Tesla Model 3 Owners & Service Manuals

Tesla Model 3: HV Battery (Dual Motor) (Remove and Replace)

Tesla Model 3 2017-2025 Service Manual / Battery System / HV Battery Assembly / HV Battery (Dual Motor) (Remove and Replace)

HV Battery (Dual Motor) -  Remove

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.

  1. Lower all windows.
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  4. Move the driver seat fully rearwards.
  5. Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  6. Remove the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  7. Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  8. Remove the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  9. Remove the LH front floor mat.
  10. Remove the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  11. Move the front passenger seat fully rearwards.
  12. Remove the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  13. Remove the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  14. Remove the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  15. Remove the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  16. Remove the RH front floor mat.
  17. Remove the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  18. Move the driver and front passenger seats fully forward.
  19. Remove the 2nd row floor mat from the vehicle.
  20. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  21. Remove the RH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  22. Remove the RH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  23. Remove the RH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  24. Remove the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
  25. Repeat step 23 through step 26 for the LH side of the vehicle.

HV Battery (Dual Motor) - Remove 

  1. 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.

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. 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.
  2. Move the driver seat fully rearwards.

HV Battery (Dual Motor) - Remove

  1. Remove the clips (x3) that attach the LH front carpet to the vehicle.
  2. 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.

HV Battery (Dual Motor) - Remove

  1. Remove the LH front inner HV battery bolts.

HV Battery (Dual Motor) - Remove

  1. Check to see if the 3rd LH HV battery bolt is present. If the bolt is present, remove the bolt.

HV Battery (Dual Motor) - Remove

  1. Remove the 3rd LH inner HV battery bolt.
  2. 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.
  3. 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.

HV Battery (Dual Motor) - Remove

  1. Remove the 4th LH inner bolt that attaches the HV battery to the body.

HV Battery (Dual Motor) - Remove

  1. Remove the 5th LH rear inner bolt that attaches the HV battery to the body.

Note: Lift up the rear main carpet for access.

  1. 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.

  1. Move the front passenger seat fully rearwards.

HV Battery (Dual Motor) - Remove

  1. Remove the clips (x4) that attach the RH front carpet to the vehicle.

HV Battery (Dual Motor) - Remove

  1. Release the seat electrical harness from the clips to allow the RH front carpet to fold back more.

HV Battery (Dual Motor) - Remove

  1. Remove the RH front inner bolts (x2) that attach the HV battery to the body.

HV Battery (Dual Motor) - Remove

  1. Check if the 3rd RH bolt is present. Use a flashlight, if needed. Remove the bolt, if present. Otherwise, skip to the next step.
  2. 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.

HV Battery (Dual Motor) - Remove

  1. Remove the 4th RH inner bolt that attaches the HV battery to the body, if equipped. Otherwise, skip to the next step.

HV Battery (Dual Motor) - Remove

  1. Remove the 5th RH rear inner bolt that attaches the HV battery to the body.

HV Battery (Dual Motor) - Remove

  1. 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.

  1. Put chocks on one of the rear wheels to prevent the vehicle from rolling.
  2. Connect a laptop with Toolbox to the vehicle.
  3. 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.
  4. Press the brake pedal, click Actions, click the play button next to "PROC_EPBR_START-SERVICE-MODE," and then select Run.
  5. Click Actions, type "thermal" in the search field, click the play button next to "PROC_VCFRONT_X_THERMAL-FILL-DRAIN", and then select Run.
  6. 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.

  1. Remove the laptop from the vehicle, but do not close Toolbox.
  2. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  3. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.

HV Battery (Dual Motor) - Remove

  1. Remove the HV cap that covers the HV harness located on the LH side of the penthouse.

HV Battery (Dual Motor) - Remove

  1. Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse.

HV Battery (Dual Motor) - Remove

  1. Release the clip that attaches the charge port to HV harness connector at the sill area.

HV Battery (Dual Motor) - Remove

  1. Raise the handle, and then pull up to disconnect the charge port to HV harness connector from the penthouse.

HV Battery (Dual Motor) - Remove

  1. Remove the bolts that attach the LH and RH inner penthouse rails to the penthouse cover.
  2. Remove the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).

HV Battery (Dual Motor) - Remove

  1. 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.

  1. Partially close all doors in preparation for pushing the vehicle.
  2. Remove the wheel chocks from the wheel.
  3. 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.

  1. Remove the body plugs from the underside of the vehicle, and insert the lift pad adapters into the holes at each lifting arm pad.
  2. Raise the vehicle to a comfortable working height.

HV Battery (Dual Motor) - Remove

Caution:

Verify that the vehicle is stable on the lift.

  1. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).

HV Battery (Dual Motor) - Remove 

HV Battery (Dual Motor) - Remove

  1. Release the clips along the bottom edge of the LH and RH wheel arch liners.
  2. Install bungee straps to pull the LH and RH wheel arch liners away from the HV battery and expose the coolant hoses.
  3. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).

HV Battery (Dual Motor) - Remove

  1. Disconnect the electrical harness from the PTC heater HV connector, and then release the electrical harness from the bracket.

HV Battery (Dual Motor) - Remove

  1. Disconnect the electrical harness from the A/C HV connector, and then release the electrical harness from the bracket.

HV Battery (Dual Motor) - Remove

  1. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.

HV Battery (Dual Motor) - Remove

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

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.

HV Battery (Dual Motor) - Remove

  1. Remove the bolt that attaches the ground strap to the front drive unit.
  2. Release the clip that attaches the front drive unit ground strap to the front drive unit.

HV Battery (Dual Motor) - Remove

  1. Remove the bolt that attaches the ground strap bolt to the HV battery, and then remove the ground strap from the vehicle.
  2. Perform a rear powertrain coolant drain. See Powertrain Coolant (Drain and Refill).
  3. Perform a platter enclosure coolant drain. See Platter Enclosure Coolant (Drain and Refill).
  4. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  5. Put the support stand to support the front portion of the rear subframe.

HV Battery (Dual Motor) - Remove

  1. Release the fir tree clips that attach the coolant hoses to the LH shear plate.

HV Battery (Dual Motor) - Remove 

  1. Remove the smaller bolts that attach the LH shear plate to the body.

HV Battery (Dual Motor) - Remove

  1. Remove the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.

HV Battery (Dual Motor) - Remove

  1. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  2. Repeat steps 87 through 90 for the RH shear plate.
  3. Remove the support stand from underneath the rear subframe
  4. 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.

  1. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  2. Position the coolant drain under the rear LH side of the HV battery.

HV Battery (Dual Motor) - Remove

  1. 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.
  2. Position the coolant drain under the rear RH side of the HV battery.

HV Battery (Dual Motor) - Remove 

  1. Release the clip and disconnect the coolant outlet hose from the powertrain return hose, and immediately plug the male and female fittings.
  2. Remove the coolant drain from underneath the vehicle.

HV Battery (Dual Motor) - Remove

  1. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.

HV Battery (Dual Motor) - Remove

  1. Release the locking tab of the rear drive unit HV electrical harness.

HV Battery (Dual Motor) - Remove

  1. Raise the handle, and then disconnect the rear drive unit HV electrical harness from the HV battery connector.

HV Battery (Dual Motor) - Remove

  1. Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.

HV Battery (Dual Motor) - Remove

HV Battery (Dual Motor) - Remove

  1. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.

HV Battery (Dual Motor) - Remove

  1. Remove the front center bolt that attaches the HV battery to the vehicle.

HV Battery (Dual Motor) - Remove

  1. Remove the bolts (x4) that attach the front of the HV battery to the vehicle.

HV Battery (Dual Motor) - Remove

  1. 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.

  1. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  2. Remove the HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the LH outer HV battery supply hose fitting from the LH front of the HV battery platter enclosure.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the LH inner HV battery supply hose fitting from the LH front of the HV battery platter enclosure.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the RH inner HV battery supply hose fitting from the RH front of the HV battery platter enclosure.

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the RH inner HV battery return hose fitting from the RH rear of the HV battery platter enclosure.

HV Battery (Dual Motor) - Remove

  1. Release the clips that attach the RH inner HV battery return hose to the HV battery.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the LH inner HV battery return hose fitting from the LH rear of the HV battery platter enclosure.

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the penthouse.

HV Battery (Dual Motor) - Remove

  1. 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.
  2. Use the gantry and H-frame hoist to lift the HV battery from the manual lift battery table.
  3. If the replacement HV battery has an HV battery center rail ski, go to step 128.

HV Battery (Dual Motor) - Remove

  1. 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.

HV Battery (Dual Motor) - Remove

  1. Release the locking tab, raise the handle, and then disconnect the PTC heater and A/C compressor electrical harness from the HV battery connector.

HV Battery (Dual Motor) - Remove

  1. Release the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.

HV Battery (Dual Motor) - Remove

  1. 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.
  2. Use the gantry and H-frame hoist to lower the HV battery into the shipping container.

HV Battery (Dual Motor) - Install

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.

HV Battery (Dual Motor) - Install

  1. Install the bolts that attach the center rail ski to the HV battery.Torque 38 Nm

 HV Battery (Dual Motor) - Install

  1. Fasten the clips that attach the PTC heater and A/C compressor electrical harness cover to the rear of the HV battery.

HV Battery (Dual Motor) - Install

  1. Connect the PTC heater and A/C compressor electrical harness to the HV battery connector, lower the handle, and attach the locking tab.

HV Battery (Dual Motor) - Install

  1. 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.
  2. Use the gantry and H-frame hoist to set the HV battery onto the manual lift battery table.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Connect the powertrain supply hose fitting to the RH rear underside of the penthouse, and then fasten the clip.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Connect the LH inner HV battery return hose fitting to the LH rear of the HV battery platter enclosure, and then fasten the clip.

HV Battery (Dual Motor) - Install

  1. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.

HV Battery (Dual Motor) - Install

  1. Connect the RH inner HV battery return hose fitting to the RH rear of the HV battery platter enclosure, and then fasten the clip.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Connect the RH inner HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.

HV Battery (Dual Motor) - Install

  1. Connect the LH inner HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.

HV Battery (Dual Motor) - Install

  1. Connect the LH outer HV battery supply hose fitting to the LH front of the HV battery platter enclosure, and then fasten the clip.
  2. Perform step 11 through step 26 of the penthouse air leak test on the HV battery. See Penthouse Air Leak Test.

HV Battery (Dual Motor) - Install

  1. Install and hand-tighten the adjustable elements (x4) on the penthouse cover counter-clockwise so that they are fully engaged.
Caution: Hand-tighten only.
  1. Install a new HV battery cover gasket. See Gasket - Cover - HV Battery (Remove and Replace).
  2. Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the penthouse.
  3. With an assistant, position the HV battery underneath the vehicle.
  4. 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.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the bolts (x4) that attach the front of the HV battery to the vehicle.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the front center bolt that attaches the HV battery to the vehicle.
  2. Remove the HV battery alignment rods.

HV Battery (Dual Motor) - Install

HV Battery (Dual Motor) - Install

  1. Hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.

HV Battery (Dual Motor) - Install

  1. Hand-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
LH shown, RH similar

  1. 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.

  1. Fully raise the handle on the rear drive unit HV electrical harness.

HV Battery (Dual Motor) - Install

  1. Attach the HV connector lever lock onto the back of the HV electrical harness.
  2. Firmly connect the HV electrical harness to the HV battery connector.
Caution: Make sure that the harness fits the connector squarely and tightly.
  1. While pressing the harness to the connector, remove the HV connector lever lock.

HV Battery (Dual Motor) - Install

  1. While pressing the harness to the connector, fully lower the handle.

HV Battery (Dual Motor) - Install

  1. Slide the release to lock the HV electrical harness.

HV Battery (Dual Motor) - Install

  1. Install the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.Torque 10 Nm
  2. Position the coolant drain under the rear RH side of the HV battery.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Position the coolant drain under the rear LH side of the HV battery.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Remove the coolant drain container from underneath the vehicle.
  2. Install the rear HV battery skid plate, but only hand-tighten the fasteners. See Skid Plate - HV Battery - Rear (Remove and Replace).
  3. Open the LH rear door.

HV Battery (Dual Motor) - Install

Caution: Do not damage any components while working around this area.
  1. 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.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the 4th LH inner bolt that attaches the HV battery to the body.
  2. Partially close, but do not latch, the LH rear door.
  3. Open the LH front door.
Caution:  Do not damage any components while working around this area.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the 3rd LH inner bolt that attaches the HV battery to the body.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the LH front inner bolts (x2) that attach the HV battery to the body.
  2. Partially close, but do not latch, the LH front door.
  3. Open the RH rear door.

HV Battery (Dual Motor) - Install

Caution:  Do not damage any components while working around this area.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the 5th RH rear inner bolt that attaches the HV battery to the body.

HV Battery (Dual Motor) - Install 

  1. Hand-tighten the 4h RH inner bolt that attaches the HV battery to the body, if equipped.
  2. Partially close, but do not latch, the RH rear door.
  3. Open the RH front door.
Caution:  Do not damage any components while working around this area.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the 3rd RH inner bolt that attaches the HV battery to the body, if equipped.

HV Battery (Dual Motor) - Install

  1. Hand-tighten the RH front inner bolts (x2) that attach the HV battery to the body.
  2. Partially close, but do not latch, the RH front door.
  3. With an assistant, lower the vehicle onto the HV battery completely.

HV Battery (Dual Motor) - Install

  1. Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.  Torque 30 Nm

HV Battery (Dual Motor) - Install

  1. Torque the bolts (x4) that attach the front of the HV battery to the vehicle. Torque 30 Nm

HV Battery (Dual Motor) - Install

  1. Torque the front center bolt that attaches the HV battery to the vehicle. Torque 10 Nm

HV Battery (Dual Motor) - Install

  1. Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle. Torque 110 Nm

HV Battery (Dual Motor) - Install

HV Battery (Dual Motor) - Install

  1. Tighten the bolts (x4) that attach the center portion of the HV battery through the center ski cover. Torque 34 Nm
  2. Torque the fasteners that attach the rear skid plate to the vehicle. See Skid Plate - HV Battery - Rear (Remove and Replace).
  3. With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle. Set the vehicle to a comfortable working height.
  4. Put the support stand to support the front portion of the rear subframe.

LH shown, RH similar
LH shown, RH similar

  1. 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
LH shown, RH similar

  1. Install the LH shear plate, and then install the smaller bolts (x2) that attach the shear plate to the HV battery. Torque 30 Nm

HV Battery (Dual Motor) - Install

  1. Install 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
LH shown, RH similar

  1. Fasten the fir tree clips that attach the coolant hoses to the LH shear plate.
  2. Repeat steps 71 through 74 for the RH shear plate.
  3. Remove the support stand from underneath the rear subframe
  4. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  5. Position the coolant drain under the front LH side of the HV battery.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Fasten the clips that attach the chiller to HV battery hose to the body.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Position the coolant drain under the front RH side of the HV battery.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Remove the coolant drain from underneath the vehicle.

HV Battery (Dual Motor) - Install

  1. Install the bolt that attaches the ground strap to the HV battery Torque 10 Nm

HV Battery (Dual Motor) - Install

  1. Install the clip that attaches the front drive unit ground strap to the front drive unit.

HV Battery (Dual Motor) - Install

  1. Install the bolt that attaches the ground strap to the front drive unit. Torque 6 Nm

HV Battery (Dual Motor) - Install

  1. Install the front drive unit HV harness connector special tool on the front drive unit HV harness connector.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Remove the front drive unit HV harness connector special tool.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Slide the red release tab to lock the front drive unit HV harness connector.

HV Battery (Dual Motor) - Install

  1. Install the bolt that attaches the front drive unit HV harness to the front drive unit. Torque 10 Nm

HV Battery (Dual Motor) - Install

  1. Connect the A/C HV connector.
  2. Connect the PTC HV electrical connector, and then install the harnesses to the bracket.
  3. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  4. Remove the bungee straps from the LH and RH wheel arch liners.

HV Battery (Dual Motor) - Install

HV Battery (Dual Motor) - Install

  1. Fasten the clips along the bottom edge of the LH and RH wheel arch liners.
  2. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  3. Lower the vehicle fully, and chock a wheel.
  4. Remove the lift adaptors from the body, and then install the body plugs.
  5. 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.
  1. Open all doors.

HV Battery (Dual Motor) - Install

  1. 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.
  1. Replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  2. Install the DCDC ground busbar. See Busbar - DCDC Ground (Remove and Replace).

HV Battery (Dual Motor) - Install

  1. Install the bolts that attach the LH and RH inner 2nd row rails to the penthouse cover. Torque 24 Nm

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Install the clip that attaches the charge port to HV harness connector to the LH lower C-pillar.

HV Battery (Dual Motor) - Install

  1. Install the harness clips, and then the bolts that attach the charge port to HV battery harness bracket at the penthouse. Torque 10 Nm

HV Battery (Dual Motor) - Install

  1. Install the HV cap that covers the HV harness located on the LH side of the penthouse.
  2. Connect 12V power. See 12V Power (Disconnect and Connect).
  3. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  4. Connect a laptop with Toolbox to the vehicle.
  5. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  6. Disconnect the laptop from the vehicle.

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Tighten the 4th LH inner bolt that attaches the HV battery to the body. Torque 66 Nm
  2. Unfold the carpet back to its original position.
  3. Move the driver seat fully rearwards.

HV Battery (Dual Motor) - Install

  1. Tighten the 3rd LH inner HV battery bolt. Torque 66 Nm

HV Battery (Dual Motor) - Install

  1. Tighten the LH front inner HV battery bolts (x2) that attach the HV battery to the body. Torque 136 Nm

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Install the clips (x3) that attach the LH front carpet to the vehicle.
  2. Move the driver seat fully forwards.

HV Battery (Dual Motor) - Install

  1. Tighten the 5th RH rear inner bolt that attaches the HV battery to the body. Torque 66 Nm

HV Battery (Dual Motor) - Install

  1. Tighten the 4th RH inner bolt that attaches the HV battery to the body, if equipped. Torque 66 Nm
  2. Unfold the RH side of the rear carpet back to its original position.
  3. Move the front passenger seat fully rearward.

HV Battery (Dual Motor) - Install

  1. Tighten the bolt that attaches the 3rd RH inner HV battery bolt to the body, if equipped.

HV Battery (Dual Motor) - Install

  1. Tighten the RH front inner bolts (x2) that attach the HV battery to the body. Torque 136 Nm

HV Battery (Dual Motor) - Install

  1. 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.

HV Battery (Dual Motor) - Install

  1. Install the clips (x4) that attach the RH front carpet to the vehicle.
  2. Move the front passenger seat fully forward.

HV Battery (Dual Motor) - Install

  1. 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.

  1. Install the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Remove and Replace).
  2. Install the LH upper B-pillar trim. See Trim - B-Pillar - Upper - LH (Remove and Replace).
  3. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  4. Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  5. Repeat step 137 through step 140 for the RH side of the vehicle.
  6. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  7. Install the 2nd row floor mat inside the vehicle.
  8. Install the RH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  9. Install the RH front floor mat.
  10. Install the front passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
  11. Install the RH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  12. Install the RH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  13. Install the RH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  14. Install the LH center console side panel carpet. See Carpet - Side Panel - Center Console - LH (Remove and Replace).
  15. Install the LH front floor mat.
  16. Install the driver footwell cover. See Cover - Footwell - Driver (Remove and Replace).
  17. Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  18. Install the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
  19. Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
  20. Restore the driver and front passenger seats back to their original position.
  21. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  23. Close the hood and all four doors.
  24. Install the LH and RH lower rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).

    READ NEXT:

     HV Battery Enclosure

    SEE MORE:

     Heat Exchanger - Front Drive Unit (Remove and Replace)

    Remove Remove the front subframe assembly. See Subframe Assembly - Front (Dual Motor) (Remove and Install) Release the clip that connects the front drive unit inverter-heat exchanger hose to the heat exchanger coolant inle Release the clips that attach the front drive unit inverter-

     Switch - Child Safety - Underhood Storage Area (Remove and Replace)

    Remove Remove the hood latch cover. See Cover - Hood Latch (Remove and Replace). Release the clips that attach the child safety switch to the hood latch cover, and remove the switch from the cover. Install Installation procedure is the reverse of removal.

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