HV Battery (RWD) (Structural Pack) (3-Phase) (Remove and Replace)
Correction code 16010132 5.16 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-09-11: Added step to support the LV system.
- 2024-06-13: Updated lift pad adapter PNs.
- 2023-11-21: Added new lift pad instructions.
- 2023-11-07: Updated UI steps and added references to wade seal procedures.
- 2023-06-01: Added Special Tools list.
- 2023-06-01: Corrected link to correct procedure for Center Console (2.0) (Structural Pack) (Remove and Install).
- 2023-05-22: Added conspicuous discharge warning table.
- 1936724-00-A - Universal Lift Pad Adapters
- 1020566-00-F ASY, Battery Table, Manual Lift
- 1065131-00-A Battery Coolant Drain Kit
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
- 1050448-00-B Coolant Vacuum Refill Tool
- 1754057-00-A Current Probe, Clamp, DC, 600V
- 1076927-00-A Hioki Tester
- 1129166-00-A Hoist, H-Frame EMEA
- 1133787-00-A Key, Seat Belt Release, Model 3
- 1134523-00-B Kit, Alignment Rods, Battery, M3
- 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
- 1479505-00-A Kit, M3 Vacuum Fill Coolant Adapter
- 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
- 1637160-00-A MYSP and Palladium Pack Lift Attachment
- 1076928-00-A Test Probes - Hioki 9461
- 1080589-00-A Wheel Chocks
Only
technicians who have been trained in High Voltage Awareness and
have completed all required certification courses (if applicable) are permitted to
perform this procedure. 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.
Discharge
WARNING:
To conform with local laws, High Voltage Lithium Batteries must
be discharged before packing for shipment. Additionally, HV
batteries must be discharged before being put into storage. HV
batteries to be surface shipped must have a State of Charge
(SoC) of less than 50%. HV batteries to be air shipped must have
a SoC of less than 30%. If the method of shipment is unknown or
uncertain, or the battery is to be stored, it is recommended to
discharge the HV battery to less than 30%.
WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977, to determine if the HV battery parameters are within safe limits for shipment or storage. |
- For Front of House and Service Advisors
-
Identify the vehicle SOC.
- If the SOC is less than the specified values, proceed with removal. See Remove.
- If the SOC is greater than the specified values, lower all of the vehicle windows and turn on the climate control system to maximum defrost. This setting will discharge the battery by approximately 10% SOC every hour.
- Move the vehicle to a location where it can safely continue to discharge the battery unattended.
- Identify the vehicle SOC every half-hour.
- When the SOC is below 50% for surface transport, or below 30% for air transport, turn off the climate control system, raise the windows, and then move the vehicle to the service bay.
- For Service Technicians
-
Identify the vehicle SOC Max
value.
- If the SOC Max value is less than the specified values, proceed with removal. See Remove.
- If the SOC Max value is greater than the specified values, continue to the next step.
- Move the vehicle to a location where it can safely discharge the battery unattended.
- Enable Service Mode Plus. See Service Mode Plus.
- On the vehicle touchscreen, touch .
-
Touch Start HV Discharge, and
then in the window that opens, touch Run.
NoteThe discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
- After discharge is complete, move the vehicle to the service bay.
Remove
- Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See Software Update.
- Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Remove and Replace).
-
Remove the butyl patches (x2) that
cover the LH rocker access holes.
-
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)
WarningDO NOT use any other lift pad adapters.NoteOutside 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.NoteIn 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:
- Depending on the lift type, install the correct thread adapter onto the lift adapter.
- 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.
- Install the lift adapters onto the
lift arms so that the black lift pad is toward the vehicle.WarningMake sure the adapter is install in the correct orientation.
- Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
- Lift the lift arms to fully seat the lift pads into the vehicle.
- Make sure all 4 adapters are fully seated into the vehicle.
- Repeat steps 2 through 4 for the RH side of the vehicle.
- Open all doors and lower the windows.
- Release the LH and RH parking brake calipers. See Parking Brake - Caliper - Rear - LH (Release).
-
Run the Thermal Fill Drain (Coolant
Only) routine using the touchscreen. See Cooling System (Non-Structural Pack) (Drain and Refill).
NoteSelect Run. Close once the routine is completed., then touch
- Disconnect the laptop from the vehicle.
- Remove the seats and the interior carpet from the vehicle. See Carpet - Interior Complete (Remove and Replace).
- Remove the center console. See Center Console (2.0) (Structural Pack) (Remove and Install).
-
Remove LH riser side carpet support
bracket.
Note2x tabs
-
Remove RH riser side carpet support
bracket
Note2x tabs
-
Remove and discard the bolts (x4) that
attach the LH and RH center console lower rails.
-
Remove LH and RH floor ducts
Note2x clips
-
Release the center console harness
from the HV battery.
Note1x clip
-
Remove the bolts (x4) that attach the
LH and RH lower IP carrier brackets.
-
Secure the center seat belt buckles
away from the ancillary bay.
-
Remove the rear inner HV battery bolts
(x4).
-
Push the vehicle onto a lift.
NoteRecommend assistance. Note that this vehicle can only be safely pushed for a very short distance and at very slow speed.
-
Raise and support the vehicle. See
Raise Vehicle - 2 Post Lift.
NoteVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
-
Raise vehicle fully and lower the lift
onto locks.
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
-
Pull the RH front wheel liner away
from the HV battery.
-
Pull the LH front wheel liner away
from the HV battery.
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Structural Pack).
- Lower the vehicle until the tires are touching the ground.
-
Release the 2nd row 60 seat connector
from the LH seat frame.
-
Disconnect the 3-phase connector from
the HV battery.
NoteRelease locking tab upwards then lift up the connector.
-
Remove the bolt that attaches the
busbar cover access door.
-
Remove the bolts that attach the
charge port busbar kit to the HV header.
-
Release the LH body harness from the
rear body and move it aside.
-
Lift the busbar kit connector to
remove it from the HV header.
NoteUse an inflatable airbag to suspend the busbar away from the HV header during removal and installation. Hold busbar firmly as there is tension on it.
-
Disconnect the HVC logic connector and
install the logic cap.
NoteRelease the locking tab, then pivot the handle downward to release connector.
-
Disconnect the LV power connector from
the HV battery.
-
Close all doors.
NoteLatch rear doors to prevent accidental closure.
- Raise the vehicle to a comfortable working height.
-
Position a coolant drain container
underneath the LH front of the HV battery.
-
Disconnect the PT supply hose at the
LH front side of the vehicle.
NotePlug the hose connections.
-
Install the PCS flush adapter onto the
PT supply hose.
NoteRemove plugs as needed. Perform a push-pull-push test to make sure the adapter is fully seated.
-
Attach the coolant cart flush hose to
the regulator and PCS flush adapter.
NoteMake sure that the regulator valve is closed. The pressure regulator is not adjustable.
-
Position the coolant drain container
underneath the LH RDU area.
NotePosition neck to catch all coolant loss.
-
Release the RDU inverter inlet hose
from the RDU.
-
Disconnect the RDU inverter inlet hose
from the fluid coupling.
NotePlug the drive unit coupling.
-
Attach a compressed air line to the
coolant pressure tester.
NoteMake sure the valve on the pressure regulator is closed.
-
Slowly open the valve on the pressure
regulator and allow the coolant to completely drain.
NoteKeep an eye on all hose connections to verify there are no leaks from the tools.
-
Close the valve on the pressure
regulator when coolant has stopped draining from the RDU inverter inlet hose.
-
Disconnect the compressed air line
from the coolant pressure tester.
-
Position the coolant drain container
underneath the LH front of the HV battery.
-
Remove the PCS flush adapter from the
PT supply hose.
NotePlug hose connections.
-
Remove the PT flush fitting adapter
from the cart pressure hose.
-
Position the coolant drain container
underneath the center front of the HV battery pack.
NotePosition underneath the front left manifold battery supply tube.
-
Disconnect the front left manifold
battery supply tube.
NotePlug hose connections.
-
Attach the battery drain fitting
adapter onto the female front left manifold battery supply tube.
NoteMake sure that the valve is closed and that the adapter is locked to the manifold tube.
-
Attach the coolant cart flush hose to
the battery drain fitting adapter.
-
Position the coolant drain container
underneath the RH front of the HV battery.
-
Disconnect the HV battery RH front
inlet hose.
NotePlug hose connections.
-
Release the clip that attaches the HV
battery RH front inlet hose to the skid plate.
-
Attach a compressed air line to the
coolant pressure tester.
NoteMake sure the valve on the pressure regulator is closed.
-
Open the valve on the battery drain
fitting adapter.
-
Slowly open the valve on the pressure
regulator and allow the coolant to completely drain.
NoteKeep an eye on all hose connections to verify there are no leaks from the tools.
-
Close the valve on the pressure
regulator once coolant has stopped draining from the HV battery RH front inlet
port.
-
Disconnect the compressed air line
from the coolant pressure tester.
-
Position the coolant drain container
underneath the center front of the HV battery pack.
NotePosition underneath the front left manifold battery supply tube.
-
Remove the battery drain fitting
adapter from the female front left manifold battery supply tube.
NotePlug hose connections.
-
Remove the battery drain fitting
adapter from the cart drain hose.
-
Position the coolant drain container
underneath the RH front of the HV battery.
-
Disconnect the PT return hose at the
RH front side of the vehicle.
NotePlug hose connections.
-
Release the clip that attaches the PT
return hose to the RH front side of the HV battery pack.
-
Release the PT coolant hose from the
LH side of the front HV battery bash plate.
-
Position the coolant drain container
underneath the LH rear side of the HV battery.
-
Remove the RDU inverter inlet
hose.
NoteRotate the hose between the subframe and battery out of the vehicle.
-
Disconnect the compressor HV harness
from the HV battery.
NoteHold down the red locking tab, and the disengage the release lever. Do not force the release lever up.
-
Release the clips (x4) that attach the
compressor HV harness to the HV battery.
-
Release the RDU oil cooler outlet
pipe.
NotePlug hose connections.
-
Remove the RDU oil cooler outlet
pipe.
NoteRotate the pipe down over the RDU and rearward around the subframe.
- Remove the coolant drain container from underneath the vehicle.
-
Release the RDU HV cable bracket from
the RDU.
-
Disconnect the RDU HV cable from the
RDU.
NoteRelease the locking tab, and then rotate the release lever up to disengage the connector. Do not force the release lever up.
-
Remove the RDU HV cable.
NoteRotate the cable underneath the logic cable harness between the subframe and the HV battery.
-
Remove the smaller bolts of the LH and
RH shear plates.
-
Loosen the large bolt that attaches
the LH shear plate and subframe to the body and rotate the shear plate clear of the HV
battery.
NoteHand tighten the bolt once the shear plate is in position.
-
Loosen the large bolt that attaches
the RH shear plate and subframe to the body and rotate the shear plate clear of the HV
battery.
NoteHand tighten the bolt once the shear plate is in position.
-
Put the battery table into position
and lower vehicle to support the battery.
NoteRecommend assistance. Line up the table so the bolts at the front bash plate are accessible and the rear HV cables are accessible. Adjust the final battery table position using adjustable caster jacks on the table.
-
Loosen the front bolts that attach the
HV battery through the skid plate cover with ratchet, and then remove them with a
battery powered drill.
-
Loosen the bolts that attach the skid
plate to the vehicle with ratchet, and then remove them with a battery powered
drill.
-
Loosen the bolts that attach the rear
HV battery to the vehicle with a ratchet, and then remove them with a battery powered
drill.
-
Loosen the LH bolts that attach the V
battery to the vehicle with a ratchet, and then remove them with a battery powered
drill.
-
Loosen the RH bolts that attach the HV
battery to the vehicle with a ratchet, and then remove them with a battery powered
drill.
-
Raise the vehicle to free it from the
HV battery.
NoteRecommend assistance.
-
Remove the battery from under the
vehicle.
NoteRecommend assistance.
-
Release the PT supply tube from the
rear of the HV battery pack.
NotePlug hose connections.
-
Remove the PT supply tube from the LH
side of the HV battery pack.
NoteEach clamp has 1x datum that need to be released from the bracket holes.
-
Remove the FDU dummy plug from the HV
battery pack.
NoteDisengage the locking tab, then release the connector body.
-
Remove the front left manifold battery
supply tube from the HV battery pack.
NoteUse a shop towel to clean any residue coolant as necessary. Plug hose connections.
-
Remove the PT return tube from the RH
side of the HV battery pack.
NoteEach clamp has 3x datums that need to be released from 3x bracket holes
-
Attach the HV battery H-frame to the
gantry and raise it into position.
-
Position the HV battery under the
gantry.
NoteRecommend assistance
-
Attach the P2 sling adapter onto the
HV battery pack.
Note4x locking joints. The hoist is color coded and will come with instructions. Verify locking joints are fully secured, DO NOT secure the middle joints. Perform a push and pull test. If not properly secured, then top pin will be recessed. Take care to secure properly and safely.
-
Raise the HV battery pack off the
battery table.
-
Position the gantry over a
pallet.
NoteRecommend assistance
-
Lower the HV battery pack onto the
pallet.
-
Release the P2 battery sling adapter
from the HV battery pack.
NotePush down on top pin to release.
-
Raise the gantry and H-frame from the
old HV battery pack.
-
Remove the logic cap from the old HV
battery pack.
Install
-
Open the crate top of the crate that
contains the new HV battery pack.
NoteRecommend assistance.
-
Inspect and clean the wade seal on the
HV battery prior to installation.
If the wade seal is damaged, rework or replace the seal.
- If the damage is less than 25 mm, rework the wade seal. See Wade Seal - HV Battery (Structural Pack) (Rework).
- If the damage is more than 25 mm, replace the wade seal. See Wade Seal - HV Battery (Structural Pack) (Remove and Replace).
- If there is no damage, clean the seal with water and dry the surface completely.
-
Install the logic cap onto the new HV
battery pack.
-
Remove the fasteners that attach the
new HV battery pack to the crate/pallet.
-
Position the gantry and H-frame over
the crate, and then attach the P2 sling adapter to the new HV battery pack.
Note4x locking joints. The hoist is color coded and comes with instructions. Make sure that the locking joints are fully secured. DO NOT secure the middle joints. Perform a push-pull test. If not properly secured, the top pin will be recessed. Take care to secure properly and safely.
-
Raise the new HV battery pack off the
crate.
NoteRecommend assistance.
-
Move the gantry away from the crate
and bring the HV battery table in position.
NoteRecommend assistance
-
Lower the HV battery pack onto the
battery table.
NoteRecommend assistance. Make sure to align the battery pack to the table with clear access to all bolt-to-body holes.
-
Release the P2 sling adapter from the
HV battery pack.
Note4x locking joints. Push down on top pin to release.
-
Remove the HV battery pack from under
the gantry.
NoteRecommend assistance.
-
Position the gantry over the old HV
battery pack.
NoteRecommend assistance.
-
Lower the gantry and H-frame and
secure the P2 sling adapter to the old HV battery pack.
Note4x locking joints. The hoist is color coded and comes with instructions. Make sure that the locking joints are fully secured. DO NOT secure the middle joints. Perform a push-pull test If not properly secured, the top pin will be recessed. Take care to secure properly and safely.
-
Raise the old HV battery pack above
height of crate.
-
Position the crate underneath the old
HV battery pack.
-
Lower the old HV battery pack onto the
crate.
NoteRecommend assistance.
-
Release the P2 sling adapter from the
old HV battery pack.
Note4x locking joints. Push down on top pin to release.
-
Raise the gantry and H-frame from the
old HV battery pack.
-
Lower the gantry and remove the HV
battery H-frame from the gantry.
-
Install fasteners to attach the old HV
battery pack to the crate hand tight.
-
Close the crate top housing the old HV
battery pack.
NoteRecommend assistance
-
Install the PT return tube onto the RH
side of the HV battery pack.
Note6x clamps, 6x brackets. Each clamp has 3x datums that need to be secured onto 3x bracket holes.
-
Install the front left manifold
battery supply tube onto the HV battery pack.
Note1x spring clip, 3x clips. Remove plugs as needed.
-
Install the FDU dummy plug onto the HV
battery pack.
NoteFully seat the connector body, then engage the locking latch.
-
Install the PT supply tube to the LH
side of the HV battery pack.
Note6x clamps, 6x brackets. Each clamp has 1x datum that need to be secured to the bracket holes.
-
Attach the PT supply tube onto the
rear of the HV battery pack.
Note1x spring clip, 2x clips. Remove plugs as needed.
-
Clean the HV connector contact surface
of any residual Penetrox.
NoteAllow 1 minute dry time after removing Penetrox. New busbar comes with Penetrox applied to the HV connector.
-
Clean the busbar HV connector contact
surface of any residual Penetrox.
NoteAllow 1 minute dry time after removing Penetrox. It is necessary to clean the HV connector during re-use of the busbar.
-
Apply Penetrox onto the HV connector
joints.
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads. Spread evenly to ensure that the contact surface is fully covered.
-
Inspect and clean the body side of the
HV battery wade seal interface.
NoteClean with water and dry surface completely.
-
Install the HV battery alignment rods
(x2) onto the body.
NoteOnly use the smaller rods. Thread onto RH front most and LH rear most side holes
-
Position the HV battery pack under the
vehicle.
NoteRecommend assistance
-
Carefully lower the vehicle onto the
HV battery pack and align the battery holes with the rods.
NoteRecommend assistance. Make sure that coolant hoses and harnesses do not get pinched.
-
Remove the HV battery alignment rods
from the body once the HV battery is aligned.
-
Thread in by hand all bolts that
attach the HV battery to vehicle. Do not install bolts to the shear plates yet.
Note34x bolts. Includes top bolts. Start with bolts nr 35-36-37-38. Ensure smooth thread engagement and bolts are not cross threaded into the casting.
-
Completely lower the vehicle onto the
battery pack.
NoteRecommend assistance.
-
Seat all bolts (x 34) that attach the
HV battery to the vehicle with a battery powered drill.
NoteEnsure smooth thread engagement and bolts are not cross threaded into the casting. Flush down the bolts. Do not over tighten bolts, fully torque them at later steps.
-
Fully torque the LH bolts (x7) that
attach the HV battery to the vehicle (torque 56 Nm).
NoteBolt position 1-7.
-
Fully torque the RH bolts (x7) that
attach the HV battery to the vehicle (torque 56 Nm).
NoteBolt position 16-22.
-
Fully torque the rear bolts (x4) that
attach the HV battery to the vehicle (torque 62 Nm).
NoteBolt position 10-13.
-
Fully torque the front bolts (x6) that
attach the HV battery through the bash plate openings (torque 90 Nm).
NoteLater production vehicles have E14 bolts torqued at 75 Nm. Bolt location 23 to 28.
-
Fully torque the front bolts (x6) that
attach the bash plate to the vehicle (torque 62 Nm).
NoteBolt location 29-34.
-
Loosen the RH rear subframe bolt and
align the RH rear shear plate with the HV battery.
NoteHand tighten bolt once the shear plate is in position.
-
Install the bolts that attach the RH
shear plate to the HV battery hand tight.
-
Torque the bolt that attaches the
subframe and RH rear shear plate to the body (torque 130 Nm).
-
Torque the 2 smaller bolts that attach
the RH rear shear plate to the body (torque 62 Nm).
- Repeat steps 42 through 45 on the LH side of the vehicle.
-
Open the LH rear door.
NoteUse caution while working around this area not to damage any components.
-
Fully torque the LH rear inner bolts
(x2) that attach the HV battery pack to the vehicle (torque 49 Nm).
NoteBolt position 35-36.
-
Visually inspect the wade seal to make
sure that no gaps are present.
-
Close LH rear door.
NoteDo not latch the door.
-
Open the RH rear door.
NoteUse caution while working around this area not to damage any components
-
Fully torque the RH rear inner bolts
that attach the HV battery pack to vehicle (torque 49 Nm).
NoteBolt position 37-38.
-
Close RH rear door
NoteDo not latch the door.
- Raise vehicle and lower onto locks, then remove the battery table from under the vehicle.
-
Position the RDU HV cable up to the
RDU.
NoteRotate cable underneath logic cable harness between subframe and HV battery.
-
Connect the RDU HV cable onto the
RDU.
NoteVerify lever is in the upright and open position, then carefully seat connector and allow the lever to engage. Fully secure lever and verify red tab is locked. Do not damage any pins.
-
Secure the RDU HV harness onto the HV
battery.
NoteVerify lever is in the upright and open position, then carefully seat the connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked. Do not damage any pins.
-
Install the bolt that attaches the RDU
HV cable bracket to the RDU (torque 6 Nm).
-
Install the RDU oil cooler outlet
pipe.
NoteRotate up over the RDU and rearward around the subframe to oil cooler.
-
Attach the RDU oil cooler outlet
pipe.
Note2x spring clips, 5x clips. Remove plugs as needed
-
Attach the compressor HV harness to
the HV battery.
Note4x clips
-
Connect the compressor HV harness onto
the HV battery.
NoteVerify that the lever is in the upright and open position, then carefully seat the connector and allow the lever to engage. Fully secure lever and verify that the red tab is locked.
-
Install the RDU inverter inlet
hose.
Note2x spring clip, 1x clip. Rotate between subframe and battery into the RDU and PCS outlet. Remove plugs as needed.
-
Attach the RDU inverter inlet hose to
the RDU HV cable.
Note1x clip
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
-
Position a coolant drain container
underneath the LH front of the HV battery.
-
Connect the PT supply hose at the LH
front side of the vehicle.
Note1x spring clip. Remove plugs as needed.
-
Attach the PT coolant hose onto the LH
side of the front HV battery bash plate.
Note1x clip
-
Position the coolant drain container
underneath the RH front of the HV battery.
-
Connect the PT return hose at the RH
front side of vehicle.
Note1x spring clip. Remove plugs as needed.
-
Attach the PT return hose to the RH
front side of the HV battery pack.
Note1x clip
-
Connect the HV battery RH front inlet
hose.
Note1x spring clip. Remove plugs as needed.
-
Attach the HV battery RH front inlet
hose to the skid plate.
Note1x clip
-
Position the coolant drain container
underneath the center front of the HV battery pack.
NotePosition container underneath front left manifold battery supply tube.
-
Connect the front left manifold
battery supply tube.
Note1x spring clip, 1x clip. Remove plugs as needed.
- Remove the coolant drain container from underneath the vehicle.
-
Release the LH front wheel liner from
the bungee strap.
-
Release the RH front wheel liner from
the bungee strap.
- Install the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
-
Fully lower the vehicle, and then push
the vehicle away from the lift.
NoteRecommend assistance. Place wheel chocks to prevent the vehicle from moving. Note that this vehicle can only be safely pushed for a very short distance and at very slow speed.
-
Open all doors
NoteLatch rear doors to prevent accidental closure
-
Connect the LV power connector to the
HV battery.
NotePush the red locking tab down to secure the connection.
-
Remove the HVC logic cap, and then
connect HVC logic connector.
NotePivot the handle upward to engage the connector and secure the locking tab.
-
Position the busbar kit connector and
lower it onto the HV header.
-
Install the bolts (x2) that attach the
charge port busbar kit to the HV Header (torque 9 Nm).
-
Put on HV insulating gloves and leather over gloves.
NoteCheck gloves for damage and expiry details. Refer to Service Document TN-15-92-003 for further details.
-
Perform a Hioki resistance test at
each HV joint from HV busbar lead to bolt head.
NoteThe 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), the Hioki test passed; proceed to the next step.
- Remove leather over gloves and HV insulating gloves.
-
Install the bolt that attaches the
busbar cover access door (torque 9 Nm).
-
Install the LH body harness onto the
rear body.
-
Connect the 3-phase connector onto the
HV battery.
NotePivot the handle downwards to engage the connector and secure the locking tab.
-
Attach the 2nd row 60 seat connector
to the LH seat frame.
Note1x clip.
-
Remove the tape from the seat
frame.
-
Install the bolts (x4) that attach the
LH and RH lower IP carrier brackets (torque 25 Nm)..
-
Install the center console harness to
the HV battery.
Note1x clip.
-
Install the LH and RH floor
ducts.
-
Install new bolts (x4) that attach the
LH and RH center console lower rails (torque 4.5 Nm).
NoteSlide rails rearward to engage it onto center console riser assembly.
-
Install the LH riser side carpet
support bracket.
-
Install the RH riser side carpet
support bracket.
- Install the center console. See Center Console (2.0) (Structural Pack) (Remove and Install).
- Install the seats and the interior carpet to the vehicle. See Carpet - Interior Complete (Remove and Replace).
- Connect LV power. See 12V/LV Power (Disconnect and Connect).
- Connect an LV maintainer to the vehicle, but do not disconnect the LV battery. See LV Maintainer (Connect and Disconnect).
- Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
- Press and hold the Park button to exit EPB service mode.
-
Access the thermal system routines
using the UI: Select
.
- Unlock the vehicle gateway. See Gateway (Unlock).
-
Perform a coolant purge from the
touchscreen.
NoteTouch time only. Wait until coolant pumps stop running (audible noise), "Routine Passed" appears, but pumps will run for 10 minutes. If you start another routine during this time, it will fail. Make sure vehicle is not in "Drive". Routine is still running despite the completed message. Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM. The rest will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL. Putting the vehicle into "Drive" will stop this routine. If speeds hover at 7000 RPM, this indicates the pumps are air locked; perform a vacuum fill. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
-
Inspect the coolant level at the
reservoir and top off as necessary.
NoteEnsure coolant is filled using G-48 coolant.
-
Install the coolant bottle cap.
-
Perform the Thermal Performance Test
using the touchscreen: touch Run and allow the routine to complete.
, touch
- Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
- Enable Service Mode Plus. See Service Mode Plus.
- On the vehicle touchscreen, touch .
- Under High-Voltage-Battery, touch High Voltage Battery Replacement.
- Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
- Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
- Disable Service Mode Plus. See Service Mode Plus.
- Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
-
Exit Service Mode through the
touchscreen.
- Disconnect the 12V/LV battery maintainer.
- Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
-
Remove the lift pad adapters from the
LH and RH rocker panel.
Note2x lift pad adapters per side.
-
Install butyl patches onto the LH and
RH rocker panel access holes.
Note2x butyl patches per side. Apply pressure along patch to verify it is fully secured to body. Use new butyl patches if needed, roughly 2" x 2 1/2" (5 cm x 6.5 cm).
- Install the LH and RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
- Install the LH and RH rocker panel covers onto the rocker panel carrier. See Cover - Rocker Panel - Lower - LH (Remove and Replace).