12/04/2024 09:25:01

High Voltage Battery Assembly - HV Battery, Long, 4680, Center (Remove and Replace)

Correction code 1601070082 FRT 4.02 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.

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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Special tools required for this procedure:

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

Open tonneau cover

Note
Press forward arrow on LH bed rail
Open tailgate

Note
Press button to release
Remove fastener covers from bed floor assembly

Note
10x fastener covers
Remove bed floor assembly

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10x bolts, 15mm, 56 Nm, Lift front edge with trim tool then remove panel, Recommend assistance to hand off panel
Close tonneau cover

Note
Press reverse arrow on LH bed rail
Remove bolts securing HV battery to RUB

Note
4x bolts, 21mm, 115 Nm, Break free before using power tools, Tonneau must be closed to access forward bolts, Shown without tonneau for clarity
Open tonneau cover

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Press forward arrow on LH bed rail
Open all 4 doors

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Push pillar door triggers to release
Lower all 4 windows
Manually latch all doors to prevent lockout

Note
Engage latch with screwdriver
Partially release aft section of front LH fender flare cover

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11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
Remove LH front rocker fastener from step reinforcement

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1x bolt, 10mm, 4 Nm
Remove clip securing LH rocker cover to front wheel liner

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1x clip
Partially release fore section of rear LH fender flare cover

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13x clips, 3x datums total, Release as needed for clearance, Full removal not required
Remove LH rear rocker fastener from step reinforcement

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1x bolt, 10mm, 4 Nm
Remove clip securing LH rocker cover to rear wheel liner

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1x clip
Remove rocker cover fasteners from LH side ski

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6x bolts, 10mm, 10 Nm
Release LH rocker cover from rocker carrier

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11x clips, 1x datum, Remove any clips that remained on carrier
Partially release aft section of front RH fender flare cover

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11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
Remove RH front rocker fastener from step reinforcement

Note
1x bolt, 10mm, 4 Nm
Remove clip securing RH rocker cover to front wheel liner

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1x clip
Partially release fore section of rear RH fender flare cover

Note
13x clips, 3x datums total, Release as needed for clearance, Full removal not required
Remove RH rear rocker fastener from step reinforcement

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1x bolt, 10mm, 4 Nm
Remove clip securing RH rocker cover to rear wheel liner

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1x clip
Remove rocker cover fasteners from RH side ski

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6x bolts, 10mm, 10 Nm
Release RH rocker cover from rocker carrier

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11x clips, 1x datum, Remove any clips that remained on carrier
Adjust steering column fully forward and fully up in height level

Note
Via UI > Controls > Steering , Use left steering wheel scroll wheel to adjust steering column
Remove LH front floor mat
Remove footwell cover

Note
3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether
Remove LH center floor rail

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4x clips, 3x datums, Pull upwards to release
Remove center console front panel

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10x clips
Remove LH mid A-pillar trim

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2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
Remove LH lower A-pillar trim

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7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Move LH front seat forward
Release LH front seat belt from pretensioner

Note
Unlock the linkage by rotating the lock screw counterclockwiseA light audible click will be heard, and the screw should remain horizontalDo not rotate clockwise to avoid damage to the mechanism
Fold up 2nd row 60 seat

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Pull tether to release then lift up until locked in place
Remove bolts securing rear of LH front seat tracks to the floor panel

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Move LH front seat backward
Remove bolts securing front of LH front seat tracks to risers

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Adjust position of LH front seat for easy removal

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Move seat to middle of track at most upright position with seat fully up off floor
Remove RH front floor mat
Remove RH center floor rail

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4x clips, 3x datums, Pull upwards to release
Remove center floor trim

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17x clips, Release upper section first
Remove RH mid A-pillar trim

Note
2x clips, 2x tabs, Release tabs, Slightly bend live hinge and release clips
Remove RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Move RH front seat forward
Release RH front seat belt from pretensioner

Note
Unlock the linkage by rotating the lock screw counterclockwiseA light audible click will be heard, and the screw should remain horizontalDo not rotate clockwise to avoid damage to the mechanism
Fold up 2nd row 40 seat

Note
Pull tether to release then lift up until locked in place
Remove bolts securing rear of RH front seat tracks to the floor panel

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Move RH front seat backward
Remove bolts securing front of RH front seat tracks to risers

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Adjust position of RH front seat for easy removal

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Move seat to middle of track at most upright position with seat fully up off floor
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
Unlock vehicle gateway

Note
After 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'

Note
Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
Open powered front trunk

Note
Via exterior switch or UI
Remove rear underhood apron

Note
9x clips
Remove frunk assembly

Note
6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
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
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
Disconnect RH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove RH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Remove RH front seat riser crossmember cover

Note
1x connector, Release 4 clips securing cover, Unfold then remove from 2nd row
Remove RH front seat crossmember from outboard

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1x bolt, 13mm, 35 Nm, Discard bolt
Remove RH outboard riser bolt cover
Remove RH front seat outboard riser

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2x bolts, 13mm, 40 Nm, Discard bolts after removal, Slide riser forward then lift to clear crossmember assembly
Remove RH lower B-pillar trim

Note
2x push clips, 11x clips, 4x datums, 4x seal retainers, Release bottom rear section first
Disconnect LH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove LH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Remove bolt securing LH front seat crossmember to outboard riser

Note
1x bolt, 13mm, 35 Nm, Discard bolt
Remove bolts securing riser crossmember to LH inboard seat riser

Note
2x bolts, 10mm, Torque?
Remove LH outboard riser bolt cover

Note
Lift from outer edge then pull away
Remove LH front seat outboard riser

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2x bolts, 13mm, 40 Nm, Discard bolts after removal, Slide riser forward then lift to clear crossmember assembly
Remove LH lower B-pillar trim

Note
2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Release bottom rear section first
Remove accelerator pedal side trim

Note
3x clips, Lift from forward edge then slide over accelerator pedal
Remove accelerator pedal

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2x nuts, 13mm, 16 Nm, 1x connector, Release locking tab
Release HV outlet from front console panel

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2x screws, T20, 1 Nm, 1x clip
Remove front bolts securing center console to riser

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4x bolts, 10mm, 5 Nm
Disconnect center console harness connectors

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2x connectors
Remove center console

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Lift up to release from riser
Release clips securing rear cabin carpet to LH front cabin carpet

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2x clips
Remove LH front cabin carpet

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Plastic portions at rear of carpet need to clear risers
Remove LH carpet support foam

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Lift up from rear edge
Remove LH inboard riser cover

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6x clips, 1x datum
Remove rearward duct from inboard risers

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2x clips
Remove LH front seat inboard riser

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2x bolt, 13mm, Torque?
Release LH MV controller dry side locking cover

Note
1x bolt, 8mm, 4 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 connectorsPlastic Locking CoverUse 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 stuckMetal Locking CoverYou can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically
Disconnect floor harness connector from LH MV controller

Note
1x connector, 2x edge clips, Depress tabs to release connector housing from locking cover
Remove LH front interior HV Battery mounting bolts

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3x bolts, 24mm, 160 Nm
Release clips securing rear cabin carpet to RH front cabin carpet

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2x clips
Remove RH front cabin carpet

Note
Plastic portions at rear of carpet need to clear risers
Remove RH carpet support foam

Note
Lift up from rear edge
Remove RH inboard riser cover

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6x clips, 1x datum
Remove RH front seat inboard riser

Note
2x bolt, 13mm, Torque?
Release RH MV controller connector locking cover

Note
1x bolt, 8mm, 4 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 connectorsPlastic 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 sidesMetal 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

Note
1x 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 backbone harness from rear MV controller

Note
1x connector, 1x bolts, 8mm, 4 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 releasePlastic Locking CoverUse 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 coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly
Remove RH interior front HV battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Remove 2nd row floor mat
Partially release LH lower C-pillar trim

Note
1x clip, 1x datum
Partially release RH lower C-pillar trim

Note
1x clip, 1x datum
Remove rear wall lower trim

Note
2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
Remove rear carpet RH duct bezel

Note
4x clips
Remove LH rear carpet duct bezel

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4x clips
Release HV cabin outlets harness from foam

Note
Slide outwards out of groove
Remove rear carpet assembly

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4x 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 RH subwoofer

Note
1x 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

Note
2x bolts, 15mm, 62 Nm, 2x bolts, 18mm, 62 Nm, Bolts on both sides of stanchion
Remove LH subwoofer mounting bolt

Note
1x bolt, 10mm, 8 Nm, Speaker does not need to be removed
Remove LH rear interior HV battery mounting bolts

Note
2x bolts, 15mm, 62 Nm, 2x bolts, 18mm, 62 Nm, Bolts on both sides of stancion
Install Universal Lift Pad adapters

Note
4x 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
Move vehicle onto lift

Note
Recommend assistance to push vehicle to liftEnsure positioning allows partial opening of doors
Raise and support vehicle

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Set air suspension to "Jack Mode"
Raise vehicle fully

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Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Remove front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Remove all items from pockets and ensure not wearing metal items
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
Put on HV insulating gloves and leather over gloves
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
Remove leather over gloves and HV insulating gloves
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
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
Remove bolt securing busbar HV connector lid

Note
1x bolt, 10mm, 9 Nm
Remove bolts securing HV connector to DC FC header

Note
2x bolts, 10mm, 9 Nm
Release HV connector from DC FC header

Note
1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
Support HV Busbar assembly

Note
Suspend assembly to maintain clearance
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Position coolant drain container underneath RH rear of HV battery
Disconnect RDU return hose from PT return hose

Note
1x spring clip, 1x clamp clip, Pull back wheel liner as required, Plug hoses
Disconnect rear PT supply and RDU supply hoses

Note
2x spring clip, Plug hoses immediately to prevent excess coolant loss, Allow PCS coolant to drain as much as possible before plugging
Move coolant drain container to front right of HV battery
Disconnect PT supply and return hoses

Note
2x spring clips, Plug hoses
Disconnect battery coolant supply and return hoses

Note
2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed
Remove coolant drain container from underneath vehicle
Release A/C compressor HV harness connector from HV battery

Note
1x 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
Release HV harness from battery

Note
2x edge clips, 1x clips
Release FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
Position battery table

Note
Ensure table is level
Remove front exterior HV Battery mounting bolts and ground strap

Note
6x 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

Note
16x bolts, 15mm, 62 Nm
Raise vehicle away from HV battery

Note
Ensure no coolant hoses, harnesses, or brake lines are caught while lifting
Secure PCS Flush adapter to PCS inlet hose coupling

Note
Remove plugs as required, Verify fully seated, Perform push-pull-push test
Secure coolant cart flush hose to regulator and PCS Flush adapter

Note
Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)
Secure PCS Drain adapter to the end of the PCS outlet hose

Note
Verify 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

Note
Make 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

Note
Allow 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 end of PCS outlet hose

Note
1x spring clip
Remove cart flush hose from PCS Flush adapter
Remove PCS Flush adapter from PCS inlet coupling

Note
1x spring clip
Attach Battery Flush adapter to HV battery hose coupling

Note
Remove plugs as required, Verify fully seated, Perform push-pull-push test
Attach coolant cart flush hose to Battery Flush adapter

Note
Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi), Hose is still attached to cart at this point
Attach P2 Battery Drain adapter to HV battery hose coupling

Note
Verify valve is closed, Verify fully seated, Remove plugs as required, Perform push-pull-push test
Secure coolant cart drain hose and coolant drain to P2 Battery Drain adapter
Open valve on P2 Battery Drain adapter
Slowly open valve on pressure regulator and allow coolant to drain out of HV battery

Note
Allow 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 from P2 Battery Drain adapter and coolant drain container
Remove P2 Battery Drain adapter from HV battery

Note
1x spring clip
Remove cart flush hose from battery flush coolant adapter and cart
Remove Battery flush coolant adapter from HV battery

Note
1x spring clip
Attach HV battery H-frame to gantry and raise into position
Secure the P2 battery sling adapter to H-frame

Note
4x 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

Note
Recommend assistance
Position gantry over HV battery crate

Note
Recommend assistance
Lower H-frame to HV battery crate
Secure P2 sling adapter to HV battery

Note
6x 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

Note
Recommend assistance
Position unused HV battery table under gantry
Lower HV battery onto battery table
Release P2 battery sling adapter from HV battery

Note
6x locking joints, Push down on top pin to release
Remove HV battery and table from under gantry

Note
Recommend assistance
Position old HV battery and table under gantry

Note
Recommend assistance
Secure P2 sling adapter to HV battery

Note
6x 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

Note
Recommend assistance
Lower old HV battery into crate

Note
Recommend assistance, Use caution to align HV battery into crate and do not damage the battery
Release P2 battery sling adapter from HV battery

Note
6x locking joints, Push down on top pin to release
Raise gantry and H-frame from crate
Secure top housing onto HV battery crate

Note
Recommend assistance, Adhere to proper MRB process
Return gantry to position and remove HV battery H-frame from gantry
Install battery alignment rods

Note
4x rods, Screw two larger rods in to front casting hand tight, Screw two smaller rods into any of the four seat stancion mounting holes on the HV battery
Position rear carpet section for install

Note
Insert a wheel chock under carpet section to maintain 90 degree angle
Lower vehicle onto HV battery

Note
Ensure 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

Note
16x bolts, 15mm, 62 Nm
Remove battery alignment rods

Note
4x alignment rods
Install front exterior HV Battery mounting bolts and ground strap

Note
6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
Raise vehicle away from battery table

Note
Set to a comfortable working height, Ensure lift is lowered onto a lock
Remove battery table from under vehicle
Install FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
Secure HV harness to battery

Note
2x edge clips, 1x harness clip
Install RDU HV harness

Note
1x connector, 1x harness clip, Ensure locking tab is engaged
Secure A/C compressor HV harness connector to HV battery

Note
1x locking connector, Slide down primary lock then engage red secondary lock
Position coolant drain container underneath RH rear of HV battery
Remove plugs then connect RDU return hose to PT return hose

Note
1x spring clip, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
Remove plugs then connect RDU supply hose

Note
1x spring clip, 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

Note
2x spring clips, Perform a push-pull-push test to ensure hose is engaged
Connect battery inlet and outlet coolant hoses

Note
2x edge clips, 2x spring clips, 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

Note
6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Install front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
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
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
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
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
Install busbar onto HV header and install bolts

Note
2x bolts, 10mm, 9 Nm
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
Put on HV insulating gloves and leather over gloves
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
Remove leather over gloves and HV insulating gloves
Install bolt securing busbar HV connector lid

Note
1x bolt, 10mm, 9 Nm
Connect Ancillary bay MV connector

Note
1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
Perform cooling system vacuum refill. See Cooling System (Vacuum Refill).
Lower vehicle fully

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

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Remove Universal Lift Pad adapters

Note
4x Adapters, Install original lift pads, Install plugs back into holes in BIW
Install LH rear interior HV battery mounting bolts

Note
2x bolts, 15mm, 62 Nm, 2x bolts, 18mm, 62 Nm, Bolts on both sides of stancion
Install LH subwoofer mounting bolt

Note
1x bolt, 10mm, 8 Nm, Speaker does not need to be removed
Install 2nd row floor mat
Install RH interior front HV battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Connect backbone harness to rear MV controller

Note
1x connector, 1x bolt, 8mm, 4 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
Connect cabin floor harness connector and backbone cable to RH MV controller

Note
1x 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

Note
1x bolt, 8mm, 4 Nm
Install RH carpet support foam

Note
Seat at rear edge
Install center floor trim

Note
17x clips, Replace any missing or damaged clips, Install lower section first
Install RH center floor rail

Note
4x clips, 3x datums
Install RH front floor mat
Close RH front door
Connect cabin floor harness connector to LH MV controller

Note
1x connector, 2x edge clips, Secure in locking cover
Secure LH MV controller dry side locking cover

Note
1x bolt, 8mm, 4 Nm, Tilt MV controller as needed, Secure locking cover bolt by hand initially to prevent thread strippingPlastic Locking CoverUse 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 seatingMetal Locking CoverYou can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully
Install LH front interior HV Battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Install LH carpet support foam

Note
Seat at rear edge
Unfold LH front cabin carpet into position
Install accelerator pedal

Note
2x nuts, 13mm, 16 Nm, 1x connector, Secure locking tab
Install accelerator pedal side trim

Note
3x clips, Replace any missing or damaged clips
Install LH center floor rail

Note
4x clips, 3x datums
Install footwell cover

Note
3x 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
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
Select "Start Thermal Fill Drain (Coolant and Refrigerant)" through UI

Note
Allow routine to complete, ensure routine is successful
Select "Start Coolant Air Purge" using the UI

Note
Touch 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'

Note
Lighting Bolt Icon > High Voltage > Procedures
Select 'HV battery Replacement Procedure'

Note
Lighting Bolt Icon > Procedures > High Voltage Battery Replacement
Select "Software Reinstall"

Note
Lighting Bolt Icon > Procedures > High Voltage Battery Replacement
Select 'High Voltage Battery Replacement procedure'
Install rear underhood apron

Note
9x clips
Close powered front trunk

Note
Via exterior switch or UI
Install bolts securing HV battery to RUB

Note
4x bolts, 21mm, 115 Nm, Tonneau must be closed to access forward bolts, Shown without tonneau for clarity
Open tonneau cover

Note
Press forward arrow on LH bed rail
Install forward bed panel

Note
6x bolts, 15mm, 85 Nm, Recommend assistance to lift panel into bed
Install fastener covers toforward bed panel

Note
6x covers
Close tailgate
Close tonneau cover
Remove Universal Lift Pad adapters

Note
4x Adapters, Install original lift pads, Install plugs back into holes in BIW
Install RH rear interior HV battery mounting bolts

Note
2x bolts, 15mm, 62 Nm, 2x bolts, 18mm, 62 Nm, Bolts on both sides of stancion
Install RH subwoofer

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
Install rear wall lower trim

Note
2x push clips, 4x clips
Install RH lower B-pillar trim

Note
2x push clips, 11x clips, 4x datums, 4x seal retainers
Install RH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 40 seat

Note
Pull tether to release then pivot down until locked in place
Close RH rear door
Install RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs
Install RH mid A-pillar trim

Note
2x clips, 2x tabs,
Install LH lower B-pillar trim

Note
2x push clips, 11x clips, 4x datums, 4x seal retainers, 2x hooks, Secure top hooks first
Secure LH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 60 seat

Note
Pull tether to release then pivot down until locked in place
Close LH rear door
Install LH Lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
Install LH mid A-pillar trim

Note
2x clips, 2x tabs, Replace any missing or damaged clips
Install LH rocker cover to rocker carrier

Note
11x clips, 1x datum, Replace any missing or damaged clips
Install rocker cover fasteners to LH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing LH rocker cover to rear wheel liner

Note
1x clip
Install LH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of rear LH fender flare cover

Note
13x clips, 3x datums total, Replace any missing or damaged clips
Install clip securing LH rocker cover to front wheel liner

Note
1x clip
Install LH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of front LH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips
Install RH rocker cover to rocker carrier

Note
11x clips, 1x datum
Install rocker cover fasteners to RH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing RH rocker cover to rear wheel liner

Note
1x clip
Install RH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of rear RH fender flare cover

Note
13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required
Install clip securing RH rocker cover to front wheel liner

Note
1x clip
Install RH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of front RH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required
Exit Service Mode

Note
Via UI > Service > Exit, Press and hold "Exit Service Mode" button
Raise all 4 windows
Close LH front door