2025-10-10

HV Battery (AWD) (7-Seat) (Remove and Install)

Correction code 16010231 3.96 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. See Ergonomic Precautions for safe and healthy working practices.

  • 2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
  • 2025-10-06: Removed redundant step to install LH footwell cover.
  • 2024-11-07: Added 3-phase harness disconnect/connect steps.
  • 2024-06-13: Updated lift pad adapter PNs.
  • 2023-11-21: Added new lift pad instructions.
  • 2023-08-29: Updated EPB Service Mode reference.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
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. Relmove the LH and RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
  2. Remove butyl patches covering LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Clean excess butyl from area
  3. Install lift pad adapters.
    • For EMEA only, install Adapter, Lift Pad, Model Y (1614078-00-A)
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT use any other lift pad adapters.
    Informational PurposesAn informational icon, calling your attention
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.
    Informational PurposesAn informational icon, calling your attention
    Note
    In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

    Instructions for Universal Lift Pad Adapters:

    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  4. Open all doors and lower the windows.
  5. Chock LH rear wheel.
  6. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  7. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Start Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
    via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    Informational PurposesAn informational icon, calling your attention
    Note
    This will ensure the octovalve is in the Series position, Coolant pumps will also be disabled. Once run is selected, the routine is in progress despite the prompt with loading circle. The routine will time out after several hours and will return valves to the parallel position if unattended. Select 'X' at top right of window to close once routine is complete.
  8. Remove the rear underhood apron.
  9. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  10. Move the LH front seat backward.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure profile is saved to allow seat position to be restored
  11. Remove screw and clips securing LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x screw, T20, 2.5 Nm
  12. Remove connectors from LH footwell cover and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x Ethernet connector, 1x puddle light connector
  13. Remove LH front floormat
  14. Remove LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x guide pins, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  15. Remove clip securing LH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  16. Fold LH front cabin carpet rearward
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver carpet below brake pedal and accelerator pedal, Newer Vins may be equipped with additional foam installed below carpet
  17. Remove foam plugs to access LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
  18. Remove both LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  19. Raise LH front seat cushion to maximum height
    Informational PurposesAn informational icon, calling your attention
    Note
    This will allow access to HV battery bolts at LH front foot well and below LH front seat
  20. Remove RH IP end cap
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  21. Remove RH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
  22. Remove clip securing RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  23. Remove RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release trim panel
  24. Move the RH front seat back.
  25. Remove clips securing RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, Clip count may vary depending on region
  26. Remove RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  27. Remove RH front floormat
  28. Remove RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  29. Remove clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  30. Fold RH front cabin carpet rearward
    Informational PurposesAn informational icon, calling your attention
    Note
    Newer Vins may be equipped with additional foam installed below carpet
  31. Remove foam plugs to access RH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
  32. Remove both RH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  33. Raise RH front seat cushion to maximum height
    Informational PurposesAn informational icon, calling your attention
    Note
    This will allow access to HV battery bolts at RH front foot well and below RH front seat
  34. Remove 2nd row floor mat from vehicle
  35. Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    Located below rear of RH front seat
  36. Remove RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm
  37. Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    Located below rear of LH front seat
  38. Remove LH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm
  39. Partially remove LH rear door seal
  40. Remove LH 7s lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips
  41. Fold down 2nd row 60 seatback assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Press button, fold forwards
  42. Move 60 seat forward using towel bar
    Informational PurposesAn informational icon, calling your attention
    Note
    With one hand on towel bar pull up and slide the seat forward with your other hand
  43. Remove 60 seat rear outboard track fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 11mm, 37 Nm, Discard after removal
  44. Remove 60 seat rear inboard track fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm, Discard after removal
  45. Move 60 seat fully rearward using towel bar
    Informational PurposesAn informational icon, calling your attention
    Note
    With one hand on towel bar pull up and slide the seat forward with your other hand
  46. Remove 60 seat outboard track cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Slide covers forward to release from 60 seat tracks
  47. Remove center track cover from 2nd row seats
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Slide covers forward to release from 2nd row seat tracks
  48. Release cabin carpet from 60 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull cabin carpet towards front of vehicle
  49. Remove 60 seat front inboard track fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolts, 11mm, 37 Nm, Discard after removal
  50. Remove 2nd row 60 seat frame front outboard track fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolts, 11mm, 37 Nm, Discard after removal
  51. Disconnect 2nd row 60 seat connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  52. Remove 2nd row 60 seat assembly from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  53. Partially remove RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Pillar and sill trim have tabs seated underneath seal
  54. Remove RH 7s lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips
  55. Remove 40 seat outboard track cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Slide cover forward to release from 40 seat track
  56. Release cabin carpet from 40 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull cabin carpet towards front of vehicle
  57. Remove bolts securing 40 seat podium to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
  58. Fold 2nd row 40 seat down
  59. Move 40 seat forward using towel bar
    Informational PurposesAn informational icon, calling your attention
    Note
    With one hand on towel bar pull up and slide the seat forward with your other hand
  60. Remove bolts securing 40 seat inner and outer tracks to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
  61. Move 40 seat fully rearward using towel bar
    Informational PurposesAn informational icon, calling your attention
    Note
    With one hand on towel bar pull up and slide the seat rearward with your other hand
  62. Disconnect 2nd row 40 seat connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  63. Remove 40 seat from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
  64. Position object beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    Use shop towel or similar
  65. Remove RH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
  66. Remove LH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  67. Power off the vehicle using the touchscreen.
  68. Disconnect the 12V negative battery cable and First Responder Loop.
  69. Make a slit in 3rd row carpet around LH seat belt
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
  70. Make a slit in 3rd row carpet around RH seat belt
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
  71. Move 3rd row carpet aside
  72. Move 3rd row NVH insulation aside
    Informational PurposesAn informational icon, calling your attention
    Note
    Use seatbelt or bungee strap as needed
  73. Empty all pockets and remove all metal objects such as watches and jewelery.
  74. Inspect the HV insulating gloves for any damage.
  75. Put on the HV insulating gloves and leather over gloves.
  76. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
  77. Remove ancillary bay probe lid cover from ancillary bay cover
  78. 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
  79. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm no visual damage present, Replace gasket if damage is found
  80. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
  81. Remove HV insulating gloves
  82. Remove bolt securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  83. Remove bolts securing charge port busbar kit to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  84. Lift busbar kit connector to remove from HV header
  85. If there is a 3-phase (AC) connection between the charge port and HV battery, disconnect it:
    1. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
    2. Fully raise the handle on the 3-phase connector.
    3. Remove the 3-phase connector from the ancillary bay 3-phase header.
  86. Disconnect the HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  87. Remove DCDC ground strap from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 15 Nm, Discard after removal
  88. Release positive 12V output cover from PCS cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  89. Remove PCS cable from 12V passthrough output
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 15 Nm, Discard nut after removal
  90. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closure
  91. Remove wheel chocks and push vehicle onto lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Replace wheel chocks once vehicle in correct position
  92. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
  93. Fully raise the vehicle, and then lower the lift onto the locks.
  94. Remove the outer fasteners from the front aero shield.
  95. Remove the remaining nuts (x2), and then remove the front aero shield from the vehicle.
  96. Release RH front wheel liner from HV battery and lower wheel well area
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x bolt, 10mm, 5 Nm
  97. Release LH front wheel liner from HV battery and lower wheel well area
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x bolt, 10mm, 5 Nm
  98. Remove bolts securing front skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP10, 13 Nm
  99. Remove skid plate from HV battery
  100. Disconnect both AC compressor and PTC heater HV harness connectors on HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
  101. Secure LH front wheel liner away from HV battery
  102. Secure RH front wheel liner away from HV battery
  103. Position coolant drain container underneath RH front of HV battery
  104. Disconnect PT return hose at RH side of vehicle and plug female side of hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x hose clip, 1x plug
  105. Disconnect rear PT supply hose at RH side of vehicle and plug male side of hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x hose clip, 1x plug
  106. Position coolant drain container underneath LH front of HV battery
  107. Disconnect HV battery return hose at LH side of vehicle and plug male side of hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug
  108. Position coolant drain container below HV battery manifold hose
  109. Remove HV battery front manifold hose clips from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Newer vehicles may be equipped with 1x clip
  110. Disconnect HV battery front manifold hose and plug both hose ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  111. Remove coolant drain container from underneath vehicle
  112. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
  113. Position support stand to support front portion of rear subframe
  114. Release clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  115. Remove smaller fasteners for LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  116. Remove large bolt securing LH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard at later step
  117. Hand tighten bolt securing LH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  118. Release clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  119. Remove smaller fasteners for RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  120. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard at later step
  121. Hand tighten bolt securing RH side of subframe to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  122. Remove support stand from under vehicle
  123. Release LH side hose clip from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  124. Release RH side hose clips from rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  125. Remove lower bolts securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm
  126. Remove upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  127. Remove upper bolts securing rear battery enclosure skid plate from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  128. Remove rear battery enclosure skid plate from HV battery pack
  129. Position coolant drain container underneath LH rear of HV battery
  130. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs
  131. Position coolant drain underneath RH rear of HV battery
  132. Remove nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  133. Disconnect RDU HV cable from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 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 RDU header are not damaged
  134. Place battery table into position and lower vehicle to support battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
  135. Remove central bolts securing HV battery through center ski cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm
  136. Remove bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  137. Remove bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  138. Remove LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  139. Remove RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  140. Raise vehicle to free from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  141. Remove battery from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  142. Remove ancillary bay perimeter seal from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard after removal

Install

  1. Install ancillary bay perimeter seal to HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new perimeter seal every time the HV battery is removed and reinstalled
  2. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  3. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  4. Install HV battery alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, Located on body at front of vehicle, 2x rods, Located at rear of HV battery near ancillary bay
  5. Lower vehicle onto HV battery and align holes
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
  6. Install bolts securing HV battery to body at LH shear plate area hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step
  7. Install bolts securing HV battery to body at RH shear plate area hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step
  8. Loosely install RH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  9. Loosely install LH bolts securing HV battery to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  10. Remove HV battery front alignment rods
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods
  11. Install bolts securing RH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  12. Install bolts securing LH front support bracket to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  13. Install central bolts securing HV battery through center ski cover hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm, Torque at later step
  14. Open LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  15. Remove HV battery alignment rod from LH rear inner bolt location
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rod
  16. Install LH rear inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
  17. Install LH middle inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  18. Close LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  19. Open LH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  20. Install both LH front inner HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  21. Close LH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  22. Open RH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  23. Remove HV battery alignment rod from RH rear inner bolt location
    Informational PurposesAn informational icon, calling your attention
    Note
    1x rod
  24. Install RH rear inner battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
  25. Install RH inner HV battery bolt hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  26. Close RH rear door
  27. Open RH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  28. Install both RH front inner HV battery bolts hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  29. Close RH front door
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch
  30. Lower vehicle onto pack completely
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  31. Torque RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  32. Torque LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm
  33. Torque bolts securing RH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  34. Torque bolts securing LH front support bracket to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm
  35. Torque central bolts securing HV battery through center ski cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm
  36. Raise vehicle and lower onto locks, then remove battery table from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, 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. Position support stand to support front section of rear subframe
  38. Install bolt and shear plate to LH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Torque at later step
  39. Install bolts securing LH rear shear plate to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step
  40. Torque bolt securing subframe and LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Mark bolt after torque
  41. Torque small fasteners securing LR rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  42. Install bolt and shear plate to RH side of rear subframe hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Torque at later step
  43. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step
  44. Torque bolt securing subframe and RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  45. Torque small fasteners securing RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm
  46. Remove support stand from under vehicle
  47. Install clips securing coolant hoses to RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  48. Install clips securing coolant hoses to LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  49. Connect RDU HV cable to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the 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
  50. Install nut securing RDU HV cable bracket to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  51. Position coolant drain underneath RH rear of HV battery
  52. Remove hose plugs and connect coolant outlet hose to rear PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary.Loss of coolant greater than 1L requires coolant vacuum fill
  53. Position coolant drain container underneath LH rear of HV battery
  54. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated,Loss of coolant greater than 1L requires coolant vacuum fill
  55. Remove coolant drain container from underneath vehicle
  56. Position rear battery enclosure skid plate to HV battery for installation
  57. Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step
  58. Install upper nut securing rear battery enclosure skid plate hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step
  59. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Torque at later step, Earlier vins may be equipped with additional bolts
  60. Torque bolts securing HV battery and rear skid plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm
  61. Torque upper nut securing rear battery enclosure skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm
  62. Install lower bolts securing HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Torque at later step, Earlier vins may be equipped with additional bolts
  63. Install RH side hose clips to rear battery skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  64. Install LH side hose clip to HV battery rear skid plate enclosure
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles
  65. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack has one less bolt and one extra clip
  66. Position coolant drain container underneath LH front of HV battery
  67. Remove plugs then connect HV battery coolant return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip,1x plug
  68. Position coolant drain container below HV battery manifold hose
  69. Remove plugs then connect HV battery front manifold coolant hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
  70. Install HV battery front manifold hose clips to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Newer vehicles may be equipped with 1x clip
  71. Position coolant drain container underneath RH front of HV battery
  72. Remove plugs then connect PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
  73. Remove plugs and connect PT return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
  74. Remove coolant drain container from underneath vehicle
  75. Connect both AC compressor and PTC heater HV harness connectors on HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
  76. Install FDU ground strap and bolt to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  77. Install FDU HV harness connector onto FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
  78. Connect FDU HV harness connector and lock release lever
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 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
  79. Install bolt securing FDU HV harness to FDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 10 Nm
  80. Install front skid plate onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Slide tabs onto front of HV battery
  81. Install the bolts securing the front skid plate to the HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP10, 13 Nm
  82. Release LH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  83. Install LH front wheel liner to HV battery and lower wheel well area
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x bolt, 10mm, 5 Nm
  84. Release RH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  85. Install RH front wheel liner to HV battery and lower wheel well area
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x bolt, 10mm, 5 Nm
  86. Position the front aero shield on the vehicle, and then install the nuts that attach the aero shield to the vehicle.
  87. Apply Loctite 222 on the front aero shield bolts, and then install the bolts on the aero shield.
  88. Lower vehicle fully and move rack arms away from vehicle
    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
  89. Push vehicle away from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
  90. Open all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closure
  91. Install positive 12V output
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 9 Nm, Install new nut, Make sure rubber boot is not pinched between cable terminal and pass through
  92. Install positive 12V output cover to PCS cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  93. Install nut securing DCDC ground strap to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 15 Nm, Install new nut
  94. Remove logic cap and connect the HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
  95. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  96. Position busbar kit connector and lower onto HV header
  97. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  98. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
  99. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  100. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  101. Remove HV insulating gloves
  102. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  103. If there is a 3-phase (AC) connection between the charge port and HV battery, connect it:
    1. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
    2. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Make sure that the connector fits the header squarely and tightly.
    3. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Make sure that the handle does not bind as it is lowered.
    4. Slide the release to lock the 3-phase connector handle in the secured position.
    5. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
      Informational PurposesAn informational icon, calling your attention
      Note
      An improperly seated connector might lead to connector damage and charging problems later on.
  104. Move 3rd row NVH insulation back into position
  105. Move 3rd row carpet back into position
  106. Install 2nd row 60 seat assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  107. Connect 2nd row 60 seat connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  108. Install fasteners securing 60 seat frame to body
    Informational PurposesAn informational icon, calling your attention
    Note
    5x patch bolts, 11mm, 37 Nm, Install new patch bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
  109. Install 40 seat into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
  110. Connect 2nd row 40 seat connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  111. Install bolts securing 40 seat podium to vehicle hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step
  112. Move 40 seat forward using towel bar
    Informational PurposesAn informational icon, calling your attention
    Note
    With one hand on towel bar pull up and slide the seat forward with your other hand
  113. Install bolts securing 40 seat inner and outer tracks to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm, Install new bolts
  114. Move 40 seat to original position
  115. Torque bolts securing 40 seat podium to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 11mm, 37 Nm
  116. Secure cabin carpet to 60 seat
    Informational PurposesAn informational icon, calling your attention
    Note
    Strap velcro on
  117. Install cabin carpet to 40 seat
  118. Install 60 seat outboard track cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  119. Install center track cover to 2nd row seats
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clip, Slide cover straight on to clip to 2nd row seat tracks
  120. Install 40 seat outboard track cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  121. Install RH 7s lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips
  122. Reseat RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  123. Install LH 7s lower C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips
  124. Reseat LH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  125. Torque LH rear inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  126. Torque RH rear inner battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet for access
  127. Torque LH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm
  128. Fold LH side of rear main carpet to its original position
  129. Torque RH middle inner HV battery bolt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm
  130. Fold RH side of rear main carpet to its original position
  131. Install 2nd row floor mat into vehicle
  132. Torque both RH forward HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  133. Install RH front cabin carpet support access plugs
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, Newer Vins may be equipped with 1x foam plug
  134. Fold the RH front main cabin carpet back to original position
  135. Install clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  136. Install clip securing RH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  137. Install RH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Make sure the seal seat on top of the trim
  138. Install RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 2x locating pins, Position side panel and align the front locator, then the rear locator, Push side panel towards console to install
  139. Install RH front floor mat
  140. Position RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  141. Install clips securing RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x connectors, Puddle lamp and speaker
  142. Torque both LH front inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm
  143. Install LH front cabin carpet support access plugs
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, Newer vins may be equipped with 1x foam plug
  144. Fold the LH front main cabin carpet back to original position
  145. Install LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x locating pins, Position side panel and align the front into front locator, then the rear locator, Push side panel towards console to install
  146. Install LH front floor mat
    Informational PurposesAn informational icon, calling your attention
    Note
    2x velcro patches, Ensure mat does not interfere with pedal operation
  147. Install screw and clips securing LH footwell cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2.5 Nm, 2x push clips
  148. Install LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2 locating pins, Align front locating pin first
  149. Install clip securing LH lower A-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  150. Install LH mid A-pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
  151. Remove coolant bottle cap
  152. Place empty coolant container into front storage area
  153. Fill container with at least 15L of coolant
  154. Place filled coolant container into front storage area
  155. Close air inlet and coolant refill valves
  156. Install refill tool cap onto coolant bottle assembly
  157. Setup vacuum refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  158. 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
  159. Place end of overflow hose into empty container
  160. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  161. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  162. Slowly open refill valve to allow coolant to be drawn into system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  163. Once gauge reads zero, close refill valve
  164. 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
  165. Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
  166. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
  167. Disconnect shop air supply from coolant refill tool
  168. Remove coolant refill hose from coolant container
  169. Remove coolant overflow hose from coolant container
  170. Remove vacuum refill hose from refill cap on coolant bottle
  171. Remove coolant refill tool from vehicle
  172. Remove both coolant containers from inside underhood area
  173. Connect the First Responder Loop and 12V negative battery cable.
  174. Press and hold park button to release EPB service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove wheel chocks if necessary
  175. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via 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
    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, Speeds can be monitored in garage under PT Thermal tab, 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
  176. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure coolant is filled using G-48 coolant
  177. Install coolant bottle cap
  178. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via 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
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete.
  179. Install the rear apron.
  180. Close the hood.
  181. Raise all four windows
  182. Remove lift pad adapters from RH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  183. Install butyl patches onto RH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  184. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing
  185. Install RH rocker carrier onto body
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  186. Install bolts securing RH rocker carrier to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5 Nm
  187. Install RH rocker panel onto RH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
  188. Install clips securing RH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  189. Remove lift pad adapters from LH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  190. Install butyl patches onto LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  191. Install LH rocker carrier onto body
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  192. Install bolts securing LH rocker carrier to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5 Nm
  193. Install LH rocker panel onto LH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
  194. Install clips securing LH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips