HV Battery (AWD) \(Remove and Replace\)
Correction code 16010202 FRT 6.70 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.
- 2025-01-14: Updated entire procedure to the latest validation.
- 2024-12-03: Updated multiple steps to include releasing/installing harness clips.
- 2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
- 2024-10-31: Added HV battery discharge steps.
- 2024-09-18: Updated to latest time study.
- 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
Discharge
WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 30% or 50%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%.
WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage. |
- Enable Service Mode Plus. See Toolbox 3 (Connect and Disconnect).
-
Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch
, and then touch the large HV battery diagram to display the HV Battery information window.
- If the SOC Max is less than the SOC shipping threshold, skip to the Remove section in this procedure.
- If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
- Move the vehicle to a location where the battery can be safely discharged unattended.
- In the Service Mode Plus menu, touch .
-
In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
NoteThe discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
- After discharge is complete, move the vehicle to the service bay.
Procedure
- Open all the doors and lower all the windows.
-
Manually latch all doors to prevent
lockout
NoteEngage latch with screwdriver
- Place the vehicle into Service Mode. See Service Mode.
- Unlock the vehicle Gateway. See Gateway (Unlock).
-
Open tailgate
NotePress button to release
-
Open tonneau cover
NotePress forward arrow on LH bed rail
-
Release LH sail applique
Note6x tabs, Release rear portion of LH sail applique and support with inflatable airbag
-
Remove LH tonneau water management
seal
Note1x clip, Pull away from rail to release from groove
-
Release LH tail lamp applique
Note2x clips
-
Remove LH tonneau hard stop
Note3x bolts, 10mm, 9 Nm
-
Remove LH tonneau slip datum
bracket
-
Remove LH tailgate bumpstop
Note1x datum, Rotate and release inboard
-
Release RH sail applique
Note6x tabs, Release rear portion of RH sail applique and support with inflatable airbag
-
Remove RH tonneau water management
seal
Note1x clip, Pull away from rail to release from groove
-
Release RH tail lamp applique
Note2x clips, 2x datums
-
Remove RH tonneau hard stop
Note3x bolts, 10mm, 9 Nm
-
Remove RH tonneau slip datum
bracket
-
Remove RH tailgate bumpstop
Note1x datum, Rotate and release
-
Install tonneau transfer frame onto
powertrain table
Note4x bolts, 4x nuts, Frame TPN: 1999662-00-A
-
Position tonneau transfer frame onto
tonneau bed rails
NoteConnect air supply, Raise and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
-
Align and secure tonneau transfer
frame onto tonneau bed rails
Note2x pins, Frame TPN: 1999662-00-A
- Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Toolbox: (link)via Service Mode: Closures ➜ Tonneau ➜ Calibrate Tonneau
-
Release tonneau chain from
motors
NoteRecommend assistance, Press close button until both motors have audibly released all links, Frame TPN: 1999662-00-A
-
Manually guide remaining tonneau slats
and chain out of bed rails
NoteRecommend assistance, 2x pins, Remove pins then move powertrain table away from vehicle and guide slats out, Frame TPN: 1999662-00-A
-
Move vehicle onto lift
NoteEnsure positioning allows rear doors to open
- Move the LH front seat fully rearward.
-
Remove bolts securing front of LH
front seat tracks to risers
Note2x patch bolts, T45P, 34 Nm, Discard after removal
- Move the LH front seat fully forward.
-
Remove bolts securing rear of LH front
seat tracks to the floor panel
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
- Move the RH front seat fully rearward.
-
Remove bolts securing front of RH
front seat tracks to risers
Note2x patch bolts, T45P, 34 Nm, Discard after removal
- Move the RH front seat fully forward.
-
Remove bolts securing rear of RH front
seat tracks to the floor panel
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
-
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
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power.
-
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
- Remove the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
-
Remove front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
- Remove mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
-
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 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
-
Disconnect EPB harness connector from
LH rear brake caliper
Note1x connector, Release locking tab
-
Release the LH rear parking brake with
EPB release tool
Note1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete
-
Connect LH rear EPB harness
Note1x connector, Engage locking tab
-
Disconnect RH rear EPB harness
Note1x connector, Release locking tab
-
Release the RH rear parking brake with
EPB release tool
Note1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete
-
Connect RH rear EPB harness
Note1x connector, Engage locking tab
-
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
-
Position wheel chocks fore and aft of
RH rear wheel
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle,
-
Roll vehicle rearward
NotePosition vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position
-
Release LH front seat belt from
pretensioner
NoteUnlock 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
-
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
-
Release RH 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
-
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
-
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
-
Remove RH outboard riser bolt
cover
NoteLift from outer edge then pull away
-
Remove RH seat riser assembly from
vehicle
Note4x bolts, 13mm, 40 Nm, 2x clips, release cabin MV harness and air duct from riser assembly
-
Remove LH outboard riser bolt
cover
NoteLift from outer edge then pull away
-
Remove LH seat riser assembly from
vehicle
Note4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, release cabin HV outlet harness, and air duct from riser assembly
- Remove the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
- Remove LH front floor mat
-
Remove LH mid A-pillar trim
Note1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
-
Remove LH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
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
-
Remove accelerator pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
-
Remove LH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Remove LH carpet support foam
NoteLift up from rear edge
-
Remove LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
- Remove RH front floor mat
-
Remove RH mid A-pillar trim
Note1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
-
Remove RH lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
-
Remove RH center floor rail
Note4x clips, 3x datums, Pull upwards to release
-
Remove center floor trim
Note17x clips, Release upper section first
-
Remove RH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Remove RH carpet support foam
NoteLift up from rear edge
-
Remove RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Fold up 2nd row 60 seat
NotePull tether to release then lift up until locked in place
- Remove 2nd row floor mat
-
Partially release LH lower C-pillar
trim
Note1x clip, 1x datum
-
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 rear wall lower trim
Note2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
-
Remove LH rear carpet duct bezel
Note4x clips
-
Remove rear carpet RH 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 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, Some vehicles may have a mix of 13mm and 15mm bolts
-
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 rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
Remove interior HV harness bulkhead
cover
Note3x nuts, 10mm, 9 Nm
-
Remove center floor lower support
bracket
Note4x clips
-
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
-
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 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 stuck, Metal Locking CoverYou can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically, Video uses rear controller for demonstration purposes only
-
Release floor harness from LH MV
controller
Note1x connector, 1x clip, Depress tabs to release connector housing from locking cover
-
Release RH MV controller connector
lower 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 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
-
Release cabin floor and backbone
harnesses from RH MV controller
Note1x connector, 1x backbone cable, 2x edge clips, 3x harness 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 cabin floor harness
Note4x clips, 2x bolts, 10mm, 10 Nm
-
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
-
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 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 backbone harness
Note6x harness clips, Pull harness through to 2nd row then remove
-
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
-
Roll vehicle forward
NoteRemove fore wheel chock, Move vehicle to position necessary to place onto lift
-
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
-
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
-
Remove fasteners securing RH tonneau
NVH barrier
Note6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover
-
Remove RH tonneau NVH barrier
NoteVehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove
-
Remove fasteners securing LH tonneau
NVH barrier
Note5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover
-
Remove LH tonneau NVH barrier
NoteVehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then remove
-
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
-
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
-
Release interior HV harness from HV
battery and remove from vehicle
Note1x bolt, 10mm, 10 Nm, 8x clips, Remove from slot in EPP, Lift rear carpet and EPP as required for access
-
Raise vehicle fully
NoteSet 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
-
Remove RH rear wheel
Note6x nuts, 21mm, 205 Nm
-
Secure RH rear wheel liner aside
-
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
-
Remove RH front wheel
Note6x nuts, 21mm, 205 Nm
-
Secure RH front wheel liner
aside
-
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
-
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, If lift is shorter then remove rear wheels as needed
-
Remove HV battery from underneath
vehicle
NoteRecommend assistance
-
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
-
Remove RH pressurized pack air
line
Note2x clips, 1x voss fitting, 12mm, 8 Nm
-
Remove FDU HV harness
Note12x bolts, 10mm, 11 Nm
-
Remove powertrain hose bundle
Note1x spring clip, 6x clips, Release hose from PCS fitting
-
Obtain HV battery vitals
screenshot
NoteReference steps in 16018725
-
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
-
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 P2 battery sling adapter from
HV battery
Note6x locking joints, Push down on top pin to release
-
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
-
Apply backbone harness abrasion
protection
Note6x abrasion tape strips, Apply narrow patch to forwardmost position between should bracket ribs, Refer to image for clarity, Skip step if abrasion protection already present and installed correctly, Wide patch dimensions: 50mm wide, 150mm long, Narrow patch dimensions: 25.4mm wide, 235mm long
-
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
-
Install RH pressurized pack air
line
Note2x clips, 1x voss fitting, 12mm, 8 Nm
-
Install HV battery alignment
rods
Note4x alignment rods, Hand tight, Install 2x larger rods onto front casting, Install 2x smaller rods onto seat stancion mounting holes on pack
-
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
-
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
-
Remove HV battery alignment rods from
front casting
Note2x alignment rods
-
Install FDU HV harness
Note1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
-
Secure A/C compressor HV harness onto
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 the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
-
Install front skid plate
Note8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
- Install the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
-
Install RH front wheel
Note6x nuts, 21mm, 205 Nm
-
Install RH rear wheel
Note6x nuts, 21mm, 205 Nm
-
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
-
Torque RH front wheel nuts
Note6x nuts, 21mm, 205 Nm
-
Torque RH rear wheel nuts
Note6x nuts, 21mm, 205 Nm
-
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
-
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
-
Place interior HV harness inside cabin
of vehicle and install bulkhead cover
NoteFeed ancillary connector through hole in rear bulkhead, 3x nuts, 10mm, 9 Nm
-
Connect HV ancillary harnesses
Note2x connectors, Pull through rear wall opening, 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 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
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
-
Position LH tonneau NVH barrier
NoteVehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position
-
Install fasteners securing LH tonneau
NVH barrier
Note5x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover
-
Position RH tonneau NVH barrier
NoteVehicles built before April 2024 will have 1-piece NVH cover, Vehicles built after April 2024 will have updated 1-piece NVH cover, Vehicles built after October 2024 will have 2-piece NVH cover, Maneuver around bed wall then position
-
Install fasteners securing RH tonneau
NVH barrier
Note6x bolts, T25, 5 Nm, Vehicles built before April 2024 will have 1-piece NVH cover, 5x bolts, 8mm, 5 Nm, Vehicles built after April 2024 will have updated 1-piece NVH cover, 9x bolts, 4mm Allen, 5 Nm, Vehicles built after October 2024 will have 2-piece NVH cover
-
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
-
Position wheel chocks fore and aft of
RH rear wheel
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle,
-
Roll vehicle rearward
NotePosition vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position
-
Install backbone harness
Note6x harness clips, Push harness through to 1st row
-
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
-
Secure front section of backbone
Note3x clips, Route connector under cabin floor harness
-
Inspect for any misalignment at rear
ribs and apply abrasion tape 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
-
Install 2nd row floor Y-Duct
Note1x clip, Maneuver into position then secure to passenger side duct
-
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
-
Install cabin floor harness
Note2x connectors, 5x clips, 2x bolts, 10mm, 10 Nm, Secure connector housings to seat riser crossmembers, Secure locking levers on RCM connectors
-
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 RH 2nd row floor duct
Note1x clip, Align floor duct with Y duct then push inward to engage
-
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
-
Connect rear display connector to car
computer
Note1x connector
-
Secure cabin floor and backbone
harnesses onto RH MV controller
Note1x connector, 1x backbone cable, 2x edge clips, 3x harness 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
-
Secure floor harness onto LH MV
controller
Note1x connector, 1x clip, 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 RH interior front HV battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Install RH carpet support foam
NoteSeat at rear edge
-
Install LH front interior HV Battery
mounting bolts
Note3x bolts, 24mm, 160 Nm
-
Install LH carpet support foam
NoteSeat at rear edge
-
Install accelerator pedal
Note2x nuts, 13mm, 10 Nm, 1x connector, Secure locking tab
-
Install center console riser
duct
Note2x clips, Install from front of riser assembly, Replace any missing or damaged clips
-
Install floor jumper duct
Note2x clips
-
Install center floor lower support
bracket
Note4x clips, Replace any missing or damaged clips
-
Install RH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Install LH front cabin carpet
NotePlastic portions at rear of carpet need to clear risers
-
Secure HV cabin outlets harness to
foam
NoteTuck harness into groove
-
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
-
Install LH seat riser assembly
Note4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, attach cabin HV outlet harness and air duct to seat riser
-
Install LH outboard riser bolt
cover
-
Install RH seat riser assembly
Note4x bolts, 13mm, 40 Nm, 2x clips, Attach cabin MV harness and air duct to riser assembly
-
Install RH outboard riser bolt
cover
-
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 center console
NoteLower onto riser
-
Connect center console harness
connectors
Note2x connectors
-
Install front bolts securing center
console to riser
Note4x bolts, 10mm, 5 Nm
-
Secure HV outlet onto front console
panel
Note2x screws, T20, 1 Nm, 1x clip
-
Install center console front
panel
Note10x clips, Replace any missing or damage clips
-
Install rear bolts securing center
console to riser
Note2x bolts, 10mm, 5 Nm
-
Secure HV outlet onto rear console
panel
Note3x screws, T20, 1 Nm, 2x clips
-
Install center console rear
panel
Note10x clips, 3x connectors, 3x harness 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
-
Remove HV battery alignment rods from
stancion mounting holes on pack
Note2x alignment rods
-
Install RH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
Install RH subwoofer
Note1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
-
Install LH rear interior HV battery
mounting bolts
Note4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
-
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
- Perform cooling system vacuum fill. See Cooling System (Vacuum Refill).
- Reconnect MV power. See Disconnect MV Power.
-
Select 'Procedures'
NoteLighting Bolt Icon > High Voltage > Procedures
-
Select 'HV Battery Replacement
Procedure'
NoteLightning Bolt Icon > High Voltage > Procedures > High Voltage Battery Replacement
-
Run ODIN routine
UPDATE_CAN-REDEPLOYvia Toolbox: (link)via Service Mode Plus:
- Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
- Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
- Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
- Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
- Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
- Run ODIN routine PROC_HV_X_PACK-REPLACEMENTvia Toolbox: (link)via Service Mode Plus: High Voltage Battery ➜ High Voltage Battery Replacement ➜ High Voltage Battery Replacement Routine
-
Remove Universal Lift Pad
adapters
Note4x Adapters, Install original lift pads, Install plugs back into holes in BIW
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
-
Run ODIN routine
PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOPvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Thermal Fill/Drainvia Service Mode Plus:
- Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
- Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
- Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
-
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
-
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
-
Secure RH front seat belt to
pretensioner
NoteEnsure the lock screw is in the horizonal 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 the RH front seat fully rearward.
-
Install bolts securing RH front seat
front tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
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 lower A-pillar trim
Note7x clips, 3x datums, 2x tabs
-
Install RH mid A-pillar trim
Note1x clip, 3x tabs, Replace any missing or damaged clips
- Install RH front floor mat
- Move the RH front seat fully forward.
-
Install bolts securing RH front seat
rear tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
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
-
Secure LH front seat belt to
pretensioner
NoteEnsure the lock screw is in the horizonal 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 the LH front seat fully rearward.
-
Install bolts securing both LH front
seat front tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Install LH center floor rail
Note4x clips, 3x datums
-
Install accelerator pedal side
trim
Note3x clips, Replace any missing or damaged clips
- Install the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
-
Install LH Lower A-pillar trim
Note7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
-
Install LH mid A-pillar trim
Note1x clip, 3x tabs, Replace any missing or damaged clips
- Install LH front floor mat
- Move the LH front seat fully forward.
-
Install bolts securing LH front seat
rear tracks to vehicle
Note2x patch bolts, T45P, 34 Nm, Install new bolts
-
Inspect coolant level and top off as
necessary
NoteEnsure that the fluid level is at the Max line, Top off fluid as required
-
Install coolant bottle cap
- Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
-
Perform Thermal Performance through
the UI
NoteSelect Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
-
Position tonneau transfer frame onto
tonneau bed rails
NoteLay tonneau chain on tailgate and secure ends to prevent breakdown or shifting, Use tape or bungees as needed, Connect air supply, Raise and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
-
Manually guide remaining tonneau slats
and chain onto bed rails
NoteRecommend assistance, 2x pins, Evenly guide slats in then install pins, Monitor Y reaction clips entering bed rails and ensure clips do not bind, Monitor slats during install and ensure all are squared during install, Adjust as needed, Frame TPN: 1999662-00-A
-
Secure tonneau chain onto motors
NoteRecommend assistance, Press open button until both motors have audibly secured all links and cover is fully open, Frame TPN: 1999662-00-A
-
Remove tonneau transfer frame from
tonneau bed rails
NoteDisconnect air supply, Lower and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
-
Install RH tailgate bumpstop
Note1x datum, Rotate and secure
-
Install RH tonneau slip datum
bracket
-
Install RH tonneau hard stop
Note3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail
-
Secure RH tail lamp applique
Note2x clips, 2x datums
-
Install RH tonneau water management
seal
Note1x clip, Push seal into rail groove
-
Secure RH sail applique
Note6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut same length tape and apply
-
Secure LH tailgate bumpstop
Note1x datum, Rotate and secure
-
Install LH tonneau slip datum
bracket
-
Install LH tonneau hard stop
Note3x bolts, 10mm, 9 Nm, Hand start center black locating bolt first, Set 2mm space between datum and end of bed rail
-
Secure LH tail lamp applique
Note2x clips 2x datums
-
Install LH tonneau water management
seal
Note1x clip, Push seal into rail groove
-
Secure rear LH sail applique
Note6x tabs, 6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut double sided tape to length and apply
-
Close tailgate
- Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Toolbox: (link)via Service Mode: Closures ➜ Tonneau ➜ Calibrate Tonneau
- Close the tonneau cover.
- Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
- Raise all the windows and close all the doors.