2026-10-20

HV Battery (AWD) (Remove and Install)

Correction code 16010201 3.24 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-02-26: Added steps to disconnect hoses from the front of the battery.
  • 2025-12-30: Moved HV glove removal steps to ensure that gloves are worn while handling all HV fittings.
  • 2025-07-11: Updated procedure to reflect Remove and Install, rather than Remove and Replace.
  • 2025-05-28: Modified step for attaching pyrotechnic battery disconnect when shipping the HV battery.
  • 2025-04-08: Added step for attaching pyrotechnic battery disconnect when shipping the HV battery.
Equipment:
  • 1936724-00-A - Universal Lift Pad Adapters
  • 1133787-00-A Key, Seat Belt Release, Model 3
  • 1020566-00-F ASY, Battery Table, Manual Lift
  • 1020566-99-A Top Plate, Battery Table, Manual Lift
  • 1129166-00-A Hoist, H-Frame EMEA
  • 1073363-00-A Gantry, Adjustable, Aluminum
  • 1134523-00-A Kit, Alignment Rods, Battery, Model 3
  • 1140311-00-A Lever Lock, HV Connector, Model 3
  • 1053600-00-B Drive Unit Pressure Test Fixture
  • 1130942-00-B Adapter, Coolant Reservoir Pressure Test
  • 1132185-00-B Kit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564 Kit, Battery Coolant Drain and Fill
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU

Torque Specifications

Table 1. Torque Specifications:HV Battery (AWD) (Remove and Install) / HV Battery (AWD) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
LH/RH middle/rear inner HV battery bolt.
66 Nm (48.7 lbs-ft)
  • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
  • 16 mm deep socket
  • 3 in extension
 Reuse
LH /RH front inner HV battery bolts
136 Nm (100.3 lbs-ft)
  • Torx Plus EP20 socket
  • 1/2 inch reversible ratchet wrench with rotary disc reverse RTCH-REV-1/2IN-72TEETH-250MM ZEBRA
  • EXT, 1/2" DR, 6
 Reuse
Nut (X1) securing DCDC ground busbar to HV battery
9 Nm (6.6 lbs-ft)
  • Class 00 Electrical Protective Gloves
  • 13 mm socket
  • 4 in extension
  • RATCHET, 1/4" DR, M12, BARE TOOL
 Replace
Bolt (X1) securing front drive unit HV harness to front drive unit
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • Class 00 Electrical Protective Gloves
  • Electrical Protective Gloves
 Replace
Front drive unit ground strap bolt from HV battery
10 Nm (7.4 lbs-ft)
  • Ratcheting Combination wrench Flex head 10mm
 Reuse
Nut (X1) securing rear drive unit HV cable bracket to HV battery.
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • DRIVER KIT, 1/4" HEX, M12
 Reuse
Bolt securing LH/RH side of subframe to body
125 Nm (92.2 lbs-ft)
  • 21 mm socket
  • Cordless Ratchet/Impact Driver
 Reuse
Central bolts (X4) securing HV battery center ski cover
34 Nm (25.1 lbs-ft)
  • External Torx Plus EP14
  • Cordless Ratchet/Impact Driver
  • 3 in extension
 Reuse
Bolts securing LH/RH front support bracket to vehicle
110 Nm (81.1 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • 16 mm deep socket
  • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
 Reuse
LH /RH bolts securing HV battery to vehicle
35 Nm (25.8 lbs-ft)
  • 13 mm socket
  • Cordless Ratchet/Impact Driver
  • 3 in extension
 Reuse

Remove

  1. Remove the LH and RH rocker carrier. See Rocker Carrier - LH (Remove and Replace).
  2. Remove the butyl patches that cover the LH and RH rocker access hole.
  3. Install lift pad adapters.
    • For EMEA only, install
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning
    DO NOT use any other lift pad adapters.
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace . Discard any other versions of lift pad adapters.
    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
      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. Enable Service Mode. See Service Mode.
  5. Unlock the gateway. See Gateway (Unlock).
  6. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  7. Remove the 2nd row LH seat assembly. See Seat Assembly - 2nd Row - LH (5-Seat) (Remove and Install).
  8. Disconnect the 2nd row 40 seat connector.
  9. Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt.
  10. Remove LH middle inner HV battery bolt.
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  11. Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt.
  12. Remove RH middle inner HV battery bolt.
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  13. Position air bag beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts.
  14. Remove LH rear inner HV battery bolt.
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  15. Remove RH rear inner HV battery bolt.
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  16. Remove the LH and RH lower A-pillar trims. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  17. Remove the LH and RH center console front side panels. See Side Panel - Front - Center Console - LH (Remove and Replace) and Side Panel - Front - Center Console - RH (Remove and Replace).
  18. Fold LH and RH front cabin carpets rearward.
  19. Remove foam plugs to access LH and RH front inner HV battery bolts.
  20. Remove both LH and RH front inner HV battery bolts.
    Tip
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • 1/2 inch reversible ratchet wrench with rotary disc reverse RTCH-REV-1/2IN-72TEETH-250MM ZEBRA
    • EXT, 1/2" DR, 6
  21. Disconnect the LV power. See LV Power (Disconnect and Connect) (Modify).
  22. Perform the Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  23. Release LH body harness from rear body and move aside
    Note
    1x clip
  24. Partially remove LH B-pillar lower trim
    Note
    1x push clip
  25. Partially pull out LH rear body harness
  26. Remove all items from pockets and ensure not wearing metal items
  27. Inspect HV insulating gloves
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, For information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  28. Put on HV insulating gloves and leather over gloves
  29. Remove fastener securing busbar cover access door
    Note
    1x bolt, 10mm, 9 Nm
  30. Remove bolts securing charge port busbar kit to HV header
    Note
    2x bolts, 10mm, 9 Nm
  31. Lift busbar kit connector to remove from HV header
    Note
    Use inflatable air bag to suspend Busbar away from HV header during removal and installation, Hold busbar firmly as there is tension on, Avoid damaging the harness bracket
  32. Remove HV insulating gloves
  33. Disconnect HVC logic connector and install logic cap
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  34. Release positive 12V output cover from PCS cable
    Note
    1x cover
  35. Remove PCS cable from 12V passthrough output
    Note
    1x nut, 13mm, 9 Nm, Discard nut after removal
  36. Remove nut securing DCDC ground busbar to HV battery
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  37. Gently lift the DCDC ground busbar upwards
  38. Remove front skid plate from HV battery. See Skid Plate - HV Battery - Front (Remove and Replace).
  39. Inspect HV insulating gloves
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  40. Put on HV insulating gloves and leather over gloves
  41. Disconnect AC compressor HV harness connector from HV Ancillary harness.
    Note
    Disengage the red locking tab by pulling it away from the connector, depress yellow tab and pull the connector backward then depress the green tab to release.
  42. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  43. Slide the red release tab to unlock the front drive unit HV harness connector, and then slowly unlatch the release handle on the front drive unit HV harness connector, and then disconnect the connector from the front drive unit.
    CAUTION
    Do not apply excessive force to the handle; doing so could damage the connector alignment tabs.
    Note
    Make sure that the alignment tabs on the front drive unit header are not damaged.
  44. Remove the front drive unit harness from the casting, and then move the harness aside.
  45. Remove leather over gloves and HV insulating gloves.
  46. Remove the FDU ground strap bolt from HV battery.
    Note
    1x bolt, 10mm, 10 Nm
  47. Position coolant drain container underneath LH front of HV battery.
  48. Disconnect HV battery return hose at LH side of vehicle and plug hoses.
  49. Position coolant drain container underneath LH front of HV battery.
  50. Release chiller to battery hose from body.
  51. Disconnect HV battery front manifold hose from chiller to battery hose.
    Note
    Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill.
  52. Position coolant drain container underneath RH front of HV battery.
  53. Disconnect FDU inverter inlet hose to rear powertrain return hose and plug hoses.
    Note
    If the battery is returned to Reman, please remove the special tool plugs.
  54. Disconnect powertrain supply hose from powertrain supply tube and plug hoses.
    Note
    Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill.
  55. Remove coolant drain container from underneath vehicle
  56. Remove rear skid plate from HV battery. See Skid Plate - Rear (Remove and Replace).
  57. Put on HV insulating gloves and leather over gloves
  58. Remove nut securing RDU HV cable bracket to HV battery
    Note
    1x nut, 10mm, 10 Nm
  59. Disconnect RDU HV cable from HV battery
    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
  60. Remove HV insulating gloves
  61. Position coolant drain container under LH rear of vehicle
  62. Disconnect LH coolant hose from rear of HV battery
    Note
    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
  63. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Note
    1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill
  64. Position coolant drain underneath RH rear of HV battery
  65. Disconnect coolant outlet hose to rear return hose and plug hoses
    Note
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary, Coolant loss greater than 1 L will require vacuum fill
  66. Remove both LH and RH shear plate for the rear subframe. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  67. Hand tighten bolt securing RH side of subframe to body.
    Tip
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • Cordless Ratchet/Impact Driver
  68. Remove support stand from under vehicle.
  69. Place HV battery table into position and lower vehicle to support HV battery.
    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.
  70. Remove central bolts securing HV battery center ski cover.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  71. Remove bolts securing LH front support bracket to vehicle.
    Tip
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  72. Remove bolts securing RH front support bracket to vehicle.
    Tip
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  73. Remove LH bolts securing HV battery to vehicle.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  74. Remove RH bolts securing HV battery to vehicle
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  75. Raise vehicle free of HV battery.
  76. Remove battery from under vehicle.
    Note
    Recommend assistance.
  77. Remove penthouse engagement seal from HV battery pack.
    Note
    Discard anytime HV battery is removed from vehicle.

Install

  1. Install new penthouse engagement seal onto HV battery pack.
    Note
    This seal is a single-use item and should be replaced each time a HV battery pack is removed from the vehicle.
  2. Install HV battery alignment rods.
  3. Position HV battery under vehicle.
  4. Lower vehicle onto HV battery and align holes
  5. Loosely install RH and LH bolts securing HV battery to vehicle hand tight.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  6. Remove HV battery alignment rods.
  7. Set up ladder (Ladder - 1088037-00-A).
  8. Install LH and RH rear inner HV battery bolt hand tight.
    Tip
    Use of the following tool(s) is recommended:
    • Class 00 Electrical Protective Gloves
    • 13 mm socket
    • 4 in extension
    • RATCHET, 1/4" DR, M12, BARE TOOL
  9. Install LH and RH middle inner HV battery bolt hand tight.
    Tip
    Use of the following tool(s) is recommended:
    • Class 00 Electrical Protective Gloves
    • 13 mm socket
    • 4 in extension
    • RATCHET, 1/4" DR, M12, BARE TOOL
  10. Install both LH and RH front inner HV battery bolts hand tight.
    Tip
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • 1/2 inch reversible ratchet wrench with rotary disc reverse RTCH-REV-1/2IN-72TEETH-250MM ZEBRA
    • EXT, 1/2" DR, 6
  11. Remove ladder.
  12. Set bolts securing RH and LH front support bracket to vehicle with cordless impact
    Tip
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  13. Set central bolts securing HV battery center ski cover with cordless impact.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  14. Lower vehicle onto pack completely.
  15. Torque RH and LH bolts securing HV battery to vehicle.
    35 Nm (25.8 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  16. Torque bolts securing RH and LH front support bracket to vehicle.
    110 Nm (81.1 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 16 mm deep socket
    • 1/2 inch socket wrench hexagon short SKTWRNCH-1/2IN-SHORT-HEX-WS16 ZEBRA
  17. Torque central bolts securing HV battery through center ski cover.
    34 Nm (25.1 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP14
    • Cordless Ratchet/Impact Driver
    • 3 in extension
  18. With assistance, raise vehicle and lower onto locks, then remove battery table from under vehicle.
  19. Position support stand to support front section of rear subframe.
  20. Remove bolt securing LH and RH side of rear subframe to body.
    Tip
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • Cordless Ratchet/Impact Driver
  21. Install the LH and RH rear shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  22. Install clips securing coolant hoses to LH shear plate.
  23. Position coolant drain underneath RH rear of HV battery.
  24. Install clip securing coolant hoses to RH shear plate.
  25. Remove hose plugs and connect coolant outlet hose to rear return hose.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  26. Position coolant drain container under LH rear of vehicle.
  27. Remove plugs and connect rear drive unit inverter inlet hose to rear of HV battery.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  28. Connect LH coolant hose to rear of HV battery.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  29. Remove coolant drain container from underneath vehicle.
  30. Put on HV insulating gloves and leather over gloves.
  31. Connect rear drive unit HV cable to HV battery.
  32. Install nut securing rear drive unit HV cable bracket to HV battery.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Class 00 Electrical Protective Gloves
    • Electrical Protective Gloves
  33. Remove HV insulating gloves.
  34. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  35. Position coolant drain container underneath LH front of HV battery.
  36. Connect HV battery front manifold coolant hose
    Note
    1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  37. Secure chiller to battery hose onto body.
  38. Connect HV battery coolant return hose.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  39. Position coolant drain container underneath RH front of HV battery.
  40. Connect front drive unit inverter inlet hose to rear powertrain return hose
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  41. Connect powertrain supply hose.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  42. Remove coolant drain container from underneath vehicle.
  43. Put on HV insulating gloves and leather over gloves.
  44. Connect AC compressor HV harness connector.
  45. lnstall front drive unit HV harness to casting.
  46. Install front drive unit HV harness connector to front drive unit.
  47. Install bolt securing front drive unit HV harness to front drive unit.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Class 00 Electrical Protective Gloves
    • Electrical Protective Gloves
  48. Remove HV insulating gloves.
  49. Install front drive unit ground strap and bolt to HV battery.
    10 Nm (7.4 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Ratcheting Combination wrench Flex head 10mm
  50. Install front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  51. Move rack arms away from vehicle。
  52. Install butyl patches onto LH and RH rocker access holes.
  53. Install the LH and RH rocker carrier. See Rocker Carrier - LH (Remove and Replace).
  54. Install DCDC ground busbar to HV battery.
    Note
    Gently press down
  55. Install nut securing DCDC ground busbar to HV battery.
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
  56. Install positive 12V output from PCS cable and torque nut securing it.
    Note
    1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque
  57. Install positive 12V output cover to PCS cable.
    Note
    1x cover
  58. Remove logic cap and connect HVC logic connector.
    Note
    1x connector, 1x logic cap, Align connector then pull the handle to locking position get connector fully seated
  59. Put on HV insulating gloves and leather over gloves.
  60. Clean HV connector contact surface of residual Penetrox.
    Note
    Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
  61. Clean busbar HV connector contact surface of residual Penetrox.
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  62. Apply Penetrox onto HV connector joints.
    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
  63. Remove Inflatable Air Bag from under HV header.
  64. Position busbar kit connector and lower onto HV header.
    Note
    4x guide tabs, 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
  65. Install bolts securing charge port busbar kit to HV header.
    Note
    2x bolts, 10mm, 9 Nm, Mark after torque
  66. Perform a zero adjust of the Hioki resistance meter. See Resistance Meter (Zero Adjust).
  67. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    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), stop work and escalate the Toolbox session. 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
  68. Install fastener securing busbar cover access door.
    Note
    1x bolt, 10mm, 9 Nm
  69. Connect 3PH chargeport inlet harness to HV header.
    Note
    1x connector, Rotate lever arm and secure locking tab
  70. Remove HV insulating gloves.
  71. Position the LH rear body harness under LH lower C pillar trim.
  72. Install the LH body harness onto the rear body.
    Note
    1x clip
  73. Partially install the LH B-pillar lower trim.
    Note
    1x push clip
  74. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  75. Connect the LV battery. See LV Power (Disconnect and Connect) (Modify).
  76. Unlock the gateway. See Gateway (Unlock).
  77. Select Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  78. Select Coolant Purge Start > Run, and allow the routine to complete.
    Note
    Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  79. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Note
    Ensure that the coolant level is at the "Max" line.
  80. Torque both RH forward HV battery bolts.
    136 Nm (100.3 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx Plus EP20 socket
    • 1/2 inch reversible ratchet wrench with rotary disc reverse RTCH-REV-1/2IN-72TEETH-250MM ZEBRA
    • EXT, 1/2" DR, 6
  81. Install RH front cabin carpet support access plug.
  82. Fold RH front main cabin carpet back to original position.
  83. Install the console RH front side panel. See Side Panel - Front - Center Console - LH (Remove and Replace).
  84. Repeat step 80 through 83for LH side of the vehicle.
  85. Torque LH and RH rear inner HV battery bolt.
    66 Nm (48.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  86. Remove air bag from between rear cabin carpet and body.
  87. Torque LH and RH middle inner HV battery bolt.
    66 Nm (48.7 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 3/8 inch ratchet with rotary disc changeover RTCH-REV-3/8IN-72TEETH-L175MM ZEBRA
    • 16 mm deep socket
    • 3 in extension
  88. Fold LH and RH side of rear main carpet to its original position.
  89. Connect the 2nd row 40 seat connector.
  90. Install the 2nd row RH seat assembly. See Seat Assembly - 2nd Row - RH (5-Seat) (Remove and Install).
  91. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Note
    Ensure that the coolant level is at the "Max" line.
  92. Exist the Service Mode. See Service Mode.
  93. Install the HEPA filter assembly. See HEPA And Carbon Filters (Remove and Replace).
  94. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  95. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2-Post Lift.