraulic hub puller onto LH wheel studs
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    Note
    5x nuts, 21mm, Hand tight
  103. Separate the LH axle from the hub assembly and move axle aside
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    Note
    Turn the screw clockwise to separate the axle from the hub, Counter hold so the tool and hub does not free spin
  104. Remove the hydraulic hub puller from the LH wheel studs
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    Note
    5x nuts, 21mm, Hand tight
  105. Install hydraulic hub puller onto RH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  106. 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
  107. Remove the hydraulic hub puller from the RH wheel studs
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, Hand tight
  108. 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
  109. Move the subframe lifting tool underneath the front subframe area
  110. Connect air supply to subframe lifting tool
  111. Position and support the front subframe with subframe lifting tool
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    Note
    Recommend assistance, Latch the subframe to subframe lifting tool, Make sure to align the two guides
  112. Position the rear FDU support posts to the FDU
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    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
  113. 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
  114. Remove bolt securing the RH motor mount to the RH motor mount bracket
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    Note
    1x bolt, E18, 105 Nm
  115. Remove bolt securing LH mid mount to body
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    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  116. Remove bolt securing RH mid mount to body
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    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  117. Remove LH bolt securing the front portion of the front subframe to body
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    Note
    1x bolt, 18mm, 72 Nm, Discard after removal
  118. Remove RH bolt securing the front portion of the front subframe to body
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    Note
    1x bolt, 18mm, 72 Nm, Discard after removal
  119. Remove LH smaller bolt securing the rear portion of the front subframe to body
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    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  120. Remove RH smaller bolt securing the rear portion of the front subframe to body
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    Note
    1x bolt, 15mm, 50 Nm, Discard after removal
  121. Remove LH larger bolt securing the rear portion of the front subframe to body
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    Note
    1x bolt, 21mm, 125 Nm, Discard after removal
  122. Remove RH larger bolt securing the rear portion of the front subframe to body
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    Note
    1x bolt, 21mm, 125 Nm, Discard after removal
  123. Lower the subframe from vehicle
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    Note
    Recommend assistance
  124. Disconnect air supply from subframe lifting tool
  125. Remove subframe lifting tool from under vehicle
  126. Remove outer bolts securing steering gear assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 47 Nm
  127. Remove inner bolts securing steering gear assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 18mm, 75 Nm
  128. Remove the steering gear assembly from front subframe
  129. Remove the LH front axle shaft from the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x axle, Position cable around axle and use slide hammer to release from DU
  130. Remove the RH front axle shaft from the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x axle, Position cable around axle and use slide hammer to release from DU
  131. Disconnect the FDU inverter logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab then push the handle downward to release connector
  132. Remove the FDU harness clips from the inverter
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  133. Remove FDU harness clips from LH side of front subframe
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    Note
    3x clips
  134. Remove FDU harness clips in front of front subframe
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    Note
    2x clips
  135. Remove FDU harness clips from RH side of front subframe
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    Note
    3x clips
  136. Remove the FDU harness clip from the motor
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    Note
    1x clip
  137. Disconnect the resolver logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release red locking tab, Press down on locking tab then release connector
  138. Disconnect oil pump connector
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    Note
    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector
  139. Remove FDU harness from front subframe
  140. Remove LH nuts securing front stabar to front subframe
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    Note
    2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance
  141. Remove RH nuts securing front stabar to front subframe and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nyloc nuts, 15mm, 35 Nm, Discard after removal, Recommend assistance
  142. Remove bolts securing front subframe to LH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  143. Remove bolts securing front subframe to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  144. Remove bolt securing horn assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 12 Nm
  145. Release clip securing inverter hose to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  146. Position the front subframe assembly under gantry
  147. Install the drive unit sling onto the gantry hook
  148. Install the drive unit sling onto the FDU
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    Note
    3x FDU connections
  149. Raise gantry hook to put tension onto the sling
  150. Remove the front FDU mount bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm
  151. Lift the FDU up and away from the front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the rear FDU support posts are not moved out of their current position
  152. Remove the straps securing the front subframe to the subframe jig
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    Note
    3x straps
  153. Remove the front subframe from subframe lifting tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance

Install

  1. Position the front subframe to subframe lifting tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Make sure the 2x guides align
  2. Install straps securing the front subframe to subframe lifting tool
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    Note
    3x straps
  3. Verify the attachment point for the triumph horn on the new front subframe assembly. If the M6 rivet nut is missing, install a rivet nut (1129125-00-B) onto the front subframe assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommended Tool: 1054712-00-A Rivet Nut Setter Kit
  4. Lower the FDU into the front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the rear FDU support posts are in the same location when the FDU was lifted
  5. Install the FDU mount bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 80 Nm, May need to adjust gantry to ease install
  6. Lower gantry hook to relieve tension on the drive unit sling
  7. Remove the drive unit sling from the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    3x FDU connections
  8. Remove the drive unit sling from the gantry hook
  9. Remove the front subframe assembly from the gantry area
    Informational PurposesAn informational icon, calling your attention
    Note
    Return subframe and lifting tool to the vehicle work area
  10. Secure inverter hose to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  11. Install FDU harness to front subframe
  12. Install the FDU harness clip to the motor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  13. Connect the resolver logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  14. Connect the oil pump connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Install locking tab after the connector is fully seated, Perform push-pull test after locking tab is seated
  15. Install FDU harness clips to RH side of front subframe
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    Note
    3x clips
  16. Install FDU harness clips to front of front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  17. Install FDU harness clips to LH side of front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  18. Install the FDU harness clips to the inverter
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  19. Connect the FDU inverter logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  20. Install bolt securing horn assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 12 Nm
  21. Loosely install 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
  22. Loosely install the bolts securing front subframe to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  23. Position the front stabar to front subframe and install the RH nuts securing it to subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nyloc nuts, 15mm, 35 Nm, Recommend assistance, Install new nyloc nuts, Mark with paint pen
  24. Install the LH nuts securing the front stabar to the front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nyloc nuts, 15mm, 35 Nm, Install new nyloc nuts, Mark with paint pen
  25. Install the RH front axle shaft into the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x axle
  26. Install the LH front axle shaft into the FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x axle
  27. Position the steering gear assembly to front subframe for installation
  28. Loosely install inner bolts securing the steering gear assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 18mm, 75 Nm
  29. Install outer bolts securing the steering gear assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 47 Nm
  30. Torque inner bolts securing the steering gear assembly to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 18mm, 75 Nm
  31. Position lifting tool and subframe under vehicle for installation
  32. Connect air supply to subframe lifting tool
  33. 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 subframe jig to align mount with bolt hole
  34. 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 subframe jig to align mount with bolt hole
  35. 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
  36. 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
  37. 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
  38. 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
  39. 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
  40. 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
  41. 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
  42. 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
  43. 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
  44. 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
  45. Loosely install 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
  46. 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
  47. 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
  48. 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
  49. 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
  50. 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
  51. 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
  52. Torque the bolt securing the RH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  53. Torque the bolt securing the LH mid mount to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 15mm, 50 Nm
  54. Torque the bolts securing front subframe to RH front subframe crash can assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 53 Nm
  55. 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
  56. 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
  57. 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
  58. Lower the subframe lifting tool from the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Unlatch the subframe lifting tool from front subframe
  59. Disconnect air supply from subframe lifting tool
  60. Remove the subframe lifting tool from vehicle
  61. 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
  62. 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
  63. 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
  64. 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
  65. 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
  66. Loosely install bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 135 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  67. Install the RH front lower comp link to front subframe
  68. 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
  69. Torque bolts securing RH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 135 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  70. 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
  71. Loosely install bolts securing LH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 135 Nm, Recommend assistance if necessary, Use punch tool to align the fasteners
  72. Install LH front lower comp link to front subframe
  73. 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
  74. Torque bolts securing LH front lower lateral link to front subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 21mm, 135 Nm
  75. 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
  76. 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
  77. Install bolt securing FDU ground strap to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  78. 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
  79. 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
  80. Install bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  81. 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
  82. Install upper harness clip onto lower harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  83. Install lower harness clip into subframe
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  84. Connect the logic connectors below steering gear
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Engage locking tabs
  85. Connect connectors to horn assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  86. Position coolant drain container below LH side of radiator
  87. Remove plugs and connect coolant inlet hose to LH side of radiator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  88. Position coolant drain container under RH side of FDU
  89. Remove plugs and connect coolant hose from coolant bottle to oil cooler
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  90. Position coolant drain container underneath RH front of HV battery
  91. 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
  92. Remove coolant drain container from underneath vehicle
  93. 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
  94. 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
  95. 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
  96. 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
  97. 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
  98. Position RH front tie rod end to RH front knuckle
  99. 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
  100. Position LH tie rod end to LH front knuckle
  101. 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
  102. 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
  103. Connect 12V harness for front fascia
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab
  104. Connect pedestrian warning harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip, Engage locking tab
  105. Install bolt securing RH side of fascia to fender
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 4 Nm
  106. Install RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  107. Install clips securing RH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  108. 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
  109. Install RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Torque at later step
  110. Install bolt securing LH side of fascia to fender
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 4 Nm
  111. Install LH front wheel liner to vehicle
  112. Install LH front wheel liner clips securing LH front wheel liner to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  113. Install LH 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
  114. Install LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm, Torque at later step
  115. 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
  116. Install LH front wheel liner to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  117. Install RH front wheel liner to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x bolt, 10mm, 5 Nm
  118. Position the front aero shield to vehicle and install nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  119. 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
  120. 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
  121. Install fasteners holding upper portion of front fascia to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 4 Nm
  122. Connect the steering gear assembly connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Engage locking tab
  123. 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
  124. 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
  125. 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
  126. Torque RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  127. Torque LH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  128. Torque LH front halfshaft nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm
  129. Torque RH front halfshaft nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 32mm, 245 Nm
  130. Install RH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  131. Install LH front wheel cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap, Align valve stem with wheel cap cavity
  132. Remove coolant bottle cap
  133. Place empty coolant container into front storage area
  134. Fill container with at least 15L of coolant
  135. Place filled coolant container into front storage area
  136. Place coolant refill hose inside filled coolant container and make sure end is fully submerged
  137. Install vacuum refill cap onto coolant bottle assembly
  138. Close air inlet and coolant refill valves
  139. 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
  140. Place end of overflow hose into empty container
  141. Place coolant refill hose inside filled coolant container and make sure end is fully submerged
  142. Connect shop air supply to vacuum tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Minimum pressure 5.5 bar (80 psi)
  143. Open air inlet valve for 10 seconds to create a vacuum, then fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (24-27Hg)
  144. 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
  145. Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
  146. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  147. 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
  148. Once the gauge reads zero, close the coolant refill valve
  149. Disconnect shop air supply from coolant refill tool
  150. Remove coolant refill hose from coolant container
  151. Remove coolant overflow hose from coolant container
  152. 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
  153. 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
  154. Remove both coolant containers from inside underhood area
  155. Connect first responder loop and 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 1x connector, Connect FRL first before connecting 12V to avoid damage to car computer
  156. Remove the steering wheel holder
  157. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
    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. 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.
  158. 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
  159. Install coolant bottle cap
  160. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "X" at top right of window to close once complete.
  161. Install frunk assembly into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Replace any clips if broken or missing
  162. Install fasteners securing the frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 5 Nm
  163. Install access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x connector
  164. 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
  165. Close hood
  166. Move RH front seat to original position
  167. 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
  168. Move LH front seat to original position
  169. Raise all windows
  170. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Unlatch rear doors before closing
  171. 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
  172. Check tire pressures
    Informational PurposesAn informational icon, calling your attention
    Note
    4x tires, Set to specification if necessary, Refer to the "Tire and Loading Information" label located on the driver side B-pillar
  173. Verify the alignment slip/turn plates are locked
  174. Drive vehicle onto alignment rack
  175. Torque bolt and nut securing LH strut to lower control arm
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 1x nut, 21mm, 106 Nm
  176. Torque 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
  177. 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 correction code as a separate activity to the SV. See Alignment Requirement - Suspension.