2026-10-08

Brake Lines - Pipe - Side Sill (Remove and Replace)

Correction code 3303010202 FRT 5.28 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.

  • 2026-10-08: Removed the 2nd row 40 seat, pyro disconnect, HV front manifold tube, and stabilizer bar removal and installation steps.

Remove

  1. Open all doors and lower all windows.
  2. Place the vehicle in Service Mode by using the touchscreen. See Service Mode.
  3. Remove the LH and RH rocker carriers. See Rocker Carrier - LH (Remove and Replace).
  4. Remove the butyl patches (x2) that cover the LH rocker access holes, and clean excess butyl from area.
  5. Install lift pad adapters (x2) onto the LH lift.
  6. Remove the butyl patches (x2) that cover the RH rocker access holes, and clean excess butyl from area.
  7. Unlock the vehicle gateway. See Gateway (Unlock).
  8. 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.
  9. Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  10. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  11. Remove the 2nd row LH seat. See Seat Assembly - 2nd Row - LH (5-Seat) (Remove and Install).
  12. Disconnect the 2nd row 40 seat connector.
  13. Separate the carpet perforations below the rear of the LH and RH front seats, and remove the LH and RH middle inner HV battery bolts.
    Note
    Expand the hole if necessary.
    Tip
  14. Position an inflatable air bag beneath the rear cabin carpet to raise and allow access to the rear inner HV battery bolts.
  15. Remove the LH and RH rear inner HV battery bolts.
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  16. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  17. Remove the center console LH front side panel. See Side Panel - Front - Center Console - LH (Remove and Replace).
  18. Fold the LH front cabin carpet rearward.
    Note
    Maneuver the carpet below the brake pedal and the accelerator pedal. If the carpet and foam are stuck together, tear them apart.
  19. Remove the foam plug to access the LH front inner HV battery bolts.
  20. Remove the LH front inner HV battery bolts (x2).
    Note
    2x bolts, EP20, 136 Nm
  21. Repeat step 16 to 20 for the RH side.
    Note
    For the center console RH front side panel. See Side Panel - Front - Center Console - RH (Remove and Replace).
  22. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  23. Release the LH body harness from the rear body and move it aside.
  24. Partially remove the LH B-pillar lower trim.
  25. Partially pull out the LH rear body harness.
  26. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  27. Remove the bolt that secures the busbar cover access door.
    Note
    1x bolt, 10mm, 9 Nm
  28. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Note
    2x bolts, 10mm, 9 Nm
  29. Lift the busbar kit connector to remove it from the HV header.
    Note
    Use an inflatable air bag to suspend the busbar away from the HV header during removal and installation. Hold the busbar firmly as there is tension on. Avoid damaging the harness bracket.
  30. Disconnect the AC charge port inlet harness from the HV header.
    Note
    Release the red locking tab and rotate the lever arm to release.
  31. Disconnect the HVC logic connector and install the logic cap.
    Note
    Release the locking tab then pivot the handle downward to release the connector.
  32. Remove the PCS cable from the 12V pass through output.
    Tip
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Cordless Ratchet/Impact Driver
    • 12 mm deep socket
  33. Remove nut securing DCDC ground busbar to HV battery
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  34. Gently lift the DCDC ground busbar upwards
  35. Close all four doors
  36. Install lift pad adapters onto RH lift
    Note
    2x lift pad adapters
  37. Raise and support vehicle
    Note
    Recommended assistance, Before lifting, ensure that the vehicle is not connected to a charging device, The positioning pin must be inserted into the car body holes
  38. Remove LH front fender garnish
    Note
    1x push clip, 11x clips, 1x tab, 1x location tab, Release from front end of garnish and work your way outward towards rear ends, then release tab
  39. Remove LH front wheel cap
    Note
    1x cap, Use tool to gently pull the center wheel cap to release the clips, Wheels may be equipped with different caps
  40. Loosen LH front wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  41. Remove RH front wheel cap
    Note
    1x cap, Use tool to gently pull the center wheel cap to release the clips, Wheels may be equipped with different caps
  42. Loosen RH front wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  43. Remove LH rear wheel cap
    Note
    1x cap, Use tool to gently pull center wheel cap to release clips, Wheels may be equipped with different caps
  44. Loosen LH rear wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  45. Remove RH rear wheel cap
    Note
    1x cap, Use tool to gently pull center wheel cap to release clips, Wheels may be equipped with different caps
  46. Loosen RH rear wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  47. Raise vehicle partially and lower lift onto locks
    Note
    Set vehicle to a 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
  48. Remove LH front wheel
    Note
    5x nuts, 21mm, 175 Nm
  49. Remove bolt securing LH front wheel liner to skid plate
    Note
    1x bolt, 10mm, 5 Nm
  50. Remove clips securing LH front wheel liner to body
    Note
    15x push clips, 2x push nuts
  51. Remove LH front wheel liner
  52. Remove LH rear wheel
    Note
    5x nuts, 21mm, 175 Nm
  53. Remove clips securing LH rear wheel liner to body
    Note
    17x clips
  54. Remove LH rear wheel liner
  55. Remove RH front wheel
    Note
    5x nuts, 21mm, 175 Nm
  56. Remove bolt securing RH front wheel liner to skid plate
    Note
    1x bolt, 10mm, 5 Nm
  57. Remove clip securing RH wheel liner to body
    Note
    1x push clip
  58. Use bungee strap to pull back RH front wheel liner
    Note
    Secure to subframe
  59. Remove RH rear wheel
    Note
    5x nuts, 21mm, 175 Nm
  60. Raise vehicle fully and lower lift onto locks
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
  61. Remove bolts securing front aero shield
    Note
    7x bolts, 10mm, 5 Nm
  62. Remove front aero shield from studs
    Note
    2x nuts, 15mm, 8 Nm
  63. Remove front skid plate
    Note
    4x bolts, EP10, 13 Nm, 2x tabs, Move forward to remove
  64. 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
  65. Put on HV insulating gloves and leather over gloves
  66. Disconnect AC compressor HV harness connector
    Note
    1x locking connector, 3 stage locking connectors, 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
  67. Remove bolt securing FDU HV harness to FDU
    Note
    1x bolt,10mm, 10 Nm
  68. Release FDU HV harness connector
    Note
    1x connector. Release red 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
  69. Release FDU HV harness from casting and move aside
    Note
    1x casting datum
  70. Remove HV insulating gloves
  71. Remove FDU ground strap bolt from HV battery
    Note
    1x bolt, 10mm, 10 Nm
  72. Position coolant drain container underneath LH front of HV battery
  73. Disconnect HV battery return hose at LH side of vehicle and plug hoses
    Note
    1x spring clip
  74. Remove HV battery front manifold hose clip from body
    Note
    1x clip
  75. Disconnect HV battery manifold hoses and plug hoses
    Note
    1x spring clip, Loss of coolant greater than 1L requires coolant vacuum fill.
  76. Position coolant drain container underneath RH front of HV battery
  77. Disconnect FDU inverter inlet hose to rear powertrain return hose and plug hoses
    Note
    1x spring clip
  78. Disconnect powertrain supply hose from powertrain supply tube and plug hoses
    Note
    1x spring clip, Coolant loss greater than 1 L will require vacuum fill
  79. Position coolant drain container underneath front of HV battery
  80. Remove coolant drain container from underneath vehicle
  81. Remove LH and RH push clips securing mid aero shield to wheel house liner
    Note
    2x clips
  82. Remove mid aero shield
    Note
    11x bolts, 2x tabs, 10mm, 5 Nm
  83. Release clips securing coolant hoses to LH shear plate
    Note
    2x fir tree clips
  84. Release LH side hose clip from rear battery skid plate
    Note
    1x fir tree clip
  85. Release RH side hose clips from rear battery skid plate
    Note
    2x fir tree clips
  86. Remove lower bolts securing HV battery rear skid plate enclosure
    Note
    2x bolts, EP10, 13 Nm
  87. Remove upper bolts securing HV battery rear skid plate enclosure
    Note
    4x bolts, 13mm, 64 Nm
  88. Remove HV battery rear skid plate enclosure
  89. Put on HV insulating gloves and leather over gloves
  90. Remove nut securing RDU HV cable bracket to HV battery
    Note
    1x nut, 10mm, 10 Nm
  91. 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
  92. Remove HV insulating gloves
  93. Position coolant drain container under LH rear of vehicle
  94. Disconnect LH coolant hose from rear of HV battery
    Note
    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough
  95. 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
  96. Position coolant drain underneath RH rear of HV battery
  97. 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
  98. Release clip securing coolant hoses to RH shear plate
    Note
    1x fir tree clip
  99. Position support stand to support front portion of rear subframe
  100. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
  101. Place oil drain under front brake line junction area
    Note
    Lower vehicle if necessary
  102. Release brake pipes from coupling
    Note
    2x nuts, 12mm, 16 Nm
  103. Place oil drain pan under LH rear brake line junction block
    Note
    Raise vehicle if necessary
  104. Remove LH rear brake line tube outer nut
    Note
    1x nut, 12mm, 16 Nm
  105. Remove LH rear brake line tube inner nut
    Note
    1x nut, 12mm, 16 Nm
  106. Remove black clip from LH rear junction block
    Note
    1x clip
  107. Release brake lines from LH rear junction block
    Note
    2x brake lines
  108. Remove side sill brake lines from vehicle
    Note
    5x clips, 2x brake lines

Install

  1. Install side sill brake lines to vehicle
    Note
    5x clips, 2x brake lines, Replace damaged clips
  2. Position brake lines into LH rear brake junction block
    Note
    2x brake lines
  3. Install black clip securing brake lines to LH rear junction block
    Note
    1x clip
  4. Install LH rear brake line tube inner nut
    Note
    1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
  5. Install LH rear brake line tube outer nut
    Note
    1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
  6. Remove oil drain under LH rear brake line junction block
  7. Install brake pipes to coupling
    Note
    2x nuts, 12mm, 16 Nm, Start nut by hand to avoid cross threading
  8. Remove oil drain under LH front brake line junction area
  9. Install penthouse engagement seal onto HV battery pack
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped
  10. Install HV battery alignment rods
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
  11. Position HV battery under vehicle
    Note
    Recommend assistance
  12. Lower vehicle onto HV battery and align holes
    Note
    Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
  13. Loosely install RH bolts securing HV battery to vehicle hand tight
    Note
    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
  14. Loosely install LH bolts securing HV battery to vehicle hand tight
    Note
    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
  15. Remove HV battery alignment rods
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
  16. Install LH rear inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  17. Install LH middle inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  18. Install RH rear inner battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  19. Install RH inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  20. Install both LH front inner HV battery bolts hand tight
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  21. Install both RH front inner HV battery bolts hand tight
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  22. Set bolts securing RH front support bracket to vehicle with cordless impact
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  23. Set bolts securing LH front support bracket to vehicle with cordless impact
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  24. Set central bolts securing HV battery center ski cover with cordless impact
    Note
    4x bolts, EP14, 34 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
  25. Lower vehicle onto pack completely
    Note
    Recommend assistance
  26. Torque RH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  27. Torque LH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  28. Torque bolts securing RH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  29. Torque bolts securing LH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  30. Torque central bolts securing HV battery through center ski cover
    Note
    4x bolts, EP14, 34 Nm
  31. Raise vehicle and lower onto locks, then remove battery table from under vehicle
    Note
    Recommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  32. Position support stand to support front section of rear subframe
  33. Remove bolt securing LH side of rear subframe to body
    Note
    1x bolt, 21mm, 125 Nm
  34. Install bolts securing LH shear plate to HV battery hand tight
    Note
    2x bolts, 13mm, 64 Nm, Torque at later step
  35. Install bolt and shear plate to LH side of rear subframe hand tight
    Note
    1x bolt, 21mm, 125 Nm, Torque at later step
  36. Torque bolt securing subframe and LH shear plate to body
    Note
    1x front bolt, 21mm, 125 Nm, Mark bolt after torque
  37. Torque bolts securing LH shear plates to vehicle
    Note
    2x bolts, 13mm, 64 Nm
  38. Remove bolt securing RH side of rear subframe to body
    Note
    1x bolt, 21mm, 125 Nm
  39. Install bolts securing RH shear plate to HV battery hand tight
    Note
    2x bolts, 13mm, 65 Nm, Torque at later step
  40. Install bolt and shear plate to RH side of rear subframe hand tight
    Note
    1x bolt, 21mm, 125 Nm, Torque at later step
  41. Torque bolt securing subframe and RH rear shear plate to body
    Note
    1x bolt, 21mm, 125 Nm
  42. Torque bolts securing RH shear plates to vehicle
    Note
    2x bolts, 13mm, 64 Nm
  43. Remove support stand from under vehicle
  44. Install clips securing coolant hoses to LH shear plate
    Note
    2x fir tree clips
  45. Position coolant drain underneath RH rear of HV battery
  46. Install clip securing coolant hoses to RH shear plate
    Note
    1x fir tree clip
  47. Remove hose plugs and connect coolant outlet hose to rear return hose
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  48. Position coolant drain container under LH rear of vehicle
  49. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  50. Connect LH coolant hose to rear of HV battery
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  51. Remove coolant drain container from underneath vehicle
  52. Put on HV insulating gloves and leather over gloves
  53. Connect RDU HV cable to HV battery
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
  54. Install nut securing RDU HV cable bracket to HV battery
    Note
    1x nut, 10mm, 10 Nm
  55. Remove HV insulating gloves
  56. Position HV battery rear skid plate enclosure onto HV battery for installation
    Note
    Recommend assistance if needed
  57. Install upper bolts securing HV battery rear skid plate enclosure hand tight
    Note
    4x bolts, 13mm, 64 Nm
  58. Install lower bolts securing HV battery rear skid plate enclosure
    Note
    2x bolts, EP10, 13 Nm
  59. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Note
    4x bolts, 13mm, 64 Nm
  60. Install RH side hose clips to HV battery rear skid plate enclosure
    Note
    2x fir tree clips
  61. Install LH side hose clip to HV battery rear skid plate enclosure
    Note
    1x fir tree clip
  62. lnstall mid aero shield
    Note
    2x tabs, 11x bolts, 10mm, 5 Nm, Position rear datums first, Apply Loctite 222 onto rear aero shield bolts
  63. Install LH and RH push clips securing mid aero shield to wheel house liner
    Note
    2x clips
  64. Position coolant drain container underneath front of HV battery
  65. Position coolant drain container underneath LH front of HV battery
  66. 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
  67. Install HV battery front manifold hose clip to body
    Note
    1x clip
  68. Connect HV battery coolant return 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
  69. Position coolant drain container underneath RH front of HV battery
  70. Connect FDU inverter inlet hose to rear powertrain return 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
  71. Connect powertrain supply hose
    Note
    1x spring clip, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  72. Remove coolant drain container from underneath vehicle
  73. Put on HV insulating gloves and leather over gloves
  74. Connect AC compressor HV harness connector
    Note
    1x locking connector, 3 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector, Engage locking tab
  75. lnstall FDU HV harness to casting
    Note
    Install HV connector lever lock to FDU HV cable connector
  76. Install FDU HV harness connector to FDU
    Note
    1x connector, Align connector to FDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
  77. Install bolt securing FDU HV harness to FDU
    Note
    1x bolt, 10mm, 10 Nm
  78. Remove HV insulating gloves
  79. Install FDU ground strap and bolt to HV battery
    Note
    1x bolt, 10mm, 10 Nm
  80. Install front skid plate
    Note
    4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation
  81. Position front aero shield onto vehicle
    Note
    2x datums, 2x nuts, 15mm, 8 Nm, Hand-tighten the nuts to temporarily hold the panel in place
  82. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Note
    7x bolts, 10mm, 5 Nm
  83. Torque front aero shield nuts
    Note
    2x nuts, 15mm, 5 Nm
  84. Lower vehicle partially and set onto locks
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  85. Install DCDC ground busbar to HV battery
    Note
    Gently press down
  86. Install nut securing DCDC ground busbar to HV battery
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
  87. 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
  88. Install positive 12V output cover to PCS cable
    Note
    1x cover
  89. 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
  90. Put on HV insulating gloves and leather over gloves
  91. Clean HV connector contact surface of residual Penetrox
    Note
    Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
  92. 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
  93. 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
  94. Remove Inflatable Air Bag from under HV header
  95. 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
  96. Install bolts securing charge port busbar kit to HV header
    Note
    2x bolts, 10mm, 9 Nm, Mark after torque
  97. 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
  98. Install fastener securing busbar cover access door
    Note
    1x bolt, 10mm, 9 Nm
  99. Connect 3PH chargeport inlet harness to HV header
    Note
    1x connector, Rotate lever arm and secure locking tab
  100. Remove HV insulating gloves
  101. Position LH rear body harness under LH lower C pillar trim
  102. Install LH body harness onto rear body
    Note
    1x clip
  103. Partially install LH B-pillar lower trim
    Note
    1x push clip
  104. Remove coolant bottle cap
    Note
    Vacuum fill required if greater than 1L lost during repair
  105. Place empty coolant container into front storage area
  106. Fill container with coolant
    Note
    Do not draw in air during fill process, for RWD, the entire system requires coolant is 15l, for AWD, the entire system requires coolant is 18l
  107. Place filled coolant container into front storage area
  108. Install refill tool cap onto coolant bottle assembly
  109. Setup vacuum refill tool
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  110. Install vacuum refill hose into refill cap on coolant bottle
    Note
    Perform push-pull-push test to verify hose is fully engaged
  111. Position overflow hose into empty container
  112. Place refill hose inside filled coolant container
    Note
    Make sure hose end is fully submerged into coolant
  113. Connect shop air supply to coolant refill tool
  114. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  115. Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
  116. Slowly open refill valve to allow coolant to be drawn into system
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  117. Once gauge reads zero, close refill valve
  118. Disconnect shop air supply from coolant refill tool
  119. Remove coolant refill hose from coolant container
  120. Remove coolant overflow hose from coolant container
  121. Remove vacuum refill hose from refill cap on coolant bottle
  122. Remove refill tool cap from coolant bottle assembly
  123. Remove coolant refill tool from vehicle
  124. Remove both coolant containers from inside underhood area
  125. Connect First Responder Loop and LV battery
    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  126. Run ODIN routine
  127. Run ODIN routine
  128. Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    via Toolbox:(link)
  129. Place absorbent material underneath brake lines and brake fluid reservoirto catch any fluid lost
  130. Clean area around brake fluid reservoir and remove brake reservoir cap
  131. Top off brake fluid reservoir
    Note
    Top off brake fluid as needed
  132. Fill brake bleeder reservoir to full level
  133. Install pressure bleeder adapter onto reservoir
  134. Setup brake bleeder
    Note
    Connect power supply to bleeder and turn on the power to set pressure to 30 psi, Attach the brake reservoir hose to the brake adapter at this time
  135. Remove LH front caliper bleed valve covers then install fluid catcher to outer bleed valve
    Note
    2x covers
  136. Run ODIN routine PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
  137. Repeat bleed process until LH front caliper fluid is free of air bubbles
    Note
    Brembo: 2x bleed valves, 11mm, 18.5 Nm
  138. Remove fluid catcher then torque LH front caliper bleed valves
    Note
    2x bleed valves, 11mm, 18.5 Nm, 2x covers, Install covers when torqued
  139. Remove RH front caliper bleed valve covers then install fluid catcher to outer bleed valve
    Note
    2x covers
  140. Run ODIN routine PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link)
  141. Repeat bleed process until RH front caliper fluid is free of air bubbles
    Note
    Brembo: 2x bleed valves, 11mm, 18.5 Nm
  142. Remove fluid catcher then torque RH front caliper bleed valves
    Note
    2x bleed valves, 11mm, 18.5 Nm, 2x covers, Install covers when torqued
  143. Remove RH rear caliper bleed valve cover then install fluid catcher
    Note
    1x cover
  144. Run ODIN routine PROC_ESP_FRONT-L-REAR-R_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FL-RRvia Toolbox:(link)
  145. Repeat bleed process until RH rear caliper fluid is free of air bubbles
    Note
    1x bleeding valve, Base: 11mm, 10 Nm
  146. Remove fluid catcher then torque RH rear caliper bleed valve
    Note
    1x cover, 1x bleeding valve, Base: 11mm, 10 Nm, Install cover when torqued
  147. Remove LH rear caliper bleed valve cover then install fluid catcher
    Note
    1x cover
  148. Run ODIN routine PROC_ESP_FRONT-R-REAR-L_BRAKE-BLEEDvia Service Mode:Chassis ➜ Brakes ➜ Brake Bleed FR-RLvia Toolbox:(link)
  149. Repeat bleed process until LH rear caliper fluid is free of air bubbles
    Note
    1x bleeding valve, Base: 11mm, 10 Nm
  150. Remove fluid catcher then torque LH rear caliper bleed valve
    Note
    1x cover, 1x bleeding valve, Base: 11mm, 10 Nm, Install cover when torqued
  151. Turn off and remove pressure brake bleeder kit from vehicle
  152. Check brake fluid level
    Note
    Top off if necessary
  153. Install brake reservoir cap
  154. Remove absorbent material from underneath brake booster assembly and reservoir area
  155. Pump brake pedal a few times to ensure brake pedal feels normal
  156. Run ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICEvia Service Mode:Chassis ➜ Brakes ➜ Brake Stiffness Testvia Service Mode Plus:chassis ➜ ESP Replacement Panel ➜ Stiffness Testvia Toolbox:(link)
  157. Install LH front wheel liner
  158. Install clips securing LH wheel liner to body
    Note
    15x push clips, 2x push nuts
  159. Install bolt securing LH front wheel liner to skid plate
    Note
    1x bolt, 10mm, 5 Nm
  160. Install LH front fender garnish
    Note
    1x push clip, 11x clips, 1x tab, 1x location tab, Start at rear and maneuver into rocker panel
  161. Install LH front wheel
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  162. Release RH front wheel liner from bungee strap
    Note
    Remove strap from vehicle
  163. Install bolt securing RH front wheel liner to skid plate
    Note
    1x bolt, 10mm, 5 Nm
  164. Install clip securing RH wheel liner to body
    Note
    1x push clip
  165. Install RH front wheel
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  166. Position LH rear wheel liner for installation
  167. Install clips securing LH rear wheel liner to body
    Note
    17x clips
  168. Install LH rear wheel
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  169. Install RH rear wheel
    Note
    5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
  170. Lower vehicle until tires are touching ground
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  171. Torque LH front wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  172. Install LH front wheel cap
    Note
    1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
  173. Torque RH front wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  174. Install RH front wheel cap
    Note
    1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
  175. Torque LH rear wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  176. Install LH rear wheel cap
    Note
    1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
  177. Torque RH rear wheel nuts
    Note
    5x nuts, 21mm, 175 Nm
  178. Install RH rear wheel cap
    Note
    1x cap, Align valve stem with wheel cap cavity, Wheels may be equipped with different caps
  179. Lower vehicle fully
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  180. Move rack arms away from vehicle
  181. Install butyl patches onto LH rocker access holes
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  182. Install LH rocker carrier onto body
    Note
    10x clips, 1x location pin
  183. Install bolts securing LH rocker carrier to body
    Note
    2x bolts, 10mm, 9 Nm
  184. Install LH rocker cover onto rocker carrier
    Note
    11x clips, 11x tabs, 1x location pin, Tabs go into cavities on rocker carrier and cannot be accessed from outer side of cover, Ensure that all tabs are installed properly
  185. Install clips securing LH rocker cover and rocker carrier to LH front wheel liner
    Note
    2x clips
  186. Install clips securing LH rocker cover and rocker carrier to LH rear wheel liner
    Note
    2x clips
  187. Install butyl patches onto RH rocker access holes
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  188. Install RH rocker carrier onto body
    Note
    10x clips, 1x location pin
  189. Install bolts securing RH rocker carrier to body
    Note
    2x bolts, 10mm, 9 Nm
  190. Install RH rocker cover onto rocker carrier
    Note
    11x clips, 11x tabs, 1x location pin, Tabs go into cavities on rocker carrier and cannot be accessed from outer side of cover, Ensure that all tabs are installed properly
  191. Install clips securing RH rocker cover and rocker carrier to RH front wheel liner
    Note
    2x clips
  192. Install clips securing RH rocker cover and rocker carrier to RH rear wheel liner
    Note
    2x clips
  193. Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
  194. Torque both RH forward HV battery bolts
    Note
    2x bolts, EP20, 136 Nm
  195. Install RH front cabin carpet support access plug
    Note
    1x plug
  196. Fold RH front main cabin carpet back to original position
  197. Install console RH front side panel
    Note
    14x clips, 2x locating pins, Ensure all clips and pins seat properly
  198. Install RH knee air bag cover to IP carrier
    Note
    1x connector, 5x tabs, 1x location pin
  199. Secure front RH cabin carpet cover to RH knee air bag cover
    Note
    1x connector, 2x magnets, 2x datums
  200. Install RH lower A pillar trim
    Note
    8x clips, 2x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar
  201. Install RH IP end cap
    Note
    5x clips, 2x guide tabs
  202. Install RH front primary door seal
    Note
    Verify seal is seated properly on all trim panels
  203. Move RH front seat forward
    Note
    Adjust seat back if needed to avoid contacting headliner
  204. Torque both LH front inner HV battery bolts
    Note
    2x bolts, EP20, 136 Nm
  205. Install LH front cabin carpet support access plugs
    Note
    1x plug
  206. Fold LH front main cabin carpet back to original position
  207. Install OBD port
    Note
    2x tabs, Ensure black tabs in lock position
  208. Install console LH front side panel
    Note
    14x clips, 2x locating pins, Ensure all clips and pins seat properly
  209. Install driver footwell hush panel
    Note
    1x connector, 8x tabs, 2x location pins
  210. Secure front LH cabin carpet cover to driver footwell hush panel
    Note
    2x magnets, 2x datums
  211. Install LH lower A pillar trim
    Note
    7x clips, 3x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar
  212. Install LH IP end cap
    Note
    5x clips, 2x guide tabs
  213. Install LH front primary door seal
    Note
    Verify seal is seated properly on all trim panels
  214. Move LH front seat forward
    Note
    Adjust seat back if needed to avoid contacting headliner
  215. Torque LH rear inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  216. Torque RH rear inner battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
  217. Remove air bag from between rear cabin carpet and body
  218. Torque LH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  219. Fold LH side of rear main carpet to its original position
  220. Torque RH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  221. Fold RH side of rear main carpet to its original position
  222. Connect 2nd row 40 seat connector
    Note
    1x connector, Engage the tab
  223. Install 2nd row 60 seat assembly
    Note
    Recommend assistance
  224. Install fasteners securing 2nd row 60 seat frame to body
    Note
    5x bolts, 11mm, 37 Nm, Install new bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
  225. Install clips securing rear main cabin carpet to vehicle
    Note
    3x push clips
  226. Connect 2nd row 60 seat connector
    Note
    1x connector, Engage the tab
  227. Install LH lower C pillar trim
    Note
    7x clips, 2x guide tabs, Align guide tabs, then press down to securing all clips
  228. Install LH rear primary door seal near LH lower C pillar trim
  229. Install RH lower C pillar trim
    Note
    7x clips, 2x guide tabs, Align guide tabs, then press down to securing all clips
  230. Partially install RH rear primary door seal
    Note
    Verify seal is seated properly on all trim panels
  231. Install 2nd row seat cushion
    Note
    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test, and ensure the buckles get stuck under the 2nd row cushion
  232. Move RH front seat to original position
  233. Move LH front seat to original position
  234. Inspect coolant level and top off as necessary
    Note
    Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair
  235. Install coolant bottle cap
  236. Coolant air purge run time
    Note
    Run time: 00:10:00, Subtract overlap time spent on other operations while waiting for coolant purge run
  237. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
  238. Install HEPA filter assembly
    Note
    2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct
  239. Install rear apron
    Note
    16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron
  240. Close hood
  241. Move RH front seat to original position
  242. Move LH front seat to original position
  243. Raise all windows
  244. Close all four doors