High Voltage Battery Assembly - HV Battery, Long, 4680, Center (Remove and Replace)
Correction code 1601070082 FRT 5.52 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.
- 2024-09-12: Added step to connect MV maintainer.
- 2024-08-09: Added PN of anti-abrasion tape.
- 2024-06-26: Updated steps to latest time study.
- 1134523-00-B - Battery Alignment Rods
- 1065131-00-A - Battery Coolant Drain Kit
- 1135762-00-A - Coolant Hose Plug Kit
- 1080568-00-A - Fluid Catcher
- 1076927-00-A - Hioki tester
- 1020566-00-F - HV Battery Table
- 1076928-00-A - Test Probes - Hioki 9461
- 1936724-00-A - Universal Lift Pad adapters
- 1050448-00-B - Vacuum Refill Tool
- 1479505-00-A - Vacuum Fill Adapter
- 113343-80-A - Battery Drain Adapter
- 1879451-99-A - LV ABRASION STICKER,XM,HVB,CTSB
-
Open all 4 doors
NotePush pillar door triggers to release
-
Lower all 4 windows
-
Manually latch all doors to prevent
lockout
NoteEngage latch with screwdriver
- Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
-
Partially release aft section of front
LH fender flare cover
Note11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
-
Remove LH front rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing LH rocker cover to
front wheel liner
Note1x clip
-
Partially release fore section of rear
LH fender flare cover
Note13x clips, 3x datums total, Release as needed for clearance, Full removal not required
-
Remove LH rear rocker fastener from step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing LH rocker cover to
rear wheel liner
Note1x clip
-
Remove rocker cover fasteners from LH
side ski
Note6x bolts, 10mm, 10 Nm
-
Release LH rocker cover from rocker
carrier
Note11x clips, 1x datum, Remove any clips that remained on carrier
-
Remove front LH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Remove rear LH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm
-
Partially release aft section of front
RH fender flare cover
Note11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
-
Remove RH front rocker fastener from
step reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing RH rocker cover to
front wheel liner
Note1x clip
-
Partially release fore section of rear
RH fender flare cover
Note13x clips, 3x datums total, Release as needed for clearance, Full removal not required
-
Remove RH rear rocker fastener from step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Remove clip securing RH rocker cover to
rear wheel liner
Note1x clip
-
Remove rocker cover fasteners from RH
side ski
Note6x bolts, 10mm, 10 Nm
-
Release RH rocker cover from rocker
carrier
Note11x clips, 1x datum, Remove any clips that remained on carrier
-
Remove front RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Remove rear RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm
-
Remove 2nd row floor mat
-
Fold up 2nd row 60 seat
NotePull tether to release then lift up until locked in place
-
Partially release LH lower C-pillar
trim
Note1x clip, 1x datum
-
Remove LH mid A-pillar trim
Note2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
-
Remove LH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
Move LH front seat forward
-
Remove bolts securing rear of LH front
seat tracks to the floor panel
Note2x patch bolts, T45P, 34 Nm, Discard after removal
-
Move LH front seat backward
-
Release LH front seat belt from
pretensioner
NoteUnlock the linkage by rotating the lock screw counterclockwise. A light audible click will be heard, and the screw should remain horizontal. Do not rotate clockwise to avoid damage to the mechanism
-
Remove bolts securing front of LH front
seat tracks to risers
Note2x patch bolts, T45P, 34 Nm, Discard after removal
-
Adjust position of LH front seat for
easy removal
NoteMove seat to middle of track at most upright position with seat fully up off floor
-
Fold up 2nd row 40 seat
NotePull tether to release then lift up until locked in place
-
Partially release RH lower C-pillar
trim
Note1x clip, 1x datum
-
Remove RH mid A-pillar trim
Note2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
-
Remove RH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
Move RH front seat forward
-
Remove bolts securing rear of RH front
seat tracks to the floor panel
Note2x patch bolts, T45P, 34 Nm, Discard after removal
-
Move RH front seat backward
-
Release RH front seat belt
NoteTurn release mechanism counter clockwise, turn back clockwise after releasing
-
Remove bolts securing front of RH front
seat tracks to risers
Note2x patch bolts, T45P, 34 Nm, Discard after removal
-
Adjust position of RH front seat for
easy removal
NoteMove seat to middle of track at most upright position with seat fully up off floor
-
Remove footwell cover
Note3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether
-
Remove RH front floor mat
-
Remove RH center floor rail
Note4x clips, 3x datums, Pull upwards to release
-
Remove center floor trim
Note17x clips, Release upper section first
-
Fold back RH carpet
-
Remove RH carpet support foam
NoteLift up from rear edge
-
Remove RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Remove rear wall lower trim
Note2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
-
Remove RH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards center of vehicle to release outer port from body
-
Remove RH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion
-
Remove LH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards RH of vehicle to release outer port from body, Release locking tab
-
Remove LH front floor mat
-
Remove LH center floor rail
Note4x clips, 3x datums, Pull upwards to release
-
Remove accelerator pedal side trim
Note3x clips, Lift from forward edge then slide over accelerator pedal
-
Fold back LH front cabin carpet
-
Remove LH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion
-
Remove fastener covers from bed floor
assembly
Note6x covers
-
Remove bed floor assembly
Note10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
-
Release RH tonneau NVH barrier
Note6x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal, Vehicles built before September 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm
-
Remove RH tonneau NVH barrier
NoteRelease rearward then slide over LH side NVH cover before removing upward, Vehicles built before September 2024 will have 1-piece NVH cover, Maneuver around bed wall then remove
-
Release LH tonneau NVH barrier
Note5x bolts, 10mm, 5 Nm, 2-piece NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal
-
Remove LH tonneau NVH barrier
NoteSlide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
-
Remove bolts securing HV battery to
RUB
Note4x bolts, 21mm, 119 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity
-
Move vehicle onto lift
NoteEnsure positioning allows rear doors to open
-
Install Universal Lift Pad
adapters
Note4x Adapters, Remove original lift pads from lift arms then install respective adapter, Remove plugs from BIW holes, Align pins with lift point holes on body
-
Raise and support vehicle
NoteSet air suspension to "Jack Mode", Align lift adapter pins with lift point holes on body
-
Open powered front trunk
NoteVia exterior switch or UI
-
Remove rear underhood apron
Note9x clips
-
Place vehicle in service mode
NoteVia UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
-
Unlock vehicle gateway
NoteAfter vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
-
Select 'Coolant System' to enter coolant
circuit screen, Select 'Coolant Fill/Drain' using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT window will appear, Select
'Run'
NoteVerify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
-
Power down vehicle via UI
NoteVerify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
-
Unlock fireman's loop connector and
disconnect, Slide eCPA to left on the MV battery connector then lift lever to
release
Note2x 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
-
Disconnect LH seat
Note1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
-
Remove LH front seat from vehicle
NoteRecommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
-
Remove accelerator pedal
Note2x nuts, 13mm, 16 Nm, 1x connector, Release locking tab
-
Remove LH carpet support foam
NoteLift up from rear edge
-
Remove LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Release LH MV controller dry side
locking cover
Note1x bolt, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover are fully released before attempting to release any MV connectors, Plastic Locking Cover. .Use hand tools on any plastic locking covers, The locking cover may release crooked causing it to get stuck, secure bolt a few turns to loosen the tension then release bolt while assisting plastic locking cover by gently prying on the side that's stuck, Metal Locking Cover. You can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically, Video uses rear controller for demonstration purposes only
-
Disconnect floor harness connector from
LH MV controller
Note1x connector, Depress tabs to release connector housing from locking cover
-
Disconnect RH seat
Note1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
-
Remove RH front seat from vehicle
NoteRecommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
-
Release RH MV controller connector
locking cover
Note1x bolt, 8mm, 6 Nm, Do not remove locking covers, Loosen until bolts spins freely, Double check that bolts and locking covers are fully released before attempting to release any MV connectors. Plastic Locking Cover Use hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, secure bolts a few turns to loosen the tension then release bolts while assisting plastic locking covers by gently prying on the stuck sides. Metal Locking Cover You can use power tools, Quickly disconnecting locking covers helps connectors remove symmetrically
-
Disconnect center console and backbone
connectors from RH MV controller
Note1x connector, 1x backbone cable, 2x edge clips, Pull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radius
-
Disconnect rear display connector from
car computer
Note1x connector
-
Remove center console front panel
Note10x clips
-
Release HV outlet from front console
panel
Note2x screws, T20, 1 Nm, 1x clip
-
Remove front bolts securing center
console to riser
Note4x bolts, 10mm, 5 Nm
-
Disconnect center console harness
connectors
Note2x connectors
-
Remove center console back panel
Note10x clips, 3x connectors, 3x harness clips
-
Remove rear bolts securing center
console to riser
Note2x bolts, 10mm, 5 Nm
-
Remove center console
NoteLift up to release from riser
-
Disconnect backbone harness from rear MV
controller
Note1x connector, 1x bolts, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to release. Plastic Locking Cover. Use hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking cover. Metal Locking Cover. You can use power tools, Quickly disconnecting locking covers helps connectors release evenly
-
Remove interior HV harness bulkhead
cover
Note3x nuts, 10mm, 9 Nm, Pull harness inside once released
-
Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
Remove Mid-aero shield
Note6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
-
Remove all items from pockets and ensure
not wearing metal items
-
Inspect HV insulating gloves
NoteCheck 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
-
Put on HV insulating gloves and leather
over gloves
-
Verify no HV - Install amp clamp to RDU
HV harness
NoteVerify 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 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 damaged. 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
- Remove leather over gloves and HV insulating gloves
-
Remove front aero shield
Note11x bolts, 10mm, 6 Nm
-
Remove front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Position coolant drain container
underneath RH rear of HV battery
-
Disconnect RDU return hose from PT
return hose
Note1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
-
Disconnect RDU supply hose
Note1x spring clip, Plug hoses
-
Move coolant drain container to front
right of HV battery
-
Disconnect PT supply and return
hoses
Note2x spring clips, Plug hoses
-
Disconnect battery coolant supply and
return hoses
Note2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed
- Remove coolant drain container from underneath vehicle
-
Disconnect pressurized pack lines
Note2x VOSS fittings, 12mm, 8Nm
-
Release clips securing LH pressurized
pack line
Note3x clips
-
Release A/C compressor HV harness from
HV battery
Note1x locking connector, 4x clips, Pull down red locking tab and disengage the release lever, Do not force the release lever up, Number of connections may vary by vehicle configuration
-
Disconnect RDU HV harness
Note1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged
-
Release FDU HV harness
Note1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Disconnect ancillary bay MV
connector
Note1x 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
-
Remove bolt securing busbar HV connector
lid
Note1x bolt, EP10, 9 Nm
-
Remove bolts securing HV connector to DC
FC header
Note2x bolts, 10mm, 9 Nm
-
Release HV connector from DC FC
header
Note1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
-
Support HV Busbar assembly
NoteSuspend assembly to maintain clearance
-
Disconnect HV ancillary harnesses
Note2x connectors, Release red locking tab then slide open black lever to remove, Push cabin harness into interior
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
-
Position battery table
NoteEnsure table is level
-
Remove front exterior HV Battery
mounting bolts and ground strap
Note6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery
-
Remove side exterior HV battery mounting
bolts from LH and RH side
Note16x bolts, 15mm, 62 Nm
-
Raise vehicle away from HV battery
NoteEnsure no coolant hoses, harnesses, or brake lines are caught while lifting
-
Secure PT Flush adapter to PCS inlet
hose coupling
NoteRemove plugs as required, Verify fully seated, Perform push-pull-push test
-
Secure coolant cart flush hose to
regulator and PT Flush adapter
NoteVerify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)
-
Secure PCS Drain adapter to PCS outlet
using male-to-male adapter
NoteVerify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test
-
Secure coolant cart drain hose to PCS
drain adapter and coolant drain container
-
Open valve on PCS Drain adapter
-
Connect shop air to regulator
NoteMake sure regulator valve is closed prior to connecting shop air
-
Slowly open valve on pressure regulator
and allow coolant to drain out of HV battery
NoteAllow coolant to drain
-
Close valve on pressure regulator once
no more coolant is draining
-
Close valve on PCS Drain adapter
-
Remove cart drain hose from PCS Drain
adapter
-
Remove PCS Drain adapter from PCS
outlet
Note1x spring clip
-
Remove cart flush hose from PT Flush
adapter
-
Remove PT Flush adapter from PCS inlet
coupling
Note1x spring clip
-
Attach coolant cart flush hose to HV
battery
NoteRemove plugs as required, Verify fully seated, Perform push-pull-push test, Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi), Hose is still attached to cart at this point
-
Attach PCS drain adapter to HV battery
hose coupling using male-to-male adapter
NoteVerify valve is closed, Verify fully seated, Remove plugs as required, Perform push-pull-push test, Connect to coolant drain
-
Open valve on P2 Battery Drain
adapter
-
Slowly open valve on pressure regulator
and allow coolant to drain out of HV battery
NoteAllow coolant to drain
-
Close valve on pressure regulator once
no more coolant is draining
-
Disconnect compressed air from coolant
pressure tester
-
Close valve on P2 Battery drain
adapter
-
Remove cart drain hose and PCS drain
adapter from HV battery
-
Remove cart flush hose and PCS flush
adapter from battery
-
Attach HV battery H-frame to gantry and
raise into position
-
Secure the P2 battery sling adapter to
H-frame
Note4x anchor hooks, Install hooks, Verify anchor hooks are fully tightened and secured, Be aware and do not install anchors hooks in a manner which will cause the adapter sling to bind or twist
-
Remove top housing from new HV battery
crate
NoteRecommend assistance
-
Position gantry over HV battery
crate
NoteRecommend assistance
-
Lower H-frame to HV battery crate
-
Secure P2 sling adapter to HV
battery
Note6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely
-
Lift new HV battery out of crate
-
Move gantry away from HV battery crate
NoteRecommend assistance
-
Position unused HV battery table under
gantry
-
Lower HV battery onto battery
table
-
Release P2 battery sling adapter from HV
battery
Note6x locking joints, Push down on top pin to release
-
Remove HV battery and table from under
gantry
NoteRecommend assistance
-
Remove FDU HV harness
Note12x bolts, 10mm, 11 Nm
-
Remove powertrain hose bundle
Note1x spring clip, 6x clips, Release hose from PCS fitting
-
Remove rear carpet RH duct bezel
Note4x clips
-
Remove LH rear carpet duct bezel
Note4x clips
-
Release HV cabin outlets harness from
foam
NoteSlide outwards out of groove
-
Remove rear carpet assembly
Note4x clips, 17x stands, 6x datums, Release stands around LH and RH floor ducts then release stands at center console, Fold back carpet and stands from forward edge, Fold rear carpet and foam forwards then pull center of carpet and foam upwards to remove, Remove clips if they remain on pack side
-
Remove center floor lower support
bracket
Note4x clips
-
Release interior HV harness from HV
battery
Note1x bolt, 10mm, 10 Nm, 8x clips, Remove from slot in EPP, Lift rear carpet and EPP as required for access
-
Remove center console riser duct
Note2x clips, Maneuver forward to clear riser assembly
-
Remove floor jumper duct
NotePush forward then lift and slide out
-
Release connectors from RCM
Note2x connectors, Release locking tabs first
-
Remove RCM fasteners
Note3x nuts, 10mm, 10 Nm, Discard after removal
-
Remove RCM from vehicle
-
Remove LH outboard riser bolt
cover
NoteLift from outer edge then pull away
-
Remove RH outboard riser bolt
cover
-
Release cabin floor harness
Note4x clips, 2x bolts, 10mm, 10 Nm
-
Remove 1st row riser fasteners
Note8x bolts, 11mm, 40 Nm
-
Remove 1st row riser assembly with
harnesses
NoteRecommend assistance
-
Remove RH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Remove LH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Remove RH 2nd row floor duct
Note1x clip, Lift up then pull away to release duct from Y duct
-
Remove 2nd row floor Y-Duct
Note1x clip, Release from passenger side duct then maneuver out of position
-
Release front section of backbone
Note3x harness clips, Pass connector under cabin floor harness
-
Remove backbone harness
Note6x harness clips, Pull harness through to 2nd row then remove
-
Install backbone harness
Note6x harness clips, Push harness through to 1st row
-
Secure front section of backbone
Note3x harness clips, Pass connector under cabin floor harness
-
Install 2nd row floor Y-Duct
Note1x clip, Maneuver into position then secure to passenger side duct
-
Install RH 2nd row floor duct
Note1x clip, Align floor duct with Y duct then push inward to engage
-
Install LH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Install RH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Position 1st row riser assembly with
harnesses
NoteRecommend assistance
-
Install 1st row riser fasteners
Note8x bolts, 11mm, 40 Nm
-
Secure cabin floor harness
Note4x clips, 2x bolts, 10mm, 10 Nm
-
Position RCM for installation
-
Install bolts securing RCM
Note3x nuts, 10mm, 10 Nm, Install new nuts
-
Secure connectors onto RCM
Note2x connectors, Engage locking tabs
-
Install floor jumper duct
Note2x clips
-
Install center console riser duct
Note2x clips, Install from front of riser assembly, Replace any missing or damaged clips
-
Secure interior HV harness to HV
battery
Note1x bolt, 10mm, 10 Nm, 8x clips, Remove from slot in EPP, Lift rear carpet and EPP as required for access
-
Install RH outboard riser bolt
cover
-
Install LH outboard riser bolt
cover
-
Install center floor lower support
bracket
Note4x clips, Replace any missing or damaged clips
-
Install rear carpet assembly
Note4x clips, 6x datums, Secure center foams and datums, Secure stands at center console then secure stands around LH and RH floor ducts, Fully tuck carpet under risers and trim, Replace any missing or damaged clips
-
Secure HV cabin outlets harness to
foam
NoteTuck harness into groove
-
Install LH rear carpet duct bezel
Note4x clips, Replace any missing or damaged clips
-
Install rear carpet RH duct bezel
Note4x clips, Replace any missing or damaged clips
-
Install powertrain hose bundle
Note1x spring clip, 6x clips, Perform a push-pull-push test to ensure hose is fully seated
-
Install FDU HV harness
Note12x bolts, 10mm, 11 Nm
-
Position old HV battery and table under
gantry
NoteRecommend assistance
-
Secure P2 sling adapter to HV
battery
Note6x locking joints, The hoist is color coded and will come with instructions, Verify all the locking joints are fully secured, Perform push and pull test, If not properly secured the top pin will be recessed, Take care to secure properly and safely
-
Raise HV battery off of battery
table
-
Remove empty HV battery table from under
gantry
-
Position gantry over HV battery
crate
NoteRecommend assistance
-
Lower old HV battery into crate
NoteRecommend assistance, Use caution to align HV battery into crate and do not damage the battery
-
Release battery sling adapter from HV
battery
Note4x locking joints, Push down on top pin to release. CAD: PRD-14048139 - Prototype sling with lifting pins
-
Raise gantry and H-frame from
crate
-
Secure top housing onto HV battery
crate
NoteRecommend assistance, Adhere to proper MRB process
-
Return gantry to position and remove HV
battery H-frame from gantry
-
Install battery alignment rods
Note4x rods, Screw two larger rods in to front casting hand tight, Screw two smaller rods into any of the four seat stanchion mounting holes on the HV battery
-
Position rear carpet section for
install
NoteInsert a wheel chock under carpet section to maintain 90 degree angle
-
Lower vehicle onto HV battery
NoteEnsure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering
-
Install side exterior HV battery
mounting bolts to LH and RH side
Note16x bolts, 15mm, 60 Nm
-
Remove battery alignment rods
Note4x alignment rods
-
Install front exterior HV Battery
mounting bolts and ground strap
Note6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
-
Raise vehicle away from battery
table
NoteSet to a comfortable working height, Ensure lift is lowered onto a lock
- Remove battery table from under vehicle
-
Install FDU HV harness
Note1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
-
Secure A/C compressor HV harness to
battery
Note1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration
-
Install RDU HV harness
Note1x connector, 1x harness clip, Ensure locking tab is engaged
-
Install clips securing pressurized pack
line
Note3x clips
-
Install pressurized pack lines
Note2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings if installing new 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
-
Position coolant drain container
underneath RH rear of HV battery
-
Connect RDU return hose to PT return
hose
Note1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
-
Connect RDU supply hose
Note1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged
-
Move coolant drain container to front
right of HV battery
-
Connect PT supply and return hoses
Note2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged
-
Connect battery supply and return
coolant hoses
Note2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged
- Remove coolant drain container from underneath vehicle
-
Install Mid-aero shield
Note6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
-
Install front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
-
Install front aero shield
Note11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
-
Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Apply Penetrox onto HV connector
joints
NoteApply 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
-
Install busbar onto HV header and
install bolts
Note2x bolts, 10mm, 9 Nm
-
Connect HV ancillary harnesses
Note2x connectors, Slide black lever to engage then push in red locking tab
-
Inspect HV insulating gloves
NoteCheck 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
-
Put on HV insulating gloves and leather
over gloves
-
Perform Hioki resistance test at each HV
joint from HV busbar lead to bolt head
Note2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usage. 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
- Remove leather over gloves and HV insulating gloves
-
Install bolt securing busbar HV
connector lid
Note1x bolt, EP10, 9 Nm
-
Connect Ancillary bay MV connector
Note1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
-
Install interior HV harness bulkhead
cover
Note3x nuts, 10mm, 9 Nm, Feed harness through opening before installing cover
-
Connect backbone harness to rear MV
controller
Note1x connector, 1x bolt, 8mm, 6 Nm, Push backbone connector housing into plastic locking cover, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors too while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully
-
Inspect for any misalignment at rear
ribs and apply abrasion tape (PN: 1879451-99-A) if missing
NoteEnsure cable is lying flat without twist, Ensure cable is secured correctly to rib, Apply surface protection at seam of rearmost rib under backbone cable if missing
-
Connect rear display connector to car
computer
Note1x connector
-
Connect cabin floor harness connector
and backbone cable to RH MV controller
Note1x connector, 1x backbone cable, 2x edge clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius
-
Secure RH MV controller connector
locking cover
Note1x bolt, 8mm, 6 Nm, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt
-
Inspect for presence of backbone harness
guide at front casting
NoteEnsure backbone harness guide is installed, If backbone harness guide not installed refer to: https://pds.tesla.com/pdsui/procedure/edit/6662075b96d4ad4adcc17441Add correction code: PLACEHOLDER for https://pds.tesla.com/pdsui/procedure/edit/6662075b96d4ad4adcc17441
-
Install RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Connect cabin floor harness connector to
LH MV controller
Note1x connector, Secure in locking cover
-
Secure left MV controller connector
locking frame
Note1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt
-
Install LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Install LH carpet support foam
NoteSeat at rear edge
-
Unfold LH front cabin carpet into
position
-
Install accelerator pedal
Note2x nuts, 13mm, 16 Nm, 1x connector, Secure locking tab
-
Install accelerator pedal side
trim
Note3x clips, Replace any missing or damaged clips
-
Install LH front seat into vehicle
NoteRecommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
-
Connect LH front seat harness
Note1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
-
Install RH front seat into vehicle
NoteRecommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
-
Connect RH front seat harness
Note1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
- Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
-
Slide eCPA to the right and ensure it is
seated against the black lever, Connect fireman's loop 20 seconds after eCPA
engagement
Note2x 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
-
Secure MV battery maintainer and support
vehicle
Note1x cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, DO NOT allow positive cable to make contact with other metal components, Prevent shorting the cables
-
Select "Stop Thermal Fill Drain" through
UI
NoteAllow routine to complete, ensure routine is successful
-
Remove Universal Lift Pad adapters
Note4x Adapters, Install original lift pads, Install plugs back into holes in BIW
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
-
Select "Start Coolant Air Purge" using
the UI
NoteTouch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
-
Select 'Procedures'
NoteLighting Bolt Icon > High Voltage > Procedures
-
Select 'HV Battery Replacement
Procedure'
NoteLightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement
-
Select 'Software Reinstall'
NoteLightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement
-
Select 'High Voltage Battery Replacement
Procedure'
NoteLightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement
- Disconnect the MV maintainer.
-
Install RH carpet support foam
NoteSeat at rear edge
-
Unfold RH front cabin carpet into
position
-
Install center floor trim
Note17x clips, Replace any missing or damaged clips, Install lower section first
-
Install RH center floor rail
Note4x clips, 3x datums
-
Install RH front floor mat
-
Install LH center floor rail
Note4x clips, 3x datums
-
Install footwell cover
Note3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets
-
Install LH front floor mat
-
Install rear underhood apron
Note9x clips, Adjust windshield seal as required
-
Close powered front trunk
NoteVia exterior switch or UI
-
Install bolts securing HV battery to
RUB
Note4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity
-
Install LH tonneau NVH barrier
Note2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Ensure busbar clearance during install to avoid damage to NVH material
-
Secure LH tonneau NVH barrier
Note5x bolts, 10mm, 5 Nm
-
Install RH tonneau NVH barrier
Note2-piece NVH assembly order of operations requires LH side to be secured first to allow busbar clearance for RH side installation, Vehicles built before September 2024 will have 1-piece NVH cover, Maneuver around bed wall then position
-
Secure RH tonneau NVH barrier
Note6x bolts, 10mm, 5 Nm, Vehicles built before September 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm
-
Install forward bed panel
Note6x bolts, 15mm, 85 Nm, Recommend assistance to lift panel into bed
-
Install fastener covers to forward bed
panel
Note6x covers
-
Close tailgate
-
Secure RH front seat belt to
pretensioner
NoteEnsure the lock screw is in the horizontal position. If it is not, unlock it by following the linkage removal instructions. Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.
-
Move RH front seat backward
-
Install bolts securing RH front seat
front tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Move RH front seat forward
-
Install bolts securing RH front seat
rear tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Install RH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion
-
Install RH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
-
Install RH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs
-
Install RH mid A-pillar trim
Note2x clips, 2x tabs,
-
Secure LH front seat belt to
pretensioner
NoteEnsure the lock screw is in the horizontal position. If it is not, unlock it by following the linkage removal instructions. Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.
-
Move LH front seat backward
-
Install bolts securing both LH front
seat front tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Move LH front seat forward
-
Install bolts securing LH front seat
rear tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Install LH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion
-
Install LH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab
-
Install rear wall lower trim
Note2x push clips, 4x clips
-
Secure LH lower C-pillar trim
Note1x clip, 1x datum
-
Fold down 2nd row 60 seat
NotePull tether to release then pivot down until locked in place
-
Secure RH lower C-pillar trim
Note1x clip, 1x datum
-
Fold down 2nd row 40 seat
NotePull tether to release then pivot down until locked in place
-
Install 2nd row floor mat
-
Install LH Lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
-
Install LH mid A-pillar trim
Note2x clips, 2x tabs, Replace any missing or damaged clips
-
Install LH front rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Install rear LH step reinforcement
Note3x bolts, 10mm, 15 Nm
-
Install LH rocker cover to rocker
carrier
Note11x clips, 1x datum, Replace any missing or damaged clips
-
Install rocker cover fasteners to LH
side ski
Note6x bolts, 10mm, 10 Nm
-
Install clip securing LH rocker cover to
rear wheel liner
Note1x clip
-
Install LH rear rocker fastener to step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Secure fore section of rear LH fender
flare cover
Note13x clips, 3x datums total, Replace any missing or damaged clips
-
Install clip securing LH rocker cover to
front wheel liner
Note1x clip
-
Install LH front rocker fastener to step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Secure aft section of front LH fender
flare cover
Note11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips
-
Install front RH rocker step
reinforcement
Note3x bolts, 10mm, 15 Nm, 2x datums
-
Install rear RH step reinforcement
Note3x bolts, 10mm, 15 Nm
-
Install RH rocker cover to rocker
carrier
Note11x clips, 1x datum
-
Install rocker cover fasteners to RH
side ski
Note6x bolts, 10mm, 10 Nm
-
Install clip securing RH rocker cover to
rear wheel liner
Note1x clip
-
Install RH rear rocker fastener to step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Secure fore section of rear RH fender
flare cover
Note13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required
-
Install clip securing RH rocker cover to
front wheel liner
Note1x clip
-
Install RH front rocker fastener to step
reinforcement
Note1x bolt, 10mm, 4 Nm
-
Secure aft section of front RH fender
flare cover
Note11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required
- Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
-
Exit Service Mode
NoteVia UI > Service > Exit, Press and hold "Exit Service Mode" button
-
Raise all 4 windows
-
Close LH front door