Correction code 1630010071 1630010072 FRT 3.18 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

1. Raise and support vehicle
   Note

   Set air suspension to "Jack Mode"

   

   

2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
3. Place vehicle in service mode
   Note

   Via UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK

   

   

   

4. Remove bed floor assembly
   Note

   10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance

   

   

   

5. Release RH tonneau NVH cover
   Note

   6x bolts, 10mm, 5 Nm, 2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal

   

   

6. Remove RH tonneau NVH cover
   Note

   Release rearward then slide over LH side NVH cover before removing upward

   

   

   

7. Release LH tonneau NVH cover
   Note

   5x bolts, 10mm, 5 Nm

   

   

8. Remove LH tonneau NVH cover
   Note

   Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material

   

   

9. Remove tonneau coverbox cross supports
   Note

   8x screws, T25, 5 Nm

   

   

10. Clean all debris from ancillary cover
    Note

    During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay

    

11. Release pressurized pack air line to Ancillary
    Note

    1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.

    

12. Remove VOSS fitting from pressurized pack air line to Ancillary
    Note

    1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal

    

    

13. Release pressurized pack valve block from air suspension reservoir
    Note

    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Release lock before connector disengagement, Cut zip tie at reservoir/ancillary air line bundle, Release harness clip at bracket

    

    

14. Release air suspension valve block
    Note

    3x rubber grommets, Rotate clockwise until top 2 rubber feet have released from bracket, Pull upwards at 45 degree angle to release bottom rubber foot from bracket, Leave all air lines and connections secured and set assembly aside

    

    

    

15. Release air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

16. Place air suspension reservoir in service position then install Ancillary Access Bench
    Note

    Raise and swing air suspension reservoir to the side of the bed, Place Ancillary Access Bench onto rear casting ensuring no air lines or harnesses are being pinched

    

    

    

17. Open powered front trunk
    Note

    Via exterior switch or UI

    

    

18. Power down vehicle via UI
    Note

    Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off

    

19. Remove rear underhood apron
    Note

    9x clips

    

    

20. Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release
    Note

    2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules

    

    

21. Verify operation of multimeter
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

    

    

22. Raise vehicle fully
    Note

    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting

    

    

23. Remove Mid-aero shield
    Note

    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

    

    

    

    

    

24. Disconnect pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8Nm, Discard and replace

    

25. Remove VOSS fitting from pressurized pack air lines
    Note

    2x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal

    

    

26. Remove all items from pockets and ensure not wearing metal items

    

27. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

    

28. Put on HV insulating gloves and leather over gloves

    

29. Verify no HV - Install amp clamp to RDU HV harness
    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 requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake 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

    

    

    

    

    

    

30. Remove Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10 Nm

    

31. Remove primary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

32. Remove secondary pyro fuse
    Note

    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts

    

    

33. Release connectors at 2x4 header (AC compressor and Charger headers)
    Note

    2x connectors, Fully release red lock tab, Pull black latch down to release connector

    

    

34. Release 2x4 header assembly
    Note

    4x bolts, 5-lobe 10mm, 6 Nm

    

    

35. Release drive unit connectors from ancillary headers
    Note

    3x connectors, Release blue lock tab, Rotate black latch

    

    

    

36. Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange
    Note

    6x bolts, 5-lobe 10mm, 10 Nm

    

    

37. Remove LHRDU, FDU, RHRDU headers from ancillary flange
    Note

    3x headers, No tools required, inspect header seals, Replace header if damaged

    

    

38. Lower vehicle until tires are touching the ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

    

    

39. Disconnect ancillary bay MV connector
    Note

    1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing

    

    

    

    

    

40. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

41. Remove bolts securing HV connector to DC FC header
    Note

    2x bolts, 10mm, 9 Nm

    

42. Release HV connector from DC FC header
    Note

    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly

    

43. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

44. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

45. Release low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

46. Release fasteners securing ancillary cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

47. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

48. Remove DC header
    Note

    Slide header off DC bus links, Inspect seal, Replace header if damaged

    

    

    

49. Disconnect PCS MV connector
    Note

    1x connector, Slide red lock off of lever, Rotate lever to release connector

    

    

50. Release PCS MV harness
    Note

    1x bolt, 10mm, 6 Nm, 1x clip

    

    

51. Release MV header
    Note

    4x datums, 1x edge clip, 1x fir tree clip

    

    

    

52. Release HVC connectors
    Note

    2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harnessIf RTV is present at 2 connectors, using a ceramic knife cut through and remove RTV until connector can be disconnected

    

    

    

    

    

53. Release BMB passthrough connectors
    Note

    2x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness

    

    

    

54. Release ACJB LV connector & ACJB to device cluster HV connector
    Note

    2x clips, 2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness

    

    

    

55. Remove MV ancillary harness

    

    

56. Release HVC harness from PCS
    Note

    1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness

    

57. Release device cluster busbar fasteners
    Note

    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers

    

    

    

    

58. Remove device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

59. Remove device cluster from ancillary tray
    Note

    Place device cluster on stand to protect headers at bottom of assembly, Remove lifting/install tool, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component

    

    

60. Remove shunt jumper harness
    Note

    3x connectors, 1x clip, Turn device cluster assembly over for access, Release locking tab

    

    

    

61. Install shunt jumper harness
    Note

    3x connectors, 1x clip, Turn device cluster assembly over for access, Engage locking tab

    

    

    

62. Install device cluster to ancillary tray
    Note

    Align datums and headers to ancillary and slowly lower into place, Avoid contact of drive unit headers to ancillary tray, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component

    

    

    

    

63. Secure device cluster assembly fasteners
    Note

    4x bolts, E10 5 Lobe Torx, 6Nm

    

    

    

    

64. Secure device cluster busbar fasteners
    Note

    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers

    

    

    

    

65. Perform Hioki measurements from device cluster assembly and busbar bolts
    Note

    1x bolts, E10 5 Lobe Torx, 6Nm, 4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Perform zero adjust to Hioki meter prior to testingUse diagram in images to find probing locations and the reading specifications to look forLSL means: Lower Specification LimitUSL means: Upper Specification Limit1020_301 | T1 LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1020_304 | POS Contactor LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1010_603 | HVC Ground strap LSL 0.35 mΩ (350 μΩ) - USL 0.78 mΩ (780 μΩ)1020_303 | Shunt2 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)1020_302 | Shunt1 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)If readings are lower than the LSL numbers you are not probing correctlyIf readings are higher than USL numbers you have bolts that are not torqued correctly or connectors that may be softset or have internal connector issues

    

    

    

    

    

    

    

    

    

66. Secure HVC harness to PCS
    Note

    1x connectors, Secure connector lock

    

67. Poistion MV ancillary harness for install

    

    

68. Secure ACJB LV and HV connectors
    Note

    2x clips, 2x connectors, Secure connector locks

    

    

    

69. Secure BMB passthrough connectors
    Note

    2x connectors, Secure connector locks, Connectors are poke yoked do not force engagement, Ensure locking tabs are facing front of vehicle when connecting

    

    

    

70. Secure HVC connectors
    Note

    2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness, Apply sealant to connectors at device cluster if it was present during disassembly

    

    

    

    

    

71. Secure MV header
    Note

    4x datums, 1x edge clip, 1x fir tree clip

    

    

72. Secure PCS MV harness
    Note

    1x bolt, E10 5 Lobe, 6 Nm, 1x clip

    

    

73. Connect PCS MV connector
    Note

    1x connector, PCS header not datumed, Ensure correct orientation and polarity of connection, Harness color red for LV+ and black for LV-, Swing down locking lever, Slide lock fully to engage on top of lever

    

    

    

74. Install DC header
    Note

    Slide header on to DC bus links, Inspect seal, Replace header if damaged

    

    

    

75. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

76. Secure fasteners of cover to HV battery
    Note

    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order

    

    

    

77. Secure low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

78. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

79. Clean HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector

    

80. Clean busbar HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar

    

81. Apply Penetrox onto HV connector joints
    Note

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

    

82. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

83. Install bolts securing charge port busbar kit to HV Header
    Note

    2x bolts, 10mm, 9 Nm

    

84. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note

    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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

    

    

85. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

86. Remove leather over gloves and HV insulating gloves

    

87. Connect Ancillary bay MV connector
    Note

    1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly

    

    

    

    

    

88. Secure tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners

    

    

89. Install LH tonneau NVH cover
    Note

    Ensure busbar clearance during install to avoid damage to NVH material

    

    

90. Secure LH tonneau NVH cover
    Note

    5x bolts, 10mm, 5 Nm

    

    

91. Install RH tonneau NVH cover

    

    

    

92. Secure RH tonneau NVH cover
    Note

    6x bolts, 10mm, 5 Nm

    

    

93. Remove Ancillary Access Bench then place air suspension reservoir into position for installation
    Note

    Ensure air lines are not twisted, Ensure no harnesses are caught

    

    

    

94. Secure air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

95. Secure air suspension valve block
    Note

    3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation

    

    

    

96. Install new VOSS air fitting to pressurized pack valve block at ANC circuit
    Note

    1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed

    

    

97. Secure pressurized pack air line from Ancillary to valve block
    Note

    1x line, Remove plastic cap from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

98. Secure pressurized pack valve block to air suspension reservoir
    Note

    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Secure reservoir and ancillary air lines at white marked sections

    

    

99. Install bed floor assembly
    Note

    10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance

    

    

    

100. Raise vehicle fully

     

101. Inspect HV insulating gloves
     Note

     Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

     

102. Put on HV insulating gloves and leather over gloves

     

103. Install LHRDU, FDU, RHRDU headers to ancillary flange
     Note

     3x headers, No tools required, inspect header seals, Replace header if damaged

     

     

104. Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange
     Note

     6x bolts, 5-lobe 10mm, 10 Nm

     

     

105. Secure 2x4 header assembly
     Note

     4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings

     

     

     

106. Secure connectors at 2x4 header (AC compressor and Charger headers)
     Note

     2x connectors, Fully engage red lock tab

     

     

107. Secure drive unit connectors to ancillary headers
     Note

     3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged

     

     

     

108. Install secondary pyro fuse
     Note

     2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

     

     

109. Install primary pyro fuse
     Note

     2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts

     

     

110. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
     Note

     4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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

     

     

     

111. Remove leather over gloves and HV insulating gloves

     

112. Install Pyro Fuse Access cover
     Note

     4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged

     

     

113. Install pressurized pack lines
     Note

     2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings, Install new VOSS fittings if re-using fuse cover, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

     

     

     

114. Install Mid-aero shield
     Note

     6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm

     

     

     

     

     

115. Lower vehicle until tires are touching the ground
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

     

     

116. Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement
     Note

     2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down

     

     

     

117. Install rear underhood apron
     Note

     9x clips, Adjust windshield seal as required

     

     

118. Close powered front trunk
     Note

     Via exterior switch or UI

     

119. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
120. Remove vehicle from lift
     Note

     Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"