2026-05-28

HV Battery (RWD) (Structural Pack) (Remove and Replace)

Correction code 16010132 5.70 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See for safe and healthy working practices.

  • 2025-03-26: Released new procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
  • 2026-05-21: Added warnings to never move the gantry with a suspended load or put any part of the body underneath a suspended load. Changed wording to clarify that crates are positioned under gantries rather than gantries moved over crates.

Remove

  1. Open all four doors
  2. Lower all four windows
  3. Remove clips securing LH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  4. Remove LH rocker cover from rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Work a plastic trim tool between door panel and rocker cover to release tabs
  5. Remove clips securing LH rocker carrier to body and wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 12 Nm, 4x clips
  6. Remove LH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, 1x datum, Use pry tool to release clips and prevent damage to carrier, Negotiate carrier around rear wheel liner then front wheel liner
  7. Remove butyl patches covering LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Clean excess butyl from area
  8. Install lift pad adapters onto LH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  9. Remove clips securing RH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  10. Remove RH rocker cover from rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Work a plastic trim tool between door panel and rocker cover to release tabs
  11. Remove clips securing RH rocker carrier to body and wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 12 Nm, 4x clips
  12. Remove RH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, 1x datum, Use pry tool to release clips and prevent damage to carrier, Maneuver carrier around rear wheel liner then front wheel liner
  13. Remove butyl patches covering RH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Clean excess butyl from area
  14. Install lift pad adapters onto RH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  15. Chock LH rear wheel
  16. Connect a laptop with Toolbox 3 to the vehicle.
  17. Run ODIN routine PROC_EPB_X_SERVICE-MODE-STARTvia Toolbox:(link)
  18. Access thermal system routines via UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select quick controls > Service mode > Thermal
  19. Run Thermal Fill Drain (Coolant Only) through Service UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again
  20. Remove laptop from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close Toolbox 3.0, we will need to resume later
  21. Remove LH mid A pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release upper clip then pull mid A pillar upward to remove
  22. Remove clip securing LH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  23. Partially release LH front primary door seal
  24. Remove LH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2 guide tabs, Pull rear of lower A pillar upward to release clip then pull rearward to release trim panel
  25. Remove clip securing LH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  26. Pull LH front cabin carpet away from A-pillar to access LH front seat connector
  27. Move LH front seat forward
  28. Remove RH mid A pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release the upper clip then pull mid A pillar upward to remove
  29. Remove clip securing RH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  30. Partially release RH front primary door seal
  31. Remove RH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2 guide tabs, Pull rear of lower A pillar upward to release clip then pull rearward to release trim panel
  32. Remove clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  33. Pull RH front cabin carpet away from A-pillar to access RH front seat connector
  34. Move RH front seat forward
  35. Release RH front seat belt retractor from pretensioner
    Informational PurposesAn informational icon, calling your attention
    Note
    Insert special removal tool into the bottom of the retractor to release
  36. Release LH front seat belt retractor from pretensioner
    Informational PurposesAn informational icon, calling your attention
    Note
    Insert seat belt tool into the bottom of the retractor to release
  37. Remove LH front seat rear fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Discard after removal
  38. Move LH front seat backward
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure profile is saved to allow seat position to be restored
  39. Release LH footwell assembly from IP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clips, 1x screw, T20, 2.5 Nm
  40. Remove LH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x Ethernet connector, 1x puddle light connector, 1x OBD connector
  41. Remove LH front floor mat
  42. Remove LH front seat front fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Discard after removal
  43. Remove LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x guide pins, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  44. Adjust position of LH front seat for easy removal
    Informational PurposesAn informational icon, calling your attention
    Note
    Move seat to middle of track at most upright position
  45. Remove RH front seat rear fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Discard after removal
  46. Move the RH front seat back.
  47. Release RH footwell assembly from IP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clips, 1x screw, T20, 2.5 Nm
  48. Remove RH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  49. Remove RH front floor mat
  50. Remove RH front seat front fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Discard after removal
  51. Remove RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
  52. Adjust position of RH front seat for easy removal
    Informational PurposesAn informational icon, calling your attention
    Note
    Move seat to middle of track at most upright position
  53. Open the hood.
  54. Remove the rear apron.
  55. Release washer fluid reservoir neck from frunk
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm, Some vehicles may have a push clip in this location
  56. Release washer tank neck from washer tank and set aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x O-ring, No need to remove hose from neck
  57. Remove HEPA filter assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, Then lift up to clear frunk assembly
  58. Power off the vehicle using the touchscreen.
  59. Disconnect the LV battery connector and First Responder Loop.
  60. Disconnect LH front seat harness from VC left
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Release the lock by squeezing the release tab, Then fully disengage the lock by moving it away from the VC left, Do not force the connector, If the connector does not easily release from the VC the lock is still engaged
  61. Remove LH front seat harness clips from LH footwell support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  62. Position LH front seat up and tilt backwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully lean LH front seat backwards
  63. Release clips securing LH cabin carpet to cabin support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x vertical clip, Insert clip pry tool outboard of clip and rotate to the right to release one side of clip, Move clip pry tool inboard of clip and rotate to left to fully release carpet clip from cabin support
  64. Release clips securing LH front cabin carpet underneath front seat
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  65. Remove LH front cabin carpet from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip, Release seat harness clip and harness, Release all edges, Take note of short edge under center console
  66. Release clips securing LH front seat harness
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Lean seat back as required, Route harness out from under seat riser
  67. Remove LH front seat from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
  68. Disconnect RH front seat harness from VC right
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Release the lock by squeezing the release tab, Then fully disengage the lock by moving it away from the VC right, Do not force the connector, If the connector does not easily release from the VC the lock is still engaged
  69. Remove RH front seat harness from RH footwell support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  70. Position RH front seat up and tilt backwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully lean RH front seat backwards
  71. Release clips securing RH cabin carpet to cabin support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  72. Release clips securing RH front cabin carpet underneath front seat
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  73. Remove RH front cabin carpet from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up rear edge of carpet then slide out towards rear of vehicle, be cautious to avoid foam below catching on seat risers
  74. Release clips securing RH front seat harness and route out from under seat
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Lean seat back as required, Route harness out and release clips
  75. Remove RH front seat from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
  76. Remove LH bolt securing center console to instrument panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 6.5 Nm, Later production vehicles may have a 10mm bolt
  77. Disconnect center console harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Located behind LH center console side carpet
  78. Remove console lower rear panel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  79. Remove bolts securing center console to lower rails
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, 8mm, 9.5 Nm
  80. Disconnect USB harness at RH center console
    Informational PurposesAn informational icon, calling your attention
    Note
    1x USB connector, Located behind RH center console side bracket
  81. Remove RH bolt securing center console to instrument panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 6.5 Nm, Later production vehicles may have a 10mm bolt
  82. Slide center console assembly out of riser rails
    Informational PurposesAn informational icon, calling your attention
    Note
    Squat behind center console then pull back on cupholders, Take note of surrounding components to avoid personal injury and vehicle damage, Force applied must be parallel to rails, Shift center console from side to side to loosen
  83. Remove center console from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify lid is in closed position, Recommend assistance, Tilt rear of console upward, Pull assembly towards rear of vehicle
  84. Release the 2nd row seat cushion from the seat frame.
  85. Partially remove lower portion of LH rear door seal
  86. Remove LH Lower C-Pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ, by vehicle build location,Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly later
  87. Partially remove RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Pillar and sill trim have tabs seated underneath seal
  88. Remove RH C-pillar lower trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ by vehicle build location, and the number of clips may also vary, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall
  89. Remove rear floormat
  90. Remove rear main cabin carpet from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, pull up at the rear of rear main carpet and slide back, remove from LH rear door
  91. Remove LH riser side carpet support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  92. Remove RH riser side carpet support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  93. Remove LH and RH center console lower rails
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 4.5 Nm, 8x guides, Slide rails forward to disengage from center console riser assembly, Discard bolts after removal
  94. Remove LH and RH floor ducts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  95. Release center console harness from HV Battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  96. Remove LH and RH lower IP carrier brackets
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 25 Nm
  97. Secure center seat belt buckles away from penthouse
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply tape across seat frame
  98. Remove rear inner HV battery bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 49 Nm, Bolt position 35 to 38, loosen with ratchet and remove with battery powered drill
  99. Remove wheel chocks and push vehicle onto lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, close all doors enough as needed to fit between the lift and latch rear doors to prevent accidental closure, Replace wheel chocks once vehicle in correct position
  100. Verify operation of multimeter
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
  101. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
  102. Fully raise the vehicle, and then lower the lift onto the locks.
  103. Remove front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
  104. Secure RH front wheel liner away from HV battery
  105. Secure LH front wheel liner away from HV battery
  106. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt
  107. Remove all items from pockets and ensure not wearing metal items
  108. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  109. Put on the HV insulating gloves and leather over gloves.
  110. Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required. If current < 0.5A, OK to disconnect and check voltage at HV plug on battery side
  111. Release RDU HV harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate release lever up to disengage connector, Do not force release lever up, Ensure alignment tabs on RDU header are not damaged
  112. Verify no high voltage at RDU HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  113. Remove HV insulating gloves
  114. Lower vehicle until tires are touching ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  115. Release 2nd row 60 seat connector from LH seat frame
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Pinch tabs on clip to avoid damage
  116. Disconnect HV inlet harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab upwards then lift connector
  117. Remove bolt securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  118. Remove bolts securing charge port busbar kit to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  119. Release LH body harness from rear body and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  120. Lift busbar kit connector to remove from HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Use inflatable air bag to suspend busbar away from HV header during removal and installation, hold busbar firmly as there is tension on
  121. Disconnect HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
  122. Disconnect power connector to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pull locking tab upward then release connection
  123. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closure
  124. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
  125. Position coolant drain container underneath LH front of HV battery
  126. Disconnect PT supply hose at LH front side of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed
  127. Install PCS flush adapter onto PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove plugs as needed, Verify fully seated, Perform push-pull-push test
  128. Secure coolant cart flush hose to regulator and PCS flush adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify regulator valve is closed, Pressure regulator is not adjustable
  129. Position coolant drain container underneath LH RDU area
    Informational PurposesAn informational icon, calling your attention
    Note
    Position neck to catch all coolant loss
  130. Release RDU inverter inlet hose from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  131. Disconnect RDU inverter inlet hose from fluid coupling
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug drive unit coupling
  132. Attach compressed air line to coolant pressure tester
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valve is closed on pressure regulator
  133. Slowly open valve on pressure regulator and allow coolant to completely drain
    Informational PurposesAn informational icon, calling your attention
    Note
    Keep an eye on all hose connections to verify no leaks from tooling
  134. Close valve on pressure regulator once no coolant is draining from RDU inverter inlet hose
  135. Disconnect compressed air from coolant pressure tester
  136. Position coolant drain container underneath LH front of HV battery
  137. Remove PCS flush adapter from PT supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed
  138. Remove PT flush fitting adapter from cart pressure hose
  139. Position coolant drain container underneath center front of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Underneath front left manifold battery supply tube
  140. Disconnect front left manifold battery supply tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x clip, Plug hose connections as needed
  141. Attach battery drain fitting adapter onto female front left manifold battery supply tube
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valve is closed and adapter is locked to manifold tube
  142. Secure coolant cart flush hose to battery drain fitting adapter
  143. Position coolant drain container underneath RH front of HV battery
  144. Disconnect HV battery RH front inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed
  145. Release clip securing HV battery RH front inlet hose to skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  146. Attach compressed air line to coolant pressure tester
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valve is closed on pressure regulator
  147. Open valve on battery drain fitting adapter
  148. Slowly open valve on pressure regulator and allow coolant to completely drain
    Informational PurposesAn informational icon, calling your attention
    Note
    Keep an eye on all hose connections to verify no leaks from tooling
  149. Close valve on pressure regulator once no coolant is draining from HV battery RH front inlet port
  150. Disconnect compressed air from coolant pressure tester
  151. Position coolant drain container underneath center front of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Underneath front left manifold battery supply tube
  152. Remove battery drain fitting adapter from female front left manifold battery supply tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed
  153. Remove battery drain fitting adapter from cart drain hose
  154. Position coolant drain container underneath RH front of HV battery
  155. Disconnect PT return hose at RH front side of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose connections as needed
  156. Release clip securing PT return hose to RH front side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  157. Release PT coolant hose from LH side of front HV battery bash plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  158. Position coolant drain container underneath LH rear of HV battery
  159. Remove RDU inverter inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x clip, Rotate between subframe and battery out of vehicle, plug hose connections as needed
  160. Disconnect compressor HV harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up
  161. Release compressor HV harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  162. Release RDU oil cooler outlet pipe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, 5x clips, Plug hose connections as needed
  163. Remove RDU oil cooler outlet pipe
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate down over RDU and rearward around subframe
  164. Remove coolant drain container from underneath vehicle
  165. Release RDU HV cable bracket from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  166. Disconnect RDU HV cable from RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up
  167. Remove RDU HV cable
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate cable underneath logic cable harness between subframe and HV battery
  168. Remove smaller fasteners for LH and RH shear plates
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 47 Nm, Bolt position 8-9 and 14-15
  169. Loosen large bolt securing LH shear plate and subframe to body and rotate shear plate clear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
  170. Loosen large bolt securing RH shear plate and subframe to body and rotate shear plate clear of HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
  171. Place battery table into position and lower vehicle to support battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Line up table so bolts at front bash plate are accessible and rear HV cables are accessible, Adjust final battery table position using adjustable caster jacks on table
  172. Loosen front bolts securing HV battery through skid plate cover with ratchet and remove with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 16mm, 90 Nm, Later production vehicles have E14 bolts torqued at 75 Nm, Bolt location 23 to 28
  173. Loosen bolts securing skid plate to vehicle with ratchet and remove with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 13mm, 62 Nm, Bolt location 29-34
  174. Loosen bolts securing rear HV battery to vehicle with ratchet and remove with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 62 Nm, Bolt position 10-13
  175. Loosen LH bolts securing HV battery to vehicle with ratchet and remove with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 15mm, 56 Nm, Bolt position 16-22
  176. Loosen RH bolts securing HV battery to vehicle with ratchet and remove with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 15mm, 56 Nm, Bolt position 1-7
  177. Raise vehicle to free from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  178. Remove battery from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  179. Release PT supply tube from rear of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x clips, Plug hose connections as needed
  180. Remove PT supply tube from LH side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clamps, 6x brackets, Each clamp has 1x datum that need to be released from bracket holes
  181. Remove FDU dummy plug from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Disengage locking tab then release connector body
  182. Remove front left manifold battery supply tube from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 3x clips, Use shop towel to clean any residue coolant if necessary, Plug hose connections as needed
  183. Remove PT return tube from RH side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clamps, 6x brackets, Each clamp has 3x datums that need to be released from 3x bracket holes
  184. Attach HV battery H-frame to gantry and raise into position
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Never stand or place any part of your body underneath a suspended load.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Never attempt to move a gantry while a load is suspended.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Refer to the gantry manufacturer's instructions for safety and operational information.
  185. Placeholder - Release P2 sling adapter from H-frame
    Informational PurposesAn informational icon, calling your attention
    Note
    4x anchor hooks
  186. Position HV battery under gantry
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  187. Secure P2 sling adapter onto HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, The hoist is color coded and will come with instructions, Verify locking joints are fully secured, DO NOT secure middle joints, Perform push and pull test, If not properly secured then top pin will be recessed, Take care to secure properly and safely
  188. Raise HV battery pack off battery table
  189. Position a pallet under the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  190. Lower HV battery pack onto pallet
  191. Release P2 battery sling adapter from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, Push down on top pin to release
  192. Raise gantry and H-frame from old HV battery pack
  193. Remove logic cap from old HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  194. Open crate top housing new HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  195. Inspect and clean wade seal on battery prior to installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean with water and dry surface completely, if any damage is detected, wade seal must be reworked or replaced
  196. Install logic cap onto new HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  197. Placeholder - Remove fasteners securing new HV battery pack to crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners still in development
  198. Position the crate under the gantry and H-frame, then secure P2 sling adapter to new HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, The hoist is color coded and will come with instructions, Verify locking joints are fully secured, DO NOT secure middle joints, Perform push and pull test, If not properly secured then top pin will be recessed, Take care to secure properly and safely
  199. Raise new HV battery pack off crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  200. Move the crate from under the gantry, then position HV battery table under the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  201. Lower HV battery pack onto battery table
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Make sure to align battery pack to table with clear access to all bolt to body holes
  202. Release P2 sling adapter from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, Push down on top pin to release
  203. Remove HV battery pack from under gantry
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  204. Position the old HV battery pack under the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  205. Lower gantry and H-frame and secure P2 sling adapter to old HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, The hoist is color coded and will come with instructions, Verify locking joints are fully secured, DO NOT secure middle joints, Perform push and pull test, If not properly secured then top pin will be recessed, Take care to secure properly and safely
  206. Raise old HV battery pack above height of crate
  207. Position crate underneath old HV battery pack
  208. Lower old HV battery pack onto crate
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  209. Release P2 sling adapter from HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    4x locking joints, Push down on top pin to release
  210. Raise gantry and H-frame from old HV battery pack
  211. Lower gantry and remove HV battery H-frame from gantry
  212. Placeholder - Install fasteners securing new HV battery pack to crate hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners still in development
  213. Close crate top housing old HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance

Install

  1. Install PT return tube onto RH side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clamps, 6x brackets, Each clamp has 3x datums that need to be secured onto 3x bracket holes
  2. Install front left manifold battery supply tube onto HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a visual inspection of the bolt holes and HV headers to make sure that terminals are aligned and threads are not damaged before installing a bolt or mating a connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 3x clips, Remove plugs as needed
  3. Install FDU dummy plug onto HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Fully seat connector body, then engage locking latch
  4. Install PT supply tube to LH side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clamps, 6x brackets, Each clamp has 1x datum that need to be secured to bracket holes
  5. Secure PT supply tube onto rear of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x clips, Remove plugs as needed
  6. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  7. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  8. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of hole on both leads, Spread evenly to verify contact surface is fully covered
  9. Inspect and clean body side of HV battery wade seal interface
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean with water and dry surface completely
  10. Install HV battery alignment rods onto body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, Use smaller rods only, Thread onto RH front most and LH rear most side holes
  11. Position HV battery pack under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  12. Lower vehicle onto HV battery pack and align battery holes with rods
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use smaller rods only, Be sure coolant hoses and harnesses do not get pinched
  13. Open LH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  14. Open RH rear door
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components
  15. Remove HV battery alignment rods from body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, Remove rods once the HV battery is aligned
  16. Thread in by hand all bolts securing HV battery to vehicle - (Except for shear plates)
    Informational PurposesAn informational icon, calling your attention
    Note
    34x bolts, Includes top bolts, Do not thread shear plate bolts (8-9, 14-15), Start with bolts (35-36-37-38) Ensure smooth thread engagement and bolts are not cross threaded into casting
  17. Lower vehicle onto pack completely
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance
  18. Seat all bolts securing HV battery to vehicle with battery powered drill - (Except for shear plates)
    Informational PurposesAn informational icon, calling your attention
    Note
    34x bolts, Includes top bolts, Do not seat shear plate bolts (3-9, 14-15), Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
  19. Fully torque LH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 15mm, 56 Nm, Bolt position 1-7
  20. Fully torque RH bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 15mm, 56 Nm, Bolt position 16-22
  21. Fully torque rear bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 62 Nm, Bolt position 10-13
  22. Fully torque front bolts securing HV battery through bash plate openings
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 16mm, 90 Nm, Later production vehicles have E14 bolts torqued at 75 Nm, Bolt location 23 to 28
  23. Fully torque front bolts securing bash plate to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 13mm, 62 Nm, Bolt location 29-34
  24. Loosen RH rear subframe bolt and align RH rear shear plate with HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
  25. Install bolts securing RH shear plate to HV battery hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 62 Nm, Bolt position 8-9, Torque at later step
  26. Torque bolt securing subframe and RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  27. Torque small fasteners securing RH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 62 Nm, Bolt position 8-9
  28. Loosen LH rear subframe bolt and align LH rear shear plate with HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
  29. Install bolts securing LH rear shear plate to body hand tight
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 62 Nm, Bolt position 14-15, Torque at later step
  30. Torque bolt securing subframe and LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm
  31. Torque small fasteners securing LH rear shear plate to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 62 Nm, Bolt position 14-15
  32. Fully torque LH rear inner bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 35-36
  33. Close LH rear door
  34. Fully torque RH rear inner bolts securing HV battery to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 37-38
  35. Visually inspect wade seal to ensure no gaps are present
  36. Close RH rear door
  37. Raise vehicle and lower onto locks, then remove battery table from under vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  38. Position RDU HV cable up to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate cable underneath logic cable harness between subframe and HV battery
  39. Connect RDU HV cable onto RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
  40. Secure RDU HV harness onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Verify lever is in upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
  41. Install bolt securing RDU HV cable bracket to RDU
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm
  42. Install RDU oil cooler outlet pipe
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate up over RDU and rearward around subframe to oil cooler
  43. Secure RDU oil cooler outlet pipe
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, 5x clips, Remove plugs as needed
  44. Secure compressor HV harness to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  45. Connect compressor HV harness onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked
  46. Install RDU inverter inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clip, 1x clip, Rotate between subframe and battery into RDU and PCS outlet, Remove plugs as needed
  47. Secure RDU inverter inlet hose to RDU HV cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  48. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack has one less bolt and one extra clip
  49. Position coolant drain container underneath LH front of HV battery
  50. Connect PT supply hose at LH front side of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plugs as needed
  51. Secure PT coolant hose onto LH side of front HV battery bash plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  52. Position coolant drain container underneath RH front of HV battery
  53. Connect PT return hose at RH front side of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plugs as needed
  54. Secure PT return hose to RH front side of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  55. Connect HV battery RH front inlet hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plugs as needed
  56. Secure HV battery RH front inlet hose to skid plate
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  57. Position coolant drain container underneath center front of HV battery pack
    Informational PurposesAn informational icon, calling your attention
    Note
    Underneath front left manifold battery supply tube
  58. Connect front left manifold battery supply tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x clip, Remove plugs as needed
  59. Remove coolant drain container from underneath vehicle
  60. Release LH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  61. Release RH front wheel liner from bungee strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle
  62. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
  63. Lower vehicle fully and move rack arms away from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  64. Push vehicle away from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
  65. Open all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closure
  66. Connect LV power connector to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push red locking tab down to secure connection
  67. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  68. Connect HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
  69. Position busbar kit connector and lower onto HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold busbar firmly as there is tension on, caution not to damaged busbar connectors
  70. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  71. Inspect the HV insulating gloves for any damage.
  72. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  73. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  74. Remove HV insulating gloves
  75. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  76. Install LH body harness onto rear body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  77. Connect HV inlet harness to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pivot handle downwards to engage connector and secure locking tab
  78. Secure 2nd row 60 seat connector to LH seat frame
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  79. Remove tape from seat frame
  80. Install LH and RH lower IP carrier brackets
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 25 Nm
  81. Install center console harness to HV Battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  82. Install LH and RH floor ducts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  83. Install LH and RH center console lower rails
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 4.5 Nm, 8x guides, Slide rails rearward to engage onto center console riser assembly, Install new bolts
  84. Install LH riser side carpet support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  85. Install RH riser side carpet support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs
  86. Install rear main cabin carpet onto vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips, Position rear main carpet to floorboard and slide forward, Ensure rear main carpet tucks beneath lower B-pillar trims and air duct
  87. Install rear floormat
  88. Install RH C-pillar lower trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips, Confirm installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall
  89. Reseat RH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  90. Install LH Lower C-Pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of LH Lower C-Pillar trim into trunk side trim and work your way forward securing clips, trim part may slightly differ, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall
  91. Reseat LH rear door seal
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat pillar and sill trim tabs underneath seal
  92. Reposition 2nd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide cushion rearward then align with buckles and foam with seat rail, Make sure cushion is fully seated with push & pull test
  93. Install center console into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Tilt front of console downward, Engage into rails on risers, Slide assembly towards front of vehicle and engage into IP carrier
  94. Install RH bolt securing center console to instrument panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 6.5 Nm
  95. Connect USB harness at RH center console
    Informational PurposesAn informational icon, calling your attention
    Note
    1x USB connector, Located behind RH center console side bracket
  96. Install bolts securing center console to lower rails
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 8mm, 9.5 Nm
  97. Install console lower rear panel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips
  98. Connect center console harness connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Located behind LH center console side carpet
  99. Install LH bolt securing center console to instrument panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 6.5 Nm
  100. Install RH front seat into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim, Gateway configuration update for cfg_frontSeattype is needed when replacing from 7654324-XX-C to 7654324-XX-F or newer 1st Row LHD RH Seat Assembly with 1st Row Mini-Tilt Motor Assembly
  101. Position RH front seat up and tilt backwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully lean RH front seat backwards
  102. Route RH front seat harness under seat riser and secure clips onto seat riser and carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  103. Install RH front cabin carpet into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure all edges, Tuck short edge underneath center console
  104. Install clips securing RH front cabin carpet underneath front seat
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  105. Install clips securing RH cabin carpet to cabin support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, Secure clips and verify fitment of carpet
  106. Position RH front seat down and tilt forwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully return to original position
  107. Install RH front seat harness onto RH footwell support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  108. Connect RH front seat harness to VC right
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Ensure the connector and lock are fully engaged, Perform pull push pull test to ensure the connector and connector lock are seated
  109. Install LH front seat into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim, Gateway configuration update for cfg_frontSeattype is needed when replacing from 7654322-XX-E to 7654322-XX-F or newer 1st Row LHD LH Seat Assembly with 1st Row Mini-Tilt Motor Assembly
  110. Position LH front seat up and tilt backwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully lean LH front seat backwards
  111. Route LH front seat harness under seat riser and secure clips onto seat riser and carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  112. Install LH front cabin carpet into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure all edges, Tuck short edge underneath center console
  113. Install clips securing LH front cabin carpet underneath front seat
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  114. Install clips securing LH cabin carpet to cabin support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x vertical clip, Secure vertical clip into place first, Verify fitment of carpet
  115. Position LH front seat down and tilt forwards
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully return to original position
  116. Install LH front seat harness clips onto LH footwell support bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x retaining clips
  117. Connect LH front seat harness to VC left
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Ensure the connector and lock are fully engaged, Perform pull push pull test to ensure the connector and connector lock are seated
  118. Remove coolant bottle cap
  119. Place empty coolant container into front storage area
  120. Fill container with at least 15L of coolant
  121. Place filled coolant container into front storage area
  122. Setup vacuum refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  123. Install refill tool cap onto coolant bottle assembly
  124. Setup vacuum refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  125. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully engaged
  126. Position overflow hose into empty container
  127. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  128. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  129. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  130. Slowly open refill valve to allow coolant to be drawn into system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  131. Once gauge reads zero, close refill valve
  132. Disconnect shop air supply from coolant refill tool
  133. Remove coolant refill hose from coolant container
  134. Remove coolant overflow hose from coolant container
  135. Remove vacuum refill hose from refill cap on coolant bottle
  136. Remove coolant refill tool from vehicle
  137. Remove both coolant containers from inside underhood area
  138. Connect the First Responder Loop and LV battery connector.
  139. Press and hold park button to release EPB service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove wheel chocks if necessary
  140. Access thermal system routines via UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select quick controls > Service mode > Thermal
  141. Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
  142. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure coolant is filled using G-48 coolant
  143. Install coolant bottle cap
  144. Run ODIN routine TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)
  145. Reinstall Software from UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Controls > Service Mode > Software Reinstall > Request, Wait for the message and "Successfully requested"
  146. Select clock on center display, then select "Install Now" to start firmware update
    Informational PurposesAn informational icon, calling your attention
    Note
    Tap center display next to software update window until clock runs down to 0,After displayed installation time
  147. Once firmware redeploy is complete, Verify on center display release notes are present
    Informational PurposesAn informational icon, calling your attention
    Note
    If the redeploy fails you may receive an error message on UI
  148. Perform Battery Pack Replacement through Service UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Service mode > High Voltage > Procedures > Battery Pack Replacement > Restore HVC after battery pack replacement, click Run, close once routine is completed, if routine fails follow https://toolbox.teslamotors.com/articles/6768800
  149. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
  150. Install HEPA filter assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct, Rework requires new bolts
  151. Secure washer tank neck onto washer tank
    Informational PurposesAn informational icon, calling your attention
    Note
    1x O-ring, Ensure washer hose is properly routed
  152. Secure washer fluid reservoir neck to frunk
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm, Some vehicles may have a push clip in this location
  153. Install the rear apron.
  154. Close the hood.
  155. Move RH front seat backward
  156. Install RH front seat front fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Install new patch bolts
  157. Install RH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 2x locating pins, Position side panel and align the locator, then the rear locator, Push side panel towards console to install
  158. Install RH front floor mat
  159. Install RH footwell lighting and speaker connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  160. Secure RH footwell assembly onto IP
    Informational PurposesAn informational icon, calling your attention
    Note
    5x tabs, 1x screw, T20, 2.5 Nm, 1x push clips
  161. Move RH front seat forward
  162. Install RH front seat belt retractor to pretensioner
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the linkage onto the pretensioner cable, an audible click will be heard. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test to confirm pretensioner is engaged
  163. Install RH front seat rear fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Install new patch bolts
  164. Move the RH front seat to its original position.
  165. Fully seat RH front cabin carpet
  166. Install clip securing RH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  167. Install RH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2x locating pins, Align front locating pin first
  168. Install clip securing RH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  169. Install RH mid A pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A pillar, Make sure the seal seat on top of the trim
  170. Reseat RH front door seal along lower A pillar trim
  171. Move LH front seat backward
  172. Install LH front seat front fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Install new patch bolts
  173. Install LH console side panel carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x locating pins, Position side panel and align the locator, then the rear locator, Push side panel towards console to install
  174. Install LH front floor mat
    Informational PurposesAn informational icon, calling your attention
    Note
    2x velcro patches, Ensure mat does not interfere with pedal operation
  175. Position LH footwell assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    6x tabs, 1x Ethernet connector, 1x puddle light connector, 1x OBD connector
  176. Secure LH footwell assembly onto IP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2.5 Nm, 1x push clips
  177. Move LH front seat forward
  178. Install LH front seat belt retractor to quick fix
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the linkage into quick fix, an audible click will be heard, Verify there are no twists in the webbing from the upper trim to quick fix, Perform a firm pull test to confirm pretensioner is engaged
  179. Install LH front seat rear fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, TP45, 33.5 Nm, Install new patch bolts
  180. Move LH front seat to original position
  181. Fully seat LH front cabin carpet
  182. Install clip securing LH front cabin carpet to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  183. Install LH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 2 locating pins, Align front locating pin first
  184. Install clip securing LH lower A pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  185. Install LH mid A pillar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A pillar, Pull seal over trim
  186. Reseat LH front door seal along lower A-pillar trim
  187. Remove lift pad adapters from RH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  188. Install butyl patches onto RH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  189. Install RH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, 1x datum, Maneuver carrier around front wheel liner then rear wheel liner
  190. Install clips securing RH rocker carrier to body and wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 12 Nm, 4x clips
  191. Install RH rocker panel onto RH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
  192. Install clips securing RH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  193. Remove lift pad adapters from LH rocker
    Informational PurposesAn informational icon, calling your attention
    Note
    2x lift pad adapters
  194. Install butyl patches onto LH rocker access holes
    Informational PurposesAn informational icon, calling your attention
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  195. Install LH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, 1x datum, Maneuver carrier around front wheel liner then rear wheel liner
  196. Install clips securing LH rocker carrier to body and wheel liners
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 12 Nm, 4x clips
  197. Install LH rocker panel onto LH rocker carrier
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
  198. Install clips securing LH rocker cover to front and rear wheel liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  199. Raise all four windows
  200. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If LV is powered up, Unlatch rear doors before closing