17/06/2024 21:24:32
高压电池(全轮驱动)(三相)(拆卸和安装)
校正代码 16010221 注意:除非本程序中另有明确规定,否则上述校正代码和 FRT 反映的是执行本程序(包括关联程序)所需的所有工作。除非明确要求,否则请勿堆叠校正代码。注意:请参阅平均维修工时,深入了解 FRT 及其创建方式。要提供有关 FRT 值的反馈,请发送电子邮件至LaborTimeFeedback@tesla.com。注意:请参阅人员保护,确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。
- 2024-06-13: Updated lift pad adapter PNs.
- 2023-11-21: Added new lift pad instructions.
- 2023-08-23: Updated EPB Service Mode reference.
- 2023-07-11: Reorganized steps to accommodate service while standing.
- 2023-07-06: Added step to perform a charge port voltage check.
- 2023-05-05: Added step to position battery table under vehicle.
警告
尽管此程序已经过验证,但仍是一个草案。可能没有警告和注意事项。请遵守安全要求,处理或靠近高压系统和部件时,请谨慎操作。请将校正修理内容及反馈发送至ServiceDevelopment@teslamotors.com。
拆卸
-
Remove bolts securing LH rocker panel
lower cover to body.
注4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
-
Remove clips securing the LH rocker
panel lower cover to wheel liners.
注4x push clips.
-
Remove LH rocker panel lower
cover.
注10x clips.
-
Remove bolts securing RH rocker panel
lower cover to body.
注4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
-
Remove clips securing the RH rocker
panel lower cover to wheel liners.
注4x push clips.
-
Remove RH rocker panel lower
cover.
注10x clips.
-
Open all four doors.
注If vehicle is being powered down, Latch rear doors to prevent accidental closure.
- Lower all four windows.
-
Open hood.
注Press "Open" button on the touchscreen to release the latch, Lift the lid manually.
-
Remove rear apron.
注12x clips, Only store rear apron visible face upwards .
-
Remove cabin intake upper duct
assembly.
注4x clips, Heat pump vehicles have 3x clips.
- Move LH front seat backward.
-
Remove LH IP end cap.
注3x clips.
-
Remove LH mid A-pillar assembly.
注1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove.
-
Remove clip for LH lower A-pillar
trim.
注1x push clip.
-
Remove LH lower A-pillar trim.
注2x clips, 3 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
-
Remove screw and clips securing LH
footwell cover.
注2x push clips, 1x screw, T20, 2.5 Nm.
-
Remove connectors from LH footwell
cover and remove from vehicle.
注3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected.
-
Remove LH front floor mat.
-
Remove LH console side panel
carpet.
注12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips.
- Move RH front seat backward.
-
Remove RH IP end cap.
注3x clips.
-
Remove RH mid A-pillar assembly.
注1x clip, 1x tab, Release upper clip then pull mid A-pillar upward to remove from vehicle.
-
Remove clip for RH lower A-pillar
trim.
注1x push clip.
-
Remove RH lower A-pillar trim.
注1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
-
Remove clips securing RH footwell
assembly.
注4x push clips.
-
Disconnect RH foot well assembly
connectors and remove from vehicle.
注2x electrical connectors.
-
Remove RH front floor mat.
-
Remove RH console side panel
carpet.
注12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips.
- Move RH front seat forward.
- Move LH front seat forward.
- Remove 2nd row floor mat from vehicle.
-
Remove 2nd row seat cushion and
disconnect harness.
注2x tabs, 2x connectors, Press tab toward vertical backward of vehicle on each side to release front edge of seat cushion.
-
Fold the 40 seat in down
position.
注Protect the seat cushion.
-
Remove RH side bolster.
注1x clip, 1 tab, Pull outward then slightly upward to remove.
-
Remove and discard bolster plastic
bracket from RH side.
注2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
-
Fold the 40 seat into vertical
position.
-
Remove the RH rear door sill trim
panel.
注3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
-
Release clips securing the RH upper
B-pillar assembly and move aside.
注4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top of trim to release the remaining clips.
-
Remove the RH lower B-pillar
assembly.
注1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
-
Fold the 60 seat in down
position.
注Protect the seat cushion.
-
Remove LH side bolster.
注1x clip, 1 tab, Pull outward then slightly upward to remove.
-
Remove and discard bolster plastic
bracket from LH side.
注2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
-
Fold the 60 seat into vertical
position.
注Remove seat protection.
-
Remove the LH rear door sill trim
panel.
注3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
-
Release clips securing the LH upper
B-pillar assembly and move aside.
注4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top to release the remaining clips.
-
Remove the LH lower B-pillar
assembly.
注1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
-
Remove clips securing rear main cabin
carpet to vehicle.
注4x push clips, Velcro strips, The number of clips on newer vehicles may vary.
- Move LH front seat backward.
-
Remove clips securing LH front main
carpet to vehicle.
注3x clips, Number of clips on new vehicles may vary.
-
Fold the LH front main cabin carpet
aside for access.
注Dead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more.
-
Remove LH front footwell HV battery
bolts.
注2x bolts, EP20, 136 Nm.
-
Remove LH rear HV battery interior
bolt.
注1x bolt, 16mm, 66 Nm, Lift up carpet for access.
- Move RH front seat backward.
-
Remove clips securing RH front main
cabin carpet to footwell area.
注3x push clips, Number of clips may vary on older vehicles.
-
Fold RH front main cabin carpet aside
for access.
注2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more.
-
Remove RH front footwell HV battery
bolts.
注2x bolts, EP20, 136 Nm.
-
Remove RH rear HV battery interior
bolt.
注1x bolt, 16mm, 66 Nm, Lift up carpet for access.
-
Place wheel chocks to keep vehicle
from moving.
- Enable the EPB Service Mode. See 驻车制动 - 钳 - 后 - LH(释放)
-
Power off vehicle from center
display.
注Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box.
-
Disconnect 12V negative terminal.
注1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V.
-
Remove 12V cap from ancillary bay.
注1x cap.
-
Disconnect HVC logic connector and
install logic cap.
注1x connector, 1x cap, Release locking tab then push the handle downward to release connector.
- Remove all items from pockets and ensure not wearing metal items.
-
Inspect HV insulating gloves.
注Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves.
注Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
- Perform a charge port voltage check. See 充电接口电压检查.
-
Remove bolts securing ancillary bay probe
lid cover to ancillary bay cover.
注2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal.
-
Remove ancillary bay probe lid cover from
ancillary bay cover.
-
Verify no high voltage.
注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.
-
Inspect ancillary bay probe lid cover
gasket then position onto the ancillary bay cover.
注Confirm no damage is present, Seal can be re-used.
-
Install bolts securing ancillary bay probe
lid cover to ancillary bay cover.
注2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners.
-
Remove HV cap from ancillary bay.
注1x cap.
-
Remove edge support bracket.
注2x bolts, 10mm, 10 Nm, 1x clip.
-
Remove fastener securing busbar cover
access door.
注1x bolt, 10mm, 9 Nm.
-
Remove bolts securing chargeport
busbar to HV header.
注2x bolts, 10mm, 9 Nm.
-
Lift chargeport busbar connector to
remove from HV header.
注4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal.
-
Disconnect 3PH chargeport inlet
harness from HV header.
注1x connector, Release red locking tab and rotate lever arm to release.
-
Remove bolts securing LH inner
ancillary bay rail to the ancillary bay cover.
注2x bolts, T40, 24 Nm.
-
Remove bolts securing RH inner
ancillary bay rail to the ancillary bay cover.
注2x bolts, T40, 24 Nm.
-
Remove nut securing DCDC ground busbar
to HV battery.
注1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
-
Remove bolt securing DCDC ground
busbar to body.
注1x bolt, 13mm, 20 Nm.
-
Remove DCDC ground busbar.
-
Remove positive 12V output cover from
PCS cable.
注1x cover.
-
Remove nut securing positive 12V
output from PCS cable and move cable aside.
注1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
-
Close all four doors.
注Make sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down.
-
Push vehicle onto lift.
注Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed.
-
安装举升垫适配器。
- 仅适用于欧洲、中东和非洲:安装举升机垫适配器,Model 3 (1453419-00-A
- 其他地区:安装通用举升垫适配器 (1936724-00-A)。
警告请勿使用任何其他举升垫适配器。注欧洲、中东和非洲以外的地区:使用通用举升垫适配器 (1936724-00-A) 代替举升机垫适配器,Model 3 (1453419-00-A。请弃用任何其他版本的举升垫适配器。注通用举升垫适配器在欧洲、中东和非洲尚不可用。请确保在 Model Y 上使用 Model Y 橡胶举升垫,在 Model 3 上使用 Model 3 举升垫。通用举升垫适配器说明:
- 将与举升机类型相匹配的正确螺纹适配器安装到举升机适配器上。
- 确保将螺纹止动垫圈正确安装并紧固至举升机适配器底部。如果未安装螺纹止动垫圈,请勿继续使用举升机适配器。
- 将举升机适配器安装到举升臂上,使黑色的举升垫朝向车辆。警告确保适配器安装方向正确。
- 调整举升臂位置,使举升机适配器与车辆上的固定销孔对齐。
- 抬起举升臂,将举升垫完全放置到车辆上。
- 确保所有 4 个适配器均已完全就位在车辆上。
- Raise and support vehicle.
-
Raise vehicle fully and lower lift
onto locks.
注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, Verify doors are clear of surrounding objects.
-
Remove outer fasteners securing front
aero shield.
注9x bolts, 10mm, 5 Nm.
-
Remove remaining nuts and remove front
aero shield from vehicle.
注2x nuts, 15mm, 5 Nm.
-
Remove the clips securing the front LH
and RH wheel liners to the front skid plate.
注2x push clips.
-
Remove bolts securing front skid
plate.
注4x bolts, EP10, 13 Nm.
-
Remove skid plate from HV
battery.
-
Release connector from bracket.
注1x connector.
-
Disconnect A/C compressor HV harness
connector.
注1x connector, 1x Red locking tab, 2 stage push release, Unlock by pulling back red tab, Push orange lip and pull back ''stage 1'', Push green lip and pull back to disconnect.
-
Remove bolt securing FDU HV harness to
FDU.
注1x bolt, 10mm, 10 Nm.
-
Disconnect the FDU HV harness
connector.
注1x clip, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged.
-
Remove the FDU HV harness connector
from the FDU and move aside.
注1x connector.
-
Remove FDU ground strap bolt from HV
battery and remove ground strap from vehicle.
注1x bolt, 10mm, 10 Nm.
-
Remove push clip securing LH front
wheel liner to LH rocker panel.
注1x push clip.
-
Remove push clip securing RH front
wheel liner to RH rocker panel.
注1x push clip.
-
Use bungee strap to pull back LH front
wheel liner.
注Secure to subframe.
-
Use bungee strap to pull back RH front
wheel liner.
注Secure to subframe.
-
Position coolant drain container
underneath RH front of HV battery.
-
Release FDU Inverter Inlet hose RH
side of vehicle and plug both hoses.
注1x hose clips, Plug both ends, Coolant loss greater than 1 L will require vacuum fill.
-
Disconnect rear PT supply hose at RH
side of vehicle and plug both hoses.
注2x plugs, 1x spring clip, Coolant loss greater than 1 L will require vacuum fill.
-
Position coolant drain container
underneath LH front of HV battery.
-
Disconnect HV battery return tube from
HV battery hose.
注2x clips, 2x plugs, Located on LH front of HV battery, Install cap and plug to both ends, Coolant loss greater than 1 L will require vacuum fill.
-
Release HV battery front manifold hose
from body.
注2x clips.
-
Disconnect HV battery front manifold
hose and plug both hose ends.
注1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill.
- Remove coolant drain container from underneath vehicle.
-
Remove mid aero shield.
注13x bolts, 10mm, 5 Nm.
-
Support front portion of rear
subframe.
-
Release clips securing coolant hoses
to LH shear plate.
注2x fir tree clips.
-
Remove smaller fasteners securing LH
shear plate.
注2x bolts, 13mm, 35 Nm.
-
Remove large bolt securing LH shear
plate and subframe to body and remove shear plate.
注1x bolt, 21mm, 130 Nm, Discard after removal.
-
Hand tighten bolt securing LH side of
subframe to body.
注1x bolt, 21mm, 130 Nm.
-
Release clips securing coolant hoses
to RH shear plate.
注2x fir tree clips.
-
Remove smaller fasteners for RH shear
plate.
注2x bolts, 13mm, 35 Nm.
-
Remove large bolt securing RH shear
plate and subframe to body and remove shear plate.
注1x bolt, 21mm, 130 Nm, Discard at later step.
-
Hand tighten bolt securing RH side of
subframe to body.
注1x bolt, 21mm, 130 Nm.
-
Remove support stand from under
vehicle.
-
Release LH side hose clip from rear
battery skid plate enclosure.
注2x clips, Clip quantity may vary on older vehicles.
-
Release RH side hose clips from rear
battery skid plate enclosure.
注2x fir tree clips.
-
Remove lower bolts securing HV battery
rear skid plate enclosure .
注2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count.
-
Remove upper nut securing HV battery
rear skid plate enclosure .
注1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles.
-
Remove upper bolts securing HV battery
rear skid plate enclosure .
注4x bolts, 13mm, 35 Nm.
-
Remove HV battery rear skid plate
enclosure .
- Position coolant drain container underneath LH rear of HV battery.
-
Disconnect RDU inverter inlet tube
from LH rear of HV battery.
注1x spring clip, 2x plugs, Plug HV battery and hose, Coolant loss greater than 1 L will require vacuum fill.
-
Position coolant drain container
underneath RH rear of vehicle.
-
Disconnect RDU outlet hose from PT
return tube and plug both hose ends.
注1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
- Remove coolant drain container from underneath vehicle.
-
Remove nut securing RDU HV cable
bracket to HV battery.
注1x nut, 10mm, 10 Nm, Number of fasteners may vary.
-
Disconnect RDU HV cable from HV
battery.
注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.
-
Place HV battery table into position
and lower vehicle to support HV battery.
注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.
-
Remove central bolts securing HV
battery center ski cover.
注4x bolts, EP14, 34 Nm.
-
Remove bolts securing LH front support
bracket to vehicle.
注4x bolts, 16mm, 110 Nm.
-
Remove bolts securing RH front support
bracket to vehicle.
注4x bolts, 16mm, 110 Nm.
-
Remove front bolts securing HV battery
to vehicle.
注4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary.
-
Remove LH bolts securing HV battery to
vehicle.
注8x bolts, 13mm, 35 Nm.
-
Remove RH bolts securing HV battery to
vehicle.
注8x bolts, 13mm, 35 Nm.
-
Raise vehicle free of HV battery.
注Recommend assistance.
-
Remove battery from under
vehicle.
注Recommend assistance.
安装
-
Spin Flexitol adjustable elements down
on the ancillary bay cover.
注4x nuts, Reverse thread.
-
Install HV battery alignment
rods.
注2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
-
Position HV battery under
vehicle.
注Recommend assistance.
-
Lower vehicle onto HV battery and
align holes.
注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).
-
Set RH bolts securing HV battery to
vehicle with cordless impact.
注8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Set LH bolts securing HV battery to
vehicle with cordless impact.
注8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Install front bolts securing HV
battery to vehicle hand tight.
注4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, Reinstall fastener unless the body is patched or no hole exists, Patch the body if HV battery doesn't have these holes.
-
Remove HV battery alignment rods.
注2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
-
Set bolts securing RH front support
bracket to vehicle with cordless impact.
注4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Set bolts securing LH front support
bracket to vehicle with cordless impact.
注4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Install bolts securing HV battery to
body at LH shear plate area hand tight.
注2x bolts, 13mm, 35 Nm, Torque at later step.
-
Install bolts securing HV battery to
body at RH shear plate area hand tight.
注2x bolts, 13mm, 35 Nm, Torque at later step.
-
Open LH rear door.
注Use caution while working around this area not to damage any components.
-
Set LH rear HV battery interior bolt
with cordless impact.
注1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Close LH rear door.
注Do not latch.
-
Open LH front door.
注Use caution while working around this area not to damage any components.
-
Set LH front footwell HV battery bolts
with cordless impact .
注2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Close LH front door.
注Do not latch.
-
Open RH rear door.
注Use caution while working around this area not to damage any components.
-
Set RH rear HV battery interior bolt
with cordless impact.
注1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Close RH rear door.
注Do not latch.
-
Open RH front door.
注Use caution while working around this area not to damage any components.
-
Set LH front footwell HV battery bolts
with cordless impact .
注2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
-
Close RH front door.
注Do not latch.
-
Lower vehicle onto pack
completely.
注Recommend assistance.
-
Torque RH bolts securing HV battery to
vehicle.
注8x bolts, 13mm, 35 Nm.
-
Torque LH bolts securing HV battery to
vehicle.
注8x bolts, 13mm, 35 Nm.
-
Torque front bolts securing HV battery
to vehicle.
注4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, If joint is found loose, note the VIN, joint location, take pictures and escalate via toolbox session.
-
Torque bolts securing RH front support
bracket to vehicle.
注4x bolts, 16mm, 110 Nm.
-
Torque bolts securing LH front support
bracket to vehicle.
注4x bolts, 16mm, 110 Nm.
-
Torque central bolts securing HV
battery center ski cover.
注4x bolts, EP14, 34 Nm.
-
Raise vehicle and lower onto locks,
then remove battery table from under vehicle.
注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.
-
Support front portion of rear
subframe.
-
Remove smaller fasteners for LH shear
plate.
注2x bolt, 13mm, 35 Nm.
-
Remove smaller fasteners for RH shear
plate.
注2x bolt, 13mm, 35 Nm.
-
Install LH front bolt and shear plate
to rear subframe hand tight.
注1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
-
Install bolts securing LH shear plate
to HV battery hand tight.
注2x bolts, 13mm, 35 Nm.
-
Install RH front bolt and shear plate
to rear subframe hand tight.
注1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
-
Install bolts securing RH shear plate
to HV battery hand tight.
注2x bolts, 13mm, 35 Nm.
-
Torque bolts securing shear plates to
vehicle.
注4x bolts, 13mm, 35 Nm.
-
Torque bolt securing subframe and LH
shear plate to body.
注1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
-
Torque bolt securing subframe and RH
shear plate to body.
注1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
- Remove support stand from under vehicle.
-
Install clips securing coolant hoses
to RH shear plate.
注2x fir tree clips.
-
Install clips securing coolant hoses
to LH shear plate.
注2x fir tree clips.
-
Connect RDU HV cable to HV
battery.
注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.
-
Install nut securing RDU HV cable
bracket to HV battery.
注1x nut, 10mm, 10 Nm, Number of fasteners may vary.
-
Remove hose plugs and connect RDU
outlet hose to PT return tube.
注1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary, Loss of coolant greater than 1L requires coolant vacuum fill.
-
Remove plugs and connect RDU inverter
inlet hose to LH rear of HV battery.
注1x spring clip, Perform push-pull-push test to make sure hose is fully engaged.Loss of coolant greater than 1L requires coolant vacuum fill.
-
Position HV battery rear skid plate
enclosure onto HV battery for installation.
注Recommend assistance if needed.
-
Install upper bolts securing HV
battery rear skid plate enclosure hand tight.
注4x bolts, 13mm, 35 Nm, Torque at later step.
-
Install upper nut securing HV battery
rear skid plate enclosure hand tight.
注1x nut, 10mm, 13 Nm, Torque at later step.
-
Install lower bolts securing HV
battery rear skid plate enclosure hand tight.
注2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
-
Torque bolts securing HV battery rear
skid plate enclosure to vehicle.
注4x bolts, 13mm, 35 Nm.
-
Torque upper nut securing HV battery
rear skid plate enclosure .
注1x nut, 10mm, 13 Nm.
-
Torque lower bolts securing rear
battery enclosure skid plate.
注2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
-
Install RH side hose clips to HV
battery rear skid plate enclosure .
注2x fir tree clips.
-
Install LH side hose clip to HV
battery rear skid plate enclosure .
注2x clips, Clip quantity may vary on older vehicles.
-
Apply Loctite 222 onto mid aero shield
bolts and install mid aero shield.
注13x bolts, 10mm, 5 Nm.
-
Position coolant drain container
underneath LH front of HV battery.
-
Install HV battery front manifold hose
clips to body.
注2x clips.
-
Remove plugs then connect male side to
female side of HV battery front manifold hose.
注2x plugs, 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.
-
Remove plugs then connect female side
to male side of HV battery return hose.
注2x plugs, 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.
-
Position coolant drain container
underneath RH front of HV battery.
-
Remove plugs then connect PT supply
tube.
注2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
-
Remove plugs then connect PT return
tube.
注2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
- Remove coolant drain container from underneath vehicle.
-
Release RH front wheel liner from
bungee strap.
注Remove strap from vehicle.
-
Release LH front wheel liner from
bungee strap.
注Remove strap from vehicle.
-
Install push clip securing LH front
wheel liner to LH front rocker panel.
注1x push clip.
-
Install clip securing RH front wheel
liner to RH rocker panel.
注1x push clip.
-
Install FDU ground strap and bolt to
HV battery.
注1x bolt, 10mm, 10 Nm.
-
Install FDU HV harness connector to
FDU.
注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.
-
Secure FDU HV harness connection to
FDU.
注1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and engage red locking tab, Do not damage connector or header.
-
Install bolt securing FDU HV harness
to FDU.
注1x bolt, 10mm, 10 Nm.
-
Remove plastic bracket securing HV
connectors to body.
注3x clips.
-
Connect A/C compressor HV harness
connector.
注1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
-
Connect PTC HV connector to HV cable
then reinstall bracket.
注1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
-
Install front skid plate onto HV
battery.
注2x tabs, Slide tabs onto front of HV battery.
-
Install the bolts securing the front
skid plate to the HV battery.
注4x bolts, E10, 13 Nm.
-
Install the clips securing the front
LH and RH wheel liners to the front skid plate.
注2x push clips.
-
Position front aero shield to vehicle
and install nuts.
注2x nuts, 15mm, 5 Nm.
-
Apply Loctite 222 onto front aero
shield bolts and install outer fasteners to front aero shield.
注9x bolts, 10mm, 5 Nm.
-
Lower vehicle fully and move rack arms
away from vehicle.
注Remove M3 lift adapters from body and install body plugs.
-
Push vehicle away from lift.
注Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Chock wheels.
- Open all four doors.
-
Install positive 12V output from PCS
cable and torque nut.
注1x nyloc nut, 13mm, 9 Nm, Install new nut, Mark nut after torque, Make sure rubber boot is not pinched between cable terminal.
-
Install positive 12V output
cover.
注1x cover.
-
Install DCDC ground busbar.
-
Install bolt securing DCDC ground
busbar to body.
注1x bolt, 13mm, 20 Nm.
-
Install nut securing DCDC ground
busbar to HV battery.
注1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut.
-
Install bolts securing RH inner
ancillary bay rail to the ancillary bay cover.
注2x bolts, T40, 24 Nm.
-
Install bolts securing LH inner
ancillary bay rail to the ancillary bay cover.
注2x bolts, T40, 24 Nm.
-
Connect 3PH chargeport inlet harness
to HV header.
注1x connector, Rotate lever arm and secure locking tab.
-
Clean HV connector contact surface of
residual Penetrox.
注Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector.
-
Apply Penetrox onto HV connector
joints.
注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.
-
Position chargeport busbar connector
to HV header.
注4x guide tabs, Recommend assistance, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
-
Install bolts securing chargeport
busbar connector to HV header.
注2x bolts, 10mm, 9 Nm.
-
Install edge support bracket.
注2x bolts, 10mm, 10 Nm, 1x clip.
-
Inspect HV insulating gloves.
注Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves.
-
Put on HV insulating gloves and
leather over gloves.
注Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
-
Perform Hioki resistance test at each
HV joint from HV busbar lead to bolt head.
注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.
- Remove HV insulating gloves.
-
Install fastener securing busbar cover
access door.
注1x bolt, 10mm, 9 Nm.
-
Install HV cap to ancillary bay.
注1x cap.
-
Remove logic cap and connect the HVC
logic connector.
注1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated.
-
Install 12V cap to ancillary bay.
注1x cap.
-
Connect 12V negative terminal.
注1x nut, 10mm, 6 Nm.
-
Press and hold park button to release
EPB service mode.
注Remove wheel chocks if necessary.
-
Connect to vehicle using Toolbox
3.0.
注Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle.
- Select ‘Actions/Autodiag’ and search for ‘Thermal’.
-
Select "Start Thermal Fluid Fill/Drain
(Coolant only)", click Run and allow routine to complete.
注Select ‘X’ at top right of window to close once complete, Verify vehicle is in Series via Garage > Vitals > Thermal tab > Coolant loops, Thermal Fluid Fill/Drain routine has a 5 hour limit, After 5 hours routine must be performed again.
-
Remove HVAC plenum outer duct.
注2x clips.
-
Remove superbottle cap.
-
Place empty coolant container into
front storage area.
-
Fill container with at least 15L of
coolant.
-
Place filled coolant container into
front storage area.
-
Place refill hose inside filled
coolant container .
注Make sure hose end is fully submerged into coolant.
-
Install vacuum refill cap onto
superbottle assembly.
-
Setup vacuum refill tool.
注Verify all valves on refill tool are in the closed position, See image for clarity.
-
Install vacuum refill hose into refill
cap on coolant bottle.
注Perform push-pull-push test to verify hose is fully installed.
-
Position overflow hose into empty
container.
-
Place refill hose inside filled
coolant container .
注Make sure hose end is fully submerged into coolant.
-
Connect shop air supply to coolant
refill tool.
注If not already done, Verify refill valve is set to off.
-
Slowly open the coolant refill valve
to allow coolant to be drawn into the coolant refill hose, Close the valve when the hose
is full of coolant.
注This purges trapped air from the hose.
-
Open air inlet valve to draw a vacuum,
Once gauge stabilizes, Fully close valve.
注Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed.
-
Once the gauge reads zero, close the
coolant refill valve.
-
Once the gauge reads zero, close the
refill valve.
-
Slowly open the refill valve to allow
coolant to be drawn into the system.
注Make sure hose end of refill hose is fully submerged during entire process.
-
Once the gauge reads zero, close the
refill valve.
-
Disconnect shop air supply from
coolant refill tool.
-
Remove coolant refill hose from
coolant container.
-
Remove coolant overflow hose from
coolant container.
-
Remove vacuum refill hose from refill
cap on superbottle.
注Push down on black ring to release hose and pull hose up to remove.
-
Remove coolant overflow hose from
coolant container.
-
Remove both coolant containers from
inside underhood area.
- Select ‘Actions/Autodiag’ tab and search for ‘Purge'.
-
Select
‘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
- 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
注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. -
Inspect coolant level and top off as
necessary.
注Ensure that the fluid level is 5mm above the Max line.
-
Install superbottle cap.
-
Install HVAC plenum outer duct.
注2x clips, Align tab at bottom of duct before securing clips.
-
Select
‘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
注Select ‘X’ at top right of window to close once complete. -
Remove HSD or RJ45 cable from Ethernet
port to disconnect Toolbox 3.0 from vehicle.
- Close RH rear door.
- Close LH rear door.
-
Close LH front door.
-
Remove lift arms from below
vehicle.
注Lower rack arms fully and remove them from under vehicle.
- Open all four doors.
-
Torque LH rear HV battery interior
bolt.
注1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary.
- Move LH front seat backward.
-
Torque LH front footwell HV battery
bolts.
注2x bolts, EP20, 136 Nm.
-
Fold the LH front main cabin carpet
back to original position.
注Move front edge down and slide back section up to ease positioning, Install seat harness into clip.
-
Install clips securing LH front main
cabin carpet to vehicle.
注3x push clips, Number of clips on newer vehicles may vary.
-
Move LH front seat forward.
-
Torque RH rear HV battery interior
bolt.
注1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary.
- Move RH front seat backward.
-
Torque RH front footwell HV battery
bolts.
注2x bolts, EP20, 136 Nm.
-
Unfold RH front main cabin carpet back
to original position.
注Move front edge down and slide back section up to ease positioning, Install seat harness into clips.
-
Install clips securing the RH front
main cabin carpet to footwell area.
注3x push clips, Number of clips may vary on older vehicles.
- Move RH front seat forward.
-
Install clips and secure Velcro
holding rear main cabin carpet to vehicle.
注4x push clips, The number of clips on newer vehicles may vary.
-
Install the LH lower B-pillar
assembly.
注1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
-
Install the LH upper B-pillar
assembly.
注4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
-
Install the LH rear door sill trim
panel.
注3x clips, 1x guide tab, Align the guiding tab to slot, Then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim. Newer vehicles may not be equipped with metal bracket and a foam insert will be present the bottom of trim piece.
-
Fold the 60 seat in down
position.
注Protect the seat cushion if necessary.
-
Install bolster plastic bracket to LH
side bolster.
注2x tabs, Install new bolster bracket.
-
Install LH side bolster.
注1x clip, 1x tab, Align the bottom tab then push inward to install.
-
Fold the 60 seat into vertical
position.
注Remove seat cushion protection.
-
Install the RH lower B-pillar
assembly.
注1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
-
Install the RH upper B-pillar
assembly.
注4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
-
Install RH rear door sill trim
panel.
注3x clips, 1x guide tab, Align the guiding tab to slot, then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim.
-
Fold the 40 seat in down
position.
注Protect the seat cushion if necessary.
-
Install bolster plastic bracket to RH
side bolster.
注2x tabs, Install new bolster bracket.
-
Install RH side bolster.
注1x clip, 1x tab, Align the bottom tab then push inward to install.
-
Fold the 40 seat into vertical
position.
注Remove seat cushion protection.
-
Connect 2nd row seat cushion harness
and install 2nd row seat cushion.
注2x connectors, 2x clips, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips.
-
Install 2nd row floor mat into
vehicle.
- Move RH front seat backward.
-
Install RH console side panel
carpet.
注1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
-
Install RH front floor mat.
-
Connect RH footwell assembly
connectors.
注2x connectors.
-
Install clips securing RH footwell
assembly.
注4x push clips .
-
Install RH lower A-pillar trim.
注1x clip, 2 guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar.
-
Install clip for RH lower A-pillar
trim.
注1x push clip.
-
Install RH mid A-pillar assembly.
注1x clip, 1x tab, Align bottom tab then push on top clip to fully seat mid A-pillar, Make sure seal seat on top of trim.
-
Install RH IP end cap.
注3x clips.
- Move LH front seat backward.
-
Install LH console side panel
carpet.
注1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
-
Install LH front floor mat.
-
Install connectors to LH footwell
cover and position for installation, securing front tabs to driver air bag
assembly.
注3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector.
-
Install screw and clips securing LH
footwell cover.
注2x push clips, 1x screw, T20, 2.5 Nm.
-
Install LH lower A-pillar trim.
注2x clip, 3 guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim.
-
Install clip for LH lower A-pillar
trim.
注1x push clip.
-
Install LH mid A-pillar assembly.
注1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim.
-
Install LH IP end cap.
注3x clips.
- Move LH front seat to original position.
- Move RH front seat to original position.
-
Install cabin intake upper duct
assembly.
注4x clips, Heat pump vehicles have 3x clips.
-
Install rear apron.
注12x clips .
- Close hood.
- Raise all windows.
-
Close all four doors.
注Unlatch rear doors before closing.
-
Install RH rocker panel lower cover
into position.
注10x clips.
-
Install clips securing the RH rocker
panel lower cover to wheel liners.
注4x push clips.
-
Install bolts securing RH rocker panel
lower cover to body.
注4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.
-
Install LH rocker panel lower cover
into position.
注10x clips.
-
Install clips securing the LH rocker
panel lower cover to wheel liners.
注4x push clips.
-
Install bolts securing LH rocker panel
lower cover to body.
注4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.