Fluid Coupling (Straight) - Front Drive Unit - Remove And Replace: Install

Wet the straight fluid coupling O-ring with coolant, install the fluid coupling into the front drive unit inverter, and then install a new bolt to attach the coupling to the inverter.
6 N.m (4.4 ft-lbs)

CAUTION: Do not install the fluid coupling with the O-ring dry.

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Install the bolt that attaches the front drive unit HV harness to the front drive unit.
10 N.m (7.4 ft-lbs)

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Remove the plugs from the fittings, immediately connect the front drive unit inverter inlet hose to the front drive unit inverter, fasten the clip, and then perform a Push-Pull-Push check of the fitting.

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Move the coolant drain container out from underneath the vehicle.

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Install the LH cross brace to the LH casting, and then install the bolts (x3) that attach the cross brace to the casting.
30 N.m (22.1 ft-lbs)

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Install the HV battery. See HV Battery (AWD) (Remove and Install) .
Install the front skid plate. See Skidplate - Front (Remove and Replace) .
Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.

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Install the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace) .
Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace) .
Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.

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Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.

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Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.

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Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
9 N.m (6.6 ft-lbs)

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Put on the HV insulating gloves and leather over gloves.

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Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
NOTE: The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), escalate to Service Engineering.

NOTE: If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.

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Repeat step 17 for the other charge port busbar connector lead and DC input HV header bolt head.
Remove the HV insulating gloves and leather over gloves.

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Install the bolt that secures the charge port busbar connector access door.
9 N.m (6.6 ft-lbs)

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Install the LH inner reinforcement to the body, and then install the bolts (x10) that attach the reinforcement to the body.
27 N.m (19.9 ft-lbs)

NOTE: The bottom two bolts require improvising an 8 mm ratchet box-end wrench to turn the T40 socket.

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Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace) .
Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill) .
Connect LV power. See LV Power (Disconnect and Connect) .
Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed) .
Install the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
Install the trunk side trim bracket. See:
- Trim - Side - Trunk - LH (5 Seat) (Remove And Replace)
- Trim - Side - Trunk - LH (6/7 Seat) (Remove And Replace)
Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace) .
Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace) .
Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
2.5 N.m (1.8 ft-lbs)

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Install the 2nd row rear floor panel. See:
- Floor Panel - Rear - 2nd Row (5 Seat) (Remove And Replace)
- Floor Panel - Rear - 2nd Row (6 Seat) (Remove and Replace)
- Floor Panel - Rear - 2nd Row (7 Seat) (Remove And Replace)
Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace) .
Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace) .
Install the 2nd row mid floor panel. See:
- Floor Panel - Mid - 2nd Row (5 Seat) (Remove And Replace)
- Floor Panel - Mid - 2nd Row (6 Seat) (Remove And Replace)
- Floor Panel - Mid - 2nd Row (7 Seat) (Remove And Replace)
Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace) .
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .
Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove And Replace) .
Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift .