Correction code NEW 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

1. Open LH front door
   Note

   Push LH B-pillar door trigger to release

   

   

2. Lower LH front window

   

3. Raise and support vehicle
   Note

   Set air suspension to "Jack Mode"

   

   

4. Connect to vehicle using Toolbox 3
   Note

   OBD-II connection is integrated into drivers lower IP cover, Open Toolbox 3 website and establish connection to vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner then select connect locally, Icon will turn green when connected, Successful connection will automatically unlock vehicle gateway and place UI in Service Mode Plus

   

   

   

5. Select "Actions" and search for "diagnostic_path_network.HV_isolationCheck"

   

   

6. Select "HV Isolation Diagnostic Debug", enter VIN, and click run

   

   

7. Read "HV System Global Check Autodiag" question and select "Yes" to continue

   

8. Read "HV Awareness" warning and select "Yes" to continue

   

9. Read interactive procedure instructions and select "Next" to continue
   Note

   Select "Finish Later" every time you need to perform a task to prevent timeout error, Select "Resume" after task has been performed and you are ready to submit input

   

10. Read "Vehicle Electrical Isolation Procedure" panel and select "Finish Later" to prevent timeout error

    

11. Open powered front trunk
    Note

    Via exterior switch or UI

    

    

12. Open tailgate
    Note

    Press button to release

    

13. 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

    

14. Remove rear underhood apron
    Note

    9x clips

    

    

15. Disconnect FRL connector then disconnect MV battery connector
    Note

    2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules

    

    

    

16. Verify operation of multimeter
    Note

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

    

    

17. Disconnect Toolbox 3 from vehicle and remove laptop

    

    

    

18. Raise vehicle fully
    Note

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

    

    

19. Remove Mid-aero shield
    Note

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

    

    

    

    

    

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

    

21. 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

    

22. Put on HV insulating gloves and leather over gloves

    

23. Remove clips securing AC compressor HV harness
    Note

    3x clips

    

24. 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

    

    

    

    

    

    

25. Select "Resume" to continue to "Vehicle Electrical Isolation Procedure" panel
    Note

    Read panel and select "Yes" to continue

    

    

26. Read "Rear Left DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error

    

27. Perform isolation test on LH RDU HV cable at HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

28. Select "Resume" to continue to "Rear Left DU + HV Harness Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

29. Read "Rear Left DU + HV Harness Voltage Check" panel and select "Continue"

    

30. Read "Rear Right DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error

    

31. Disconnect RDU HV harness
    Note

    1x connector, Release locking tab and rotate release lever up, Do not force release lever up, Ensure alignment tabs on header are not damaged

    

32. Perform isolation test on RH RDU HV cable at HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

33. Select "Resume" to continue to "Rear Right DU + HV Harness Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

34. Read "Rear Right DU + HV Harness Voltage Check" panel and select "Continue"

    

35. Read "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel and select "Finish Later" to prevent timeout error

    

36. Release A/C compressor HV harness 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

    

    

    

37. Perform isolation test on ancillary HV harness at rear of HV battery
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to subframe bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

38. Select "Resume" to continue to "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel
    Note

    Read panel and submit resistance to continue

    

    

39. Read CP HV Harness FC contactor question and select "Yes" to continue

    

40. Read "CP HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

41. 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

    

    

42. Remove fastener covers from bed floor assembly
    Note

    14x covers

    

    

    

    

    

43. Remove bed floor assembly
    Note

    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

    

    

    

    

44. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

46. Release HV connector from DC FC header
    Note

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

    

47. Secure CP busbar connector aside
    Note

    Move connector away from header, Install bags or bungees as needed, Do not open tonneau to prevent damage

    

48. Perform isolation test on CP HV busbar connector
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to door stricker, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

49. Select "Resume" to continue to "CP HV Harness Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

50. Read Ancillary certification question and select "Yes" to continue

    

51. Read "PCS2 DC Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

52. Connect HV harness connector to AC compressor
    Note

    1x locking electrical connector, Slide down black lock then push in red locking tab, Perform a push-pull-push test, Ensure red locking tab is fully engaged, Black tab will protrude from red locking tab when engaged correctly, Refer to images and video for clarity

    

    

    

    

53. Install frunk assembly
    Note

    6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Install bolt covers to frunk floor, Install washer fluid cap, Install bumpstops by aligning tabs then turning clockwise, Ensure emergency frunk release functions

    

    

    

    

    

    

    

    

    

54. Connect FRL connector then connect MV battery connector
    Note

    2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down

    

    

    

55. 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

    

    

56. Raise vehicle fully
    Note

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

    

    

57. 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

    

    

    

    

    

    

58. Remove pyro fuse access cover
    Note

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

    

59. Remove primary pyro fuse
    Note

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

    

    

60. Remove secondary pyro fuse
    Note

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

    

    

61. 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

    

    

62. Clean all debris from ancillary cover
    Note

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

    

63. 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

    

    

    

    

    

64. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

65. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10 Nm

    

    

66. Release low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

67. Release fasteners securing ancillary cover to HV battery
    Note

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

    

    

    

68. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

69. Disconnect PCS2 DC HV connector
    Note

    1x connector, Release locking tab, Gently pull up

    

70. Perform isolation test on PCS2 DC connector at ancillary
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

71. Select "Resume" to continue to "PCS2 DC Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

72. Read "ACJB Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

73. Release ancillary bay MV connector header
    Note

    4x tabs, Move aside as needed

    

    

74. Disconnect HVC logic connector
    Note

    1x connector

    

75. Disconnect negative pack contactor sense connectors
    Note

    2x connectors

    

76. Disconnect positive pack contactor sense connectors
    Note

    2x connectors

    

    

77. Disconnect ACJB HV connector
    Note

    1x connector, Release locking tab, Gently pull up

    

78. Perform isolation test on ACJB HV connector
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

79. Select "Resume" to continue to "ACJB Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

80. Read "External Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error

    

81. Perform isolation test on external side of negative and positive pack contactors
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

82. Select "Resume" to continue to "External Side DC Link Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

83. Read "Internal Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error

    

    

84. Perform isolation test on internal side of negative and positive pack contactors and pyro disconnect
    Note

    Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to HV battery chassis bolt, Position leads then press test button, Amber light will turn on, Test all four terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

    

    

    

    

    

    

    

85. Select "Resume" to continue to "Internal Side DC Link Isolation Test" panel
    Note

    Read panel and submit resistance to continue

    

    

86. Read "Warm Heat Pump A/C Compressor Isolation Test" panel and select "Finish Later" to prevent timeout error

    

87. Connect ACJB HV connector
    Note

    1x connector, Secure locking tab

    

88. Connect positive pack contactor sense connectors
    Note

    2x connectors

    

    

89. Connect negative pack contactor sense connectors
    Note

    2x connectors

    

90. Connect HVC logic connector
    Note

    1x connector

    

91. Secure ancillary bay MV connector header
    Note

    4x tabs

    

92. Connect PCS2 DC HV connector
    Note

    1x connector, Secure locking tab

    

93. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

94. Secure fasteners of cover to HV battery
    Note

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

    

    

    

95. Secure low voltage header
    Note

    2x bolts, EP10, 6 Nm

    

96. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

97. 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

    

98. 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

    

99. 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

    

100. Position busbar connector and lower onto HV header
     Note

     Release bungee cord

     

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

     2x bolts, 10mm, 9 Nm

     

102. 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

     

     

103. Install bolt securing busbar HV connector lid
     Note

     1x bolt, EP10, 9 Nm

     

104. Connect Ancillary bay MV connector
     Note

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

     

     

     

     

     

105. Raise vehicle fully
     Note

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

     

     

106. Clean mating surface of the pyro
     Note

     Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner

     

     

     

     

107. Install secondary pyro fuse
     Note

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

     

     

108. Install primary pyro fuse
     Note

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

     

     

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

     4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step

     

     

110. Remove HV insulating gloves
111. Install pyro fuse access cover
     Note

     4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, If HV pack is being shipped then pyro fuses must be removed

     

     

112. Secure A/C compressor HV harness onto battery
     Note

     1x locking connector, 4x clips, Engage locking tab, Do not force lever up, Number of connections may vary by vehicle configuration

     

     

     

113. Connect RDU HV harness
     Note

     1x connector, Verify lever is upright and in open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

     

114. Connect LHS RDU HV harness
     Note

     1x connector, Verify lever is upright and in open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins

     

115. Install clips securing AC compressor HV harness
     Note

     3x clips

     

116. Install Mid-aero shield
     Note

     6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aeroshield bolts and install fasteners

     

     

     

     

     

117. 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

     

     

118. 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

     

     

     

119. 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

     

     

     

     

     

     

     

     

     

120. Warm up AC compressor via UI
     Note

     Via Climate Control > ON, Set fan speed to 10, Set temperature to HI or LO, Allow 20 minute run time

     

121. Turn off the AC and blower motor

     

122. 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

     

     

123. Disconnect HV harness connector from AC compressor
     Note

     1x locking electrical connector, Pull red locking tab away from compressor then slide black lock upwards to release

     

     

124. Perform isolation test on AC compressor
     Note

     Move HV harness aside as needed, Set insulation meter to 1000V and red lead to resistance (Ω), Secure black alligator clip to shock tower brace, Position leads then press test button, Amber light will turn on, Test both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button

     

     

     

     

     

125. Select "Resume" to continue to "Warm Heat Pump A/C Compressor Isolation Test" panel
     Note

     Read panel and submit resistance to continue

     

126. Read "HV Isolation Diagnostic Debug" results
     Note

     If this panel is reached then screenshot and escalate a Toolbox session, Select "X" at top right of window to close once complete

     

127. 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

     

     

     

128. Install rear underhood apron
     Note

     9x clips, Adjust windshield seal as required

     

     

129. Close powered front trunk
     Note

     Via exterior switch or UI

     

130. Install bed floor assembly
     Note

     10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

     

     

     

     

     

131. Install fastener covers onto bed floor assembly
     Note

     14x covers

     

     

     

     

132. Close tailgate

     

133. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
134. Remove vehicle from lift
     Note

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

     

     

135. Raise LH front window

     

136. Close LH front door