HV Battery (Dual Motor) (Remove and Replace)

Correction codes 1601020216010202
  • 1453419-00-AAdapter, Lift Pad, Model 3
  • 1133787-00-AKey, Seat Belt Release, Model 3
  • 1020566-00-FASY, Battery Table, Manual Lift
  • 1020566-99-ATop Plate, Battery Table, Manual Lift
  • 1129166-00-AHoist, H-Frame EMEA
  • 1073363-00-AGantry, Adjustable, Aluminum
  • 1134523-00-AKit, Alignment Rods, Battery, Model 3
  • 1140311-00-ALever Lock, HV Connector, Model 3
  • 1053600-00-BDrive Unit Pressure Test Fixture
  • 1130942-00-BAdapter, Coolant Reservoir Pressure Test
  • 1132185-00-BKit, Coolant Leak Test Adapters, Model 3
  • 1133843-00-AKit, Coolant Drain & Fill Adapters, M3
  • 1135762-00-AKit, Svc Plug, Cooling Hose, Model 3
  • GSN-TL-000564Kit, Battery Coolant Drain and Fill
  • 1026636-00-APack Enclosure Leak Tester, HV Battery
  • 1140501-00-APack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-AKit, Encl Leak Test Adapters, HV Battery
  • 1108272-00-BCap, Logic Conn, Inv, 3DU

SPECIAL TOOLS

Adapter, Lift Pad, Model 3 (1453419-00-A)
Key, Seat Belt Release, Model 3 (1133787-00-A)
ASY, Battery Table, Manual Lift (1020566-00-F)
Top Plate, Battery Table, Manual Lift (1020566-99-A)
Hoist, H-Frame EMEA (1129166-00-A)
Gantry, Adjustable, Aluminum (1073363-00-A)
Kit, Alignment Rods, Battery, Model 3 (1134523-00-A)
Lever Lock, HV Connector, Model 3 (1140311-00-A)
Drive Unit Pressure Test Fixture (1053600-00-B)
Adapter, Coolant Reservoir Pressure Test (1130942-00-B)
Kit, Coolant Leak Test Adapters, Model 3 (1132185-00-B)
Kit, Coolant Drain & Fill Adapters, M3 (1133843-00-A)
Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)
Kit, Battery Coolant Drain and Fill (GSN-TL-000564)
Pack Enclosure Leak Tester, HV Battery (1026636-00-A)
Pack Kit, Enclosure, Leak Test, HV Battery, Complete (1140501-00-A)
Kit, Encl Leak Test Adapters, HV Battery (1144879-00-A)
Cap, Logic Conn, Inv, 3DU (1108272-00-B)

Remove

  1. Remove the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
  2. Open all doors.
    Note: Latch the rear doors to prevent accidental lockout.
  3. Lower all windows.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  6. Move the driver seat fully rearwards.
  7. Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  8. Remove the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  9. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  10. Remove the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  11. Remove the LH front floor mat.
  12. Remove the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  13. Move the front passenger seat fully rearwards.
  14. Remove the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  15. Remove the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  16. Remove the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  17. Remove the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  18. Remove the RH front floor mat.
  19. Remove the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  20. Move the driver and front passenger seats fully forward.
  21. Remove the 2nd row floor mat from the vehicle.
  22. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  23. Remove the RH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  24. Remove the RH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  25. Remove the RH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  26. Remove the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
  27. Repeat step 23 through step 26 for the LH side of the vehicle.
  28. Remove the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
    Note: The number of clips on newer vehicles might vary.
  29. Lift up the RH side of the rear carpet and insert a hand to feel if the 4th RH HV battery bolt is present. If the bolt is present, then remove the bolt.
  30. Lift up the LH side of the rear carpet and insert a hand to feel if the 4th LH HV battery bolt is present. If the bolt is present, then remove the bolt.
  31. Move the driver seat fully rearwards.
  32. Remove the clips (x3) that attach the LH front carpet to the vehicle.
  33. Fold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
    Note: The driver footrest is part of the LH front carpet.
  34. Remove the LH front inner HV battery bolts.
  35. Check to see if the 3rd LH HV battery bolt is present. If the bolt is present, remove the bolt.
  36. Remove the 3rd LH inner HV battery bolt.
  37. If the vehicle had the 3rd or the 4th LH inner HV battery bolts, move the driver seat to the center position and the seat back to the upright position. Otherwise, skip to the next step.
  38. Separate the LH side of the rear main carpet perforations to access the 4th LH inner HV battery bolt, if the bolt is present.
    Note: Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
    Note: Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
  39. Remove the 4th LH inner bolt that attaches the HV battery to the body.
  40. Remove the 5th LH rear inner bolt that attaches the HV battery to the body.
    Note: Lift up the rear main carpet for access.
  41. Unfold the LH front carpet back to its original position.
    Note: Move the front edge down, and then slide back the carpet to ease positioning.
  42. Move the front passenger seat fully rearwards.
  43. Remove the clips (x4) that attach the RH front carpet to the vehicle.
  44. Release the seat electrical harness from the clips to allow the RH front carpet to fold back more.
  45. Remove the RH front inner bolts (x2) that attach the HV battery to the body.
  46. Check if the 3rd RH bolt is present. Use a flashlight, if needed. Remove the bolt, if present. Otherwise, skip to the next step.
  47. Move the front passenger seat to the center position and the seatback to the upright position, if the 3rd RH and 4th RH inner HV battery bolts are present.
    Note: Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
    Note: Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
  48. Remove the 4th RH inner bolt that attaches the HV battery to the body, if equipped. Otherwise, skip to the next step.
  49. Remove the 5th RH rear inner bolt that attaches the HV battery to the body.
  50. Unfold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
    Note: The driver footrest is part of the LH front carpet.
  51. Put chocks on one of the rear wheels to prevent the vehicle from rolling.
  52. Connect a laptop with Toolbox to the vehicle.
  53. In Toolbox, click Actions, type "proc_epb" in the search field, click the play button next to "PROC_EPBL_START-SERVICE-MODE", and then select Run.
  54. Press the brake pedal, click Actions, click the play button next to "PROC_EPBR_START-SERVICE-MODE," and then select Run.
  55. Click Actions, type "thermal" in the search field, click the play button next to "PROC_VCFRONT_X_THERMAL-FILL-DRAIN", and then select Run.
  56. Using Toolbox, click the play button next to the "PROC_VCFRONT_X_THERMAL-FILL-DRAIN," and then select Run.
    Note: The 5-way valve is set to Series position, and the coolant pumps are disabled.
  57. Remove the laptop from the vehicle, but do not close Toolbox.
  58. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  59. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  60. Remove the HV cap that covers the HV harness located on the LH side of the penthouse.
  61. Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse.
  62. Release the clip that attaches the charge port to HV harness connector at the sill area.
  63. Raise the handle, and then pull up to disconnect the charge port to HV harness connector from the penthouse.
  64. Remove the bolts that attach the LH and RH inner penthouse rails to the penthouse cover.
  65. Remove the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
  66. Remove and discard the nut that attaches the positive 12V output cable to the DCDC passthrough, and then remove the cable from the passthrough.
    Note: Inspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
  67. Partially close all doors in preparation for pushing the vehicle.
  68. Remove the wheel chocks from the wheel.
  69. Remove the wheel chocks from the wheel, and with an assistant, push the vehicle to a lift, then re-chock the wheel.
    Caution:
    Push the vehicle for a very short distance and at less than 1 MPH.
  70. Remove the body plugs from the underside of the vehicle, and insert the lift pad adapters into the holes at each lifting arm pad.
  71. Raise the vehicle to a comfortable working height.
    Caution:
    Verify that the vehicle is stable on the lift.
  72. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  73. Release the clips along the bottom edge of the LH and RH wheel arch liners.
  74. Install bungee straps to pull the LH and RH wheel arch liners away from the HV battery and expose the coolant hoses.
  75. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  76. Disconnect the electrical harness from the PTC heater HV connector, and then release the electrical harness from the bracket.
  77. Disconnect the electrical harness from the A/C HV connector, and then release the electrical harness from the bracket.
  78. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
  79. Disconnect the front drive unit HV harness connector: Release the locking tab, and then rotate the release lever up to disengage the connector. After disconnecting the front drive unit HV harness, set it aside.
    Caution:
    Do not use excessive force when rotating the release lever.
    Note: Make sure that the alignment tabs on the front drive unit header are not damaged.
  80. Remove the bolt that attaches the ground strap to the front drive unit.
  81. Release the clip that attaches the front drive unit ground strap to the front drive unit.
  82. Remove the bolt that attaches the ground strap bolt to the HV battery, and then remove the ground strap from the vehicle.
  83. Perform a rear powertrain coolant drain. See Powertrain Coolant (Drain and Refill).
  84. Perform a platter enclosure coolant drain. See Platter Enclosure Coolant (Drain and Refill).
  85. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  86. Put the support stand to support the front portion of the rear subframe.
  87. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  88. Remove the smaller bolts that attach the LH shear plate to the body.
  89. Remove the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
  90. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  91. Repeat steps 87 through 90 for the RH shear plate.
  92. Remove the support stand from underneath the rear subframe
  93. With an assistant, put the battery table in position, and then lower the vehicle to support the HV battery.
    Note: Line up the battery table so that the center 4 bolts of the HV battery are accessible through the opening in the battery table.
  94. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  95. Position the coolant drain under the rear LH side of the HV battery.
  96. Release the clip and disconnect the rear drive unit inverter inlet hose from the LH underside of the penthouse, and immediately plug the male and female fittings.
  97. Position the coolant drain under the rear RH side of the HV battery.
  98. Release the clip and disconnect the coolant outlet hose from the powertrain return hose, and immediately plug the male and female fittings.
  99. Remove the coolant drain from underneath the vehicle.
  100. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
  101. Release the locking tab of the rear drive unit HV electrical harness.
  102. Raise the handle, and then disconnect the rear drive unit HV electrical harness from the HV battery connector.
  103. Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.
  104. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  105. Remove the front center bolt that attaches the HV battery to the vehicle.
  106. Remove the bolts (x4) that attach the front of the HV battery to the vehicle.
  107. Remove the bolts (x16) that attach the HV battery to the vehicle.
    Note: Record the positions of any installed washers, as they will be reinstalled to the same locations during the installation procedure.
  108. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  109. Remove the HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).
  110. Turn the adjustable elements (x4) clockwise to remove them from the penthouse cover.
    Note: Keep the adjustable elements so that they can be installed onto the replacement HV battery.
  111. Release the clip and disconnect the LH outer HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  112. Release the clip and disconnect the LH inner HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  113. Release the clip and disconnect the RH inner HV battery supply hose fitting from the RH front of the HV battery platter enclosure.
  114. Release the clip and disconnect the RH outer HV battery supply hose fitting from the RH front of the HV battery platter enclosure, and remove the hose assembly from the HV battery.
  115. Release the clip and disconnect the RH inner HV battery return hose fitting from the RH rear of the HV battery platter enclosure.
  116. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  117. Release the clip and disconnect the LH inner HV battery return hose fitting from the LH rear of the HV battery platter enclosure.
  118. Release the clips (x5) that attach the HV battery return hose to the LH side of the HV battery, and remove the hose from the HV battery.
  119. Release the clips (x5) that attach the powertrain return (lower) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  120. Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the penthouse.
  121. Release the clips (x5) that attach the powertrain supply (upper) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  122. Use the gantry and H-frame hoist to lift the HV battery from the manual lift battery table.
  123. If the replacement HV battery has an HV battery center rail ski, go to step 128.
  124. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
  125. Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C compressor electrical harness from the HV battery connector.
  126. Release the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
  127. With an assistant, remove the end bolts that attach the center rail ski to the HV battery, and then remove the rail ski from the battery.
  128. Use the gantry and H-frame hoist to lower the HV battery into the shipping container.
1Remove the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
2Open all doors.
Note: Latch the rear doors to prevent accidental lockout.
3Lower all windows.
4Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
5Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
6Move the driver seat fully rearwards.
7Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
8Remove the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
9Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
10Remove the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
11Remove the LH front floor mat.
12Remove the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
13Move the front passenger seat fully rearwards.
14Remove the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
15Remove the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
16Remove the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
17Remove the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
18Remove the RH front floor mat.
19Remove the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
20Move the driver and front passenger seats fully forward.
21Remove the 2nd row floor mat from the vehicle.
22Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
23Remove the RH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
24Remove the RH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
25Remove the RH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
26Remove the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
27Repeat step 23 through step 26 for the LH side of the vehicle.
28Remove the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
Note: The number of clips on newer vehicles might vary.
29Lift up the RH side of the rear carpet and insert a hand to feel if the 4th RH HV battery bolt is present. If the bolt is present, then remove the bolt.
30Lift up the LH side of the rear carpet and insert a hand to feel if the 4th LH HV battery bolt is present. If the bolt is present, then remove the bolt.
31Move the driver seat fully rearwards.
32Remove the clips (x3) that attach the LH front carpet to the vehicle.
33Fold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
Note: The driver footrest is part of the LH front carpet.
34Remove the LH front inner HV battery bolts.
35Check to see if the 3rd LH HV battery bolt is present. If the bolt is present, remove the bolt.
36Remove the 3rd LH inner HV battery bolt.
37If the vehicle had the 3rd or the 4th LH inner HV battery bolts, move the driver seat to the center position and the seat back to the upright position. Otherwise, skip to the next step.
38Separate the LH side of the rear main carpet perforations to access the 4th LH inner HV battery bolt, if the bolt is present.
Note: Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
Note: Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
39Remove the 4th LH inner bolt that attaches the HV battery to the body.
40Remove the 5th LH rear inner bolt that attaches the HV battery to the body.
Note: Lift up the rear main carpet for access.
41Unfold the LH front carpet back to its original position.
Note: Move the front edge down, and then slide back the carpet to ease positioning.
42Move the front passenger seat fully rearwards.
43Remove the clips (x4) that attach the RH front carpet to the vehicle.
44Release the seat electrical harness from the clips to allow the RH front carpet to fold back more.
45Remove the RH front inner bolts (x2) that attach the HV battery to the body.
46Check if the 3rd RH bolt is present. Use a flashlight, if needed. Remove the bolt, if present. Otherwise, skip to the next step.
47Move the front passenger seat to the center position and the seatback to the upright position, if the 3rd RH and 4th RH inner HV battery bolts are present.
Note: Might need to undo the hook-and-loop strips that are attach the front carpets to the body.
Note: Might need to move the driver seat forwards or rearwards if necessary to allow access for the bolt.
48Remove the 4th RH inner bolt that attaches the HV battery to the body, if equipped. Otherwise, skip to the next step.
49Remove the 5th RH rear inner bolt that attaches the HV battery to the body.
50Unfold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
Note: The driver footrest is part of the LH front carpet.
51Put chocks on one of the rear wheels to prevent the vehicle from rolling.
52Connect a laptop with Toolbox to the vehicle.
53In Toolbox, click Actions, type "proc_epb" in the search field, click the play button next to "PROC_EPBL_START-SERVICE-MODE", and then select Run.
54Press the brake pedal, click Actions, click the play button next to "PROC_EPBR_START-SERVICE-MODE," and then select Run.
55Click Actions, type "thermal" in the search field, click the play button next to "PROC_VCFRONT_X_THERMAL-FILL-DRAIN", and then select Run.
56Using Toolbox, click the play button next to the "PROC_VCFRONT_X_THERMAL-FILL-DRAIN," and then select Run.
Note: The 5-way valve is set to Series position, and the coolant pumps are disabled.
57Remove the laptop from the vehicle, but do not close Toolbox.
58Disconnect 12V power. See 12V Power (Disconnect and Connect).
59Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
60Remove the HV cap that covers the HV harness located on the LH side of the penthouse.
61Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse.
62Release the clip that attaches the charge port to HV harness connector at the sill area.
63Raise the handle, and then pull up to disconnect the charge port to HV harness connector from the penthouse.
64Remove the bolts that attach the LH and RH inner penthouse rails to the penthouse cover.
65Remove the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
66Remove and discard the nut that attaches the positive 12V output cable to the DCDC passthrough, and then remove the cable from the passthrough.
Note: Inspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
67Partially close all doors in preparation for pushing the vehicle.
68Remove the wheel chocks from the wheel.
69Remove the wheel chocks from the wheel, and with an assistant, push the vehicle to a lift, then re-chock the wheel.
Caution:
Push the vehicle for a very short distance and at less than 1 MPH.
70Remove the body plugs from the underside of the vehicle, and insert the lift pad adapters into the holes at each lifting arm pad.
71Raise the vehicle to a comfortable working height.
Caution:
Verify that the vehicle is stable on the lift.
72Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
73Release the clips along the bottom edge of the LH and RH wheel arch liners.
74Install bungee straps to pull the LH and RH wheel arch liners away from the HV battery and expose the coolant hoses.
75Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
76Disconnect the electrical harness from the PTC heater HV connector, and then release the electrical harness from the bracket.
77Disconnect the electrical harness from the A/C HV connector, and then release the electrical harness from the bracket.
78Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
79Disconnect the front drive unit HV harness connector: Release the locking tab, and then rotate the release lever up to disengage the connector. After disconnecting the front drive unit HV harness, set it aside.
Caution:
Do not use excessive force when rotating the release lever.
Note: Make sure that the alignment tabs on the front drive unit header are not damaged.
80Remove the bolt that attaches the ground strap to the front drive unit.
81Release the clip that attaches the front drive unit ground strap to the front drive unit.
82Remove the bolt that attaches the ground strap bolt to the HV battery, and then remove the ground strap from the vehicle.
83Perform a rear powertrain coolant drain. See Powertrain Coolant (Drain and Refill).
84Perform a platter enclosure coolant drain. See Platter Enclosure Coolant (Drain and Refill).
85Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
86Put the support stand to support the front portion of the rear subframe.
87Release the fir tree clips that attach the coolant hoses to the LH shear plate.
88Remove the smaller bolts that attach the LH shear plate to the body.
89Remove the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
90Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
91Repeat steps 87 through 90 for the RH shear plate.
92Remove the support stand from underneath the rear subframe
93With an assistant, put the battery table in position, and then lower the vehicle to support the HV battery.
Note: Line up the battery table so that the center 4 bolts of the HV battery are accessible through the opening in the battery table.
94Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
95Position the coolant drain under the rear LH side of the HV battery.
96Release the clip and disconnect the rear drive unit inverter inlet hose from the LH underside of the penthouse, and immediately plug the male and female fittings.
97Position the coolant drain under the rear RH side of the HV battery.
98Release the clip and disconnect the coolant outlet hose from the powertrain return hose, and immediately plug the male and female fittings.
99Remove the coolant drain from underneath the vehicle.
100Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
101Release the locking tab of the rear drive unit HV electrical harness.
102Raise the handle, and then disconnect the rear drive unit HV electrical harness from the HV battery connector.
103Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.
104Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
105Remove the front center bolt that attaches the HV battery to the vehicle.
106Remove the bolts (x4) that attach the front of the HV battery to the vehicle.
107Remove the bolts (x16) that attach the HV battery to the vehicle.
Note: Record the positions of any installed washers, as they will be reinstalled to the same locations during the installation procedure.
108With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
109Remove the HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).
110Turn the adjustable elements (x4) clockwise to remove them from the penthouse cover.
Note: Keep the adjustable elements so that they can be installed onto the replacement HV battery.
111Release the clip and disconnect the LH outer HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
112Release the clip and disconnect the LH inner HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
113Release the clip and disconnect the RH inner HV battery supply hose fitting from the RH front of the HV battery platter enclosure.
114Release the clip and disconnect the RH outer HV battery supply hose fitting from the RH front of the HV battery platter enclosure, and remove the hose assembly from the HV battery.
115Release the clip and disconnect the RH inner HV battery return hose fitting from the RH rear of the HV battery platter enclosure.
116Release the clips that attach the RH inner HV battery return hose to the HV battery.
117Release the clip and disconnect the LH inner HV battery return hose fitting from the LH rear of the HV battery platter enclosure.
118Release the clips (x5) that attach the HV battery return hose to the LH side of the HV battery, and remove the hose from the HV battery.
119Release the clips (x5) that attach the powertrain return (lower) hose to the RH side of the HV battery, and remove the hose from the HV battery.
120Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the penthouse.
121Release the clips (x5) that attach the powertrain supply (upper) hose to the RH side of the HV battery, and remove the hose from the HV battery.
122Use the gantry and H-frame hoist to lift the HV battery from the manual lift battery table.
123If the replacement HV battery has an HV battery center rail ski, go to step 128.
124Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
125Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C compressor electrical harness from the HV battery connector.
126Release the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
127With an assistant, remove the end bolts that attach the center rail ski to the HV battery, and then remove the rail ski from the battery.
128Use the gantry and H-frame hoist to lower the HV battery into the shipping container.

Install

  1. Use the gantry and H-frame hoist to lift the HV battery out of the shipping container.
  2. If the replacement HV battery has an HV battery center rail ski, go to step 8.
  3. With an assistant, install the center rail ski to the HV battery.
  4. Install the bolts that attach the center rail ski to the HV battery.
    Torque 38 Nm
  5. Fasten the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
  6. Connect the PTC heater and A/C compressor electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
  7. Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  8. Use the gantry and H-frame hoist to set the HV battery onto the manual lift battery table.
  9. Install the powertrain supply hose to the upper clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  10. Connect the powertrain supply hose fitting to the RH rear underside of the penthouse, and then fasten the clip.
  11. Install the powertrain return hose to the lower clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  12. Install the HV battery return hose to the clips on the LH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  13. Connect the LH inner HV battery return hose fitting to the LH rear of the HV battery platter enclosure, and then fasten the clip.
  14. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  15. Connect the RH inner HV battery return hose fitting to the RH rear of the HV battery platter enclosure, and then fasten the clip.
  16. Install the HV battery supply hose assembly to the HV battery, connect the RH outer HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
  17. Connect the RH inner HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
  18. Connect the LH inner HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
  19. Connect the LH outer HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
  20. Perform step 11 through step 26 of the penthouse air leak test on the HV battery. See Penthouse Air Leak Test.
  21. Install and hand-tighten the adjustable elements (x4) on the penthouse cover counter-clockwise so that they are fully engaged.
    Caution:
    Hand-tighten only.
  22. Install a new HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).
  23. Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the penthouse.
  24. With an assistant, position the HV battery underneath the vehicle.
  25. Lower the vehicle to the HV battery, and with an assistant, align the holes with the alignment rods.
    Note: Do not fully lower the vehicle onto the HV battery. The battery will still need to slightly move to install the bolts in the following steps.
    Caution:
    Make sure that the coolant hoses and HV harnesses are not caught on the alignment rods or sandwiched between the HV battery and the vehicle.
  26. Hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
    Note: Install the washers to the locations recorded earlier during removal.
  27. Hand-tighten the bolts (x4) that attach the front of the HV battery to the vehicle.
  28. Hand-tighten the front center bolt that attaches the HV battery to the vehicle.
  29. Remove the HV battery alignment rods.
  30. Hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  31. Hand-tighten the bolts (x4) that attach the center portion of the HV battery through the HV battery center rail ski cover.
  32. Install and hand-tighten the smaller bolts that would attach the LH and RH shear plates to the body.
    Note: Do not install the shear plates at this time.
    LH shown, RH similar
  33. Fully raise the handle on the rear drive unit HV electrical harness.
  34. Attach the HV connector lever lock onto the back of the HV electrical harness.
  35. Firmly connect the HV electrical harness to the HV battery connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  36. While pressing the harness to the connector, remove the HV connector lever lock.
  37. While pressing the harness to the connector, fully lower the handle.
  38. Slide the release to lock the HV electrical harness.
  39. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    Torque 10 Nm
  40. Position the coolant drain under the rear RH side of the HV battery.
  41. Remove the plugs from the coolant outlet hose and the powertrain return hose, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  42. Position the coolant drain under the rear LH side of the HV battery.
  43. Remove the plugs from the rear drive unit inverter inlet hose and the LH underside of the penthouse, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  44. Remove the coolant drain container from underneath the vehicle.
  45. Install the rear HV battery skid plate, but only hand-tighten the fasteners. See Skid Plate - HV Battery - Rear (Remove and Replace).
  46. Open the LH rear door.
    Caution:
    Do not damage any components while working around this area.
  47. Hand-tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
    Note: Lift up the rear main carpet for access.
  48. Hand-tighten the 4th LH inner bolt that attaches the HV battery to the body.
  49. Partially close, but do not latch, the LH rear door.
  50. Open the LH front door.
    Caution:
    Do not damage any components while working around this area.
  51. Hand-tighten the 3rd LH inner bolt that attaches the HV battery to the body.
  52. Hand-tighten the LH front inner bolts (x2) that attach the HV battery to the body.
  53. Partially close, but do not latch, the LH front door.
  54. Open the RH rear door.
    Caution:
    Do not damage any components while working around this area.
  55. Hand-tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
  56. Hand-tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
  57. Partially close, but do not latch, the RH rear door.
  58. Open the RH front door.
    Caution:
    Do not damage any components while working around this area.
  59. Hand-tighten the 3rd RH inner bolt that attaches the HV battery to the body, if equipped.
  60. Hand-tighten the RH front inner bolts (x2) that attach the HV battery to the body.
  61. Partially close, but do not latch, the RH front door.
  62. With an assistant, lower the vehicle onto the HV battery completely.
  63. Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.
    Torque 30 Nm
  64. Torque the bolts (x4) that attach the front of the HV battery to the vehicle.
    Torque 30 Nm
  65. Torque the front center bolt that attaches the HV battery to the vehicle.
    Torque 10 Nm
  66. Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    Torque 110 Nm
  67. Tighten the bolts (x4) that attach the center portion of the HV battery through the center ski cover.
    Torque 34 Nm
  68. Torque the fasteners that attach the rear skid plate to the vehicle. See Skid Plate - HV Battery - Rear (Remove and Replace).
  69. With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle. Set the vehicle to a comfortable working height.
  70. Put the support stand to support the front portion of the rear subframe.
  71. Remove the smaller bolts (x2) and the larger bolt that are used to attach the LH shear plate to the vehicle.
    LH shown, RH similar
  72. Install the LH shear plate, and then install the smaller bolts (x2) that attach the shear plate to the HV battery.
    Torque 30 Nm
    LH shown, RH similar
  73. Install the larger bolt that attaches the shear plate to the vehicle, and then mark the bolt with a paint pen.
    Torque 128 Nm
  74. Fasten the fir tree clips that attach the coolant hoses to the LH shear plate.
    LH shown, RH similar
  75. Repeat steps 71 through 74 for the RH shear plate.
  76. Remove the support stand from underneath the rear subframe
  77. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  78. Position the coolant drain under the front LH side of the HV battery.
  79. Remove the plugs from the chiller to HV battery hose and the manifold at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  80. Fasten the clips that attach the chiller to HV battery hose to the body.
  81. Remove the plugs from the HV battery return hose at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  82. Position the coolant drain under the front RH side of the HV battery.
  83. Remove the plugs from the rear powertrain supply hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  84. Remove the plugs from the powertrain return hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
  85. Remove the coolant drain from underneath the vehicle.
  86. Install the bolt that attaches the ground strap to the HV battery
    Torque 10 Nm
  87. Install the clip that attaches the front drive unit ground strap to the front drive unit.
  88. Install the bolt that attaches the ground strap to the front drive unit.
    Torque 6 Nm
  89. Install the front drive unit HV harness connector special tool on the front drive unit HV harness connector.
  90. Connect the front drive unit harness connector to the front drive unit.
    Note: Make sure the connector is fully seated, and that the front drive unit alignment tooth makes contact with the front drive unit harness connector lever.
  91. Remove the front drive unit HV harness connector special tool.
  92. Slowly latch the release handle while pressing the front drive unit HV harness connector into the front drive unit.
    Note: The front drive unit alignment teeth and HV harness connector alignment teeth should be interlocked.
  93. Slide the red release tab to lock the front drive unit HV harness connector.
  94. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    Torque 10 Nm
  95. Connect the A/C HV connector.
  96. Connect the PTC HV electrical connector, and then install the harnesses to the bracket.
  97. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  98. Remove the bungee straps from the LH and RH wheel arch liners.
  99. Fasten the clips along the bottom edge of the LH and RH wheel arch liners.
  100. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  101. Lower the vehicle fully, and chock a wheel.
  102. Remove the lift adaptors from the body, and then install the body plugs.
  103. Remove the chock, and with an assistant, push the vehicle away from the lift to a stall, and then re-chock the wheel.
    Caution:
    Push the vehicle for a very short distance and at less than 1 MPH.
  104. Open all doors.
  105. Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green paint pen after torque.
    Torque 9 Nm
    Caution:
    Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
  106. Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  107. Install the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
  108. Install the bolts that attach the LH and RH inner 2nd row rails to the penthouse cover.
    Torque 24 Nm
  109. Connect the charge port HV harness connector to the penthouse; use one hand to support the harness connector while the other hand latches the locking tab.
    Note: Verify that the charge port HV harness connector latch is not damaged and fully secured in the latched position.
  110. Install the clip that attaches the charge port to HV harness connector to the LH lower C-pillar.
  111. Install the harness clips, and then the bolts that attach the charge port to HV battery harness bracket at the penthouse.
    Torque 10 Nm
  112. Install the HV cap that covers the HV harness located on the LH side of the penthouse.
  113. Connect 12V power. See 12V Power (Disconnect and Connect).
  114. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  115. Connect a laptop with Toolbox to the vehicle.
  116. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  117. Disconnect the laptop from the vehicle.
  118. Tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
    Torque 66 Nm
    Note: Lift up the rear main carpet for access.
  119. Tighten the 4th LH inner bolt that attaches the HV battery to the body.
    Torque 66 Nm
  120. Unfold the carpet back to its original position.
  121. Move the driver seat fully rearwards.
  122. Tighten the 3rd LH inner HV battery bolt.
    Torque 66 Nm
  123. Tighten the LH front inner HV battery bolts (x2) that attach the HV battery to the body.
    Torque 136 Nm
  124. Unfold the LH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
  125. Install the clips (x3) that attach the LH front carpet to the vehicle.
  126. Move the driver seat fully forwards.
  127. Tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
    Torque 66 Nm
  128. Tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
    Torque 66 Nm
  129. Unfold the RH side of the rear carpet back to its original position.
  130. Move the front passenger seat fully rearward.
  131. Tighten the bolt that attaches the 3rd RH inner HV battery bolt to the body, if equipped.
  132. Tighten the RH front inner bolts (x2) that attach the HV battery to the body.
    Torque 136 Nm
  133. Unfold the RH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
  134. Install the clips (x4) that attach the RH front carpet to the vehicle.
  135. Move the front passenger seat fully forward.
  136. Install the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
    Note: The number of clips on newer vehicles might vary.
  137. Install the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
  138. Install the LH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  139. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  140. Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  141. Repeat step 137 through step 140 for the RH side of the vehicle.
  142. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  143. Install the 2nd row floor mat inside the vehicle.
  144. Install the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  145. Install the RH front floor mat.
  146. Install the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  147. Install the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  148. Install the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  149. Install the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  150. Install the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  151. Install the LH front floor mat.
  152. Install the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  153. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  154. Install the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  155. Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  156. Restore the driver and front passenger seats back to their original position.
  157. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  158. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  159. Close the hood and all four doors.
  160. Install the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
1Use the gantry and H-frame hoist to lift the HV battery out of the shipping container.
2If the replacement HV battery has an HV battery center rail ski, go to step 8.
3With an assistant, install the center rail ski to the HV battery.
4Install the bolts that attach the center rail ski to the HV battery.
Torque 38 Nm
5Fasten the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.
6Connect the PTC heater and A/C compressor electrical harness to the HV battery connector, lower the handle, and attach the locking tab.
7Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
8Use the gantry and H-frame hoist to set the HV battery onto the manual lift battery table.
9Install the powertrain supply hose to the upper clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
10Connect the powertrain supply hose fitting to the RH rear underside of the penthouse, and then fasten the clip.
11Install the powertrain return hose to the lower clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
12Install the HV battery return hose to the clips on the LH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
13Connect the LH inner HV battery return hose fitting to the LH rear of the HV battery platter enclosure, and then fasten the clip.
14Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
15Connect the RH inner HV battery return hose fitting to the RH rear of the HV battery platter enclosure, and then fasten the clip.
16Install the HV battery supply hose assembly to the HV battery, connect the RH outer HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
17Connect the RH inner HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
18Connect the LH inner HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
19Connect the LH outer HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
20Perform step 11 through step 26 of the penthouse air leak test on the HV battery. See Penthouse Air Leak Test.
21Install and hand-tighten the adjustable elements (x4) on the penthouse cover counter-clockwise so that they are fully engaged.
Caution:
Hand-tighten only.
22Install a new HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).
23Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the penthouse.
24With an assistant, position the HV battery underneath the vehicle.
25Lower the vehicle to the HV battery, and with an assistant, align the holes with the alignment rods.
Note: Do not fully lower the vehicle onto the HV battery. The battery will still need to slightly move to install the bolts in the following steps.
Caution:
Make sure that the coolant hoses and HV harnesses are not caught on the alignment rods or sandwiched between the HV battery and the vehicle.
26Hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
Note: Install the washers to the locations recorded earlier during removal.
27Hand-tighten the bolts (x4) that attach the front of the HV battery to the vehicle.
28Hand-tighten the front center bolt that attaches the HV battery to the vehicle.
29Remove the HV battery alignment rods.
30Hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
31Hand-tighten the bolts (x4) that attach the center portion of the HV battery through the HV battery center rail ski cover.
LH shown, RH similar
32Install and hand-tighten the smaller bolts that would attach the LH and RH shear plates to the body.
Note: Do not install the shear plates at this time.
33Fully raise the handle on the rear drive unit HV electrical harness.
34Attach the HV connector lever lock onto the back of the HV electrical harness.
35Firmly connect the HV electrical harness to the HV battery connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
36While pressing the harness to the connector, remove the HV connector lever lock.
37While pressing the harness to the connector, fully lower the handle.
38Slide the release to lock the HV electrical harness.
39Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
Torque 10 Nm
40Position the coolant drain under the rear RH side of the HV battery.
41Remove the plugs from the coolant outlet hose and the powertrain return hose, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
42Position the coolant drain under the rear LH side of the HV battery.
43Remove the plugs from the rear drive unit inverter inlet hose and the LH underside of the penthouse, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
44Remove the coolant drain container from underneath the vehicle.
45Install the rear HV battery skid plate, but only hand-tighten the fasteners. See Skid Plate - HV Battery - Rear (Remove and Replace).
46Open the LH rear door.
Caution:
Do not damage any components while working around this area.
47Hand-tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
Note: Lift up the rear main carpet for access.
48Hand-tighten the 4th LH inner bolt that attaches the HV battery to the body.
49Partially close, but do not latch, the LH rear door.
50Open the LH front door.
Caution:
Do not damage any components while working around this area.
51Hand-tighten the 3rd LH inner bolt that attaches the HV battery to the body.
52Hand-tighten the LH front inner bolts (x2) that attach the HV battery to the body.
53Partially close, but do not latch, the LH front door.
54Open the RH rear door.
Caution:
Do not damage any components while working around this area.
55Hand-tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
56Hand-tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
57Partially close, but do not latch, the RH rear door.
58Open the RH front door.
Caution:
Do not damage any components while working around this area.
59Hand-tighten the 3rd RH inner bolt that attaches the HV battery to the body, if equipped.
60Hand-tighten the RH front inner bolts (x2) that attach the HV battery to the body.
61Partially close, but do not latch, the RH front door.
62With an assistant, lower the vehicle onto the HV battery completely.
63Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.
Torque 30 Nm
64Torque the bolts (x4) that attach the front of the HV battery to the vehicle.
Torque 30 Nm
65Torque the front center bolt that attaches the HV battery to the vehicle.
Torque 10 Nm
66Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
Torque 110 Nm
67Tighten the bolts (x4) that attach the center portion of the HV battery through the center ski cover.
Torque 34 Nm
68Torque the fasteners that attach the rear skid plate to the vehicle. See Skid Plate - HV Battery - Rear (Remove and Replace).
69With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle. Set the vehicle to a comfortable working height.
70Put the support stand to support the front portion of the rear subframe.
LH shown, RH similar
71Remove the smaller bolts (x2) and the larger bolt that are used to attach the LH shear plate to the vehicle.
LH shown, RH similar
72Install the LH shear plate, and then install the smaller bolts (x2) that attach the shear plate to the HV battery.
Torque 30 Nm
73Install the larger bolt that attaches the shear plate to the vehicle, and then mark the bolt with a paint pen.
Torque 128 Nm
LH shown, RH similar
74Fasten the fir tree clips that attach the coolant hoses to the LH shear plate.
75Repeat steps 71 through 74 for the RH shear plate.
76Remove the support stand from underneath the rear subframe
77Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
78Position the coolant drain under the front LH side of the HV battery.
79Remove the plugs from the chiller to HV battery hose and the manifold at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
80Fasten the clips that attach the chiller to HV battery hose to the body.
81Remove the plugs from the HV battery return hose at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
82Position the coolant drain under the front RH side of the HV battery.
83Remove the plugs from the rear powertrain supply hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
84Remove the plugs from the powertrain return hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
Note: Perform a push-pull-push test on the fittings to make sure that they are secure.
85Remove the coolant drain from underneath the vehicle.
86Install the bolt that attaches the ground strap to the HV battery
Torque 10 Nm
87Install the clip that attaches the front drive unit ground strap to the front drive unit.
88Install the bolt that attaches the ground strap to the front drive unit.
Torque 6 Nm
89Install the front drive unit HV harness connector special tool on the front drive unit HV harness connector.
90Connect the front drive unit harness connector to the front drive unit.
Note: Make sure the connector is fully seated, and that the front drive unit alignment tooth makes contact with the front drive unit harness connector lever.
91Remove the front drive unit HV harness connector special tool.
92Slowly latch the release handle while pressing the front drive unit HV harness connector into the front drive unit.
Note: The front drive unit alignment teeth and HV harness connector alignment teeth should be interlocked.
93Slide the red release tab to lock the front drive unit HV harness connector.
94Install the bolt that attaches the front drive unit HV harness to the front drive unit.
Torque 10 Nm
95Connect the A/C HV connector.
96Connect the PTC HV electrical connector, and then install the harnesses to the bracket.
97Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
98Remove the bungee straps from the LH and RH wheel arch liners.
99Fasten the clips along the bottom edge of the LH and RH wheel arch liners.
100Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
101Lower the vehicle fully, and chock a wheel.
102Remove the lift adaptors from the body, and then install the body plugs.
103Remove the chock, and with an assistant, push the vehicle away from the lift to a stall, and then re-chock the wheel.
Caution:
Push the vehicle for a very short distance and at less than 1 MPH.
104Open all doors.
105Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green paint pen after torque.
Torque 9 Nm
Caution:
Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
106Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
107Install the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).
108Install the bolts that attach the LH and RH inner 2nd row rails to the penthouse cover.
Torque 24 Nm
109Connect the charge port HV harness connector to the penthouse; use one hand to support the harness connector while the other hand latches the locking tab.
Note: Verify that the charge port HV harness connector latch is not damaged and fully secured in the latched position.
110Install the clip that attaches the charge port to HV harness connector to the LH lower C-pillar.
111Install the harness clips, and then the bolts that attach the charge port to HV battery harness bracket at the penthouse.
Torque 10 Nm
112Install the HV cap that covers the HV harness located on the LH side of the penthouse.
113Connect 12V power. See 12V Power (Disconnect and Connect).
114Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
115Connect a laptop with Toolbox to the vehicle.
116Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
117Disconnect the laptop from the vehicle.
118Tighten the 5th LH rear inner bolt that attaches the HV battery to the body.
Torque 66 Nm
Note: Lift up the rear main carpet for access.
119Tighten the 4th LH inner bolt that attaches the HV battery to the body.
Torque 66 Nm
120Unfold the carpet back to its original position.
121Move the driver seat fully rearwards.
122Tighten the 3rd LH inner HV battery bolt.
Torque 66 Nm
123Tighten the LH front inner HV battery bolts (x2) that attach the HV battery to the body.
Torque 136 Nm
124Unfold the LH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
125Install the clips (x3) that attach the LH front carpet to the vehicle.
126Move the driver seat fully forwards.
127Tighten the 5th RH rear inner bolt that attaches the HV battery to the body.
Torque 66 Nm
128Tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped.
Torque 66 Nm
129Unfold the RH side of the rear carpet back to its original position.
130Move the front passenger seat fully rearward.
131Tighten the bolt that attaches the 3rd RH inner HV battery bolt to the body, if equipped.
132Tighten the RH front inner bolts (x2) that attach the HV battery to the body.
Torque 136 Nm
133Unfold the RH front main carpet back to its original position; move the front edge down and slide back the section up to ease positioning. Install the seat electrical harness into the clip.
134Install the clips (x4) that attach the RH front carpet to the vehicle.
135Move the front passenger seat fully forward.
136Install the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
Note: The number of clips on newer vehicles might vary.
137Install the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
138Install the LH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
139Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
140Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
141Repeat step 137 through step 140 for the RH side of the vehicle.
142Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
143Install the 2nd row floor mat inside the vehicle.
144Install the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
145Install the RH front floor mat.
146Install the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
147Install the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
148Install the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
149Install the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
150Install the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
151Install the LH front floor mat.
152Install the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
153Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
154Install the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
155Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
156Restore the driver and front passenger seats back to their original position.
157Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
158Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
159Close the hood and all four doors.
160Install the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).