2025-08-06

Isolation/Insulation Test (Test/Adjust)

Correction code 44000100 FRT 4.92 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.

2025-08-06: Updated entire procedure for CT.

Perform the isolation/insulation test when diagnosis requires verification that a circuit or component is properly isolated, or a cable has sufficient insulation.

Warning

When measuring isolation/insulation, the tester will generate high DC voltage up to 1000V. Proper HV PPE must be worn when performing an isolation/insulation test.

Warning

Residual voltage may still be present in the component after performing an isolation/insulation test – DO NOT TOUCH THE COMPONENT WITHOUT FIRST CHECKING THE VOLTAGE after an isolation/insulation test.

Warning

Make sure that the insulation meter and leads are capable of handling at least 1000V DC.

Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning

If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.

Warning

Always wear High Voltage (HV) gloves and safety glasses when handling any high voltage component, including test equipment. Before each use, test gloves using an authorized glove tester and verify that the testing date on the gloves has not expired.

Warning

All repair and operating instructions should be reviewed and understood before working on Tesla vehicles, associated components, or associated repair equipment.

Warning

Assume that high voltage is present at all times when working on a Tesla vehicle, associated high voltage components, or associated high voltage test equipment until proven otherwise. Be aware that energy states can change during testing, so err on the side of caution.

Warning

Always have an electrical safety hook in the area when working with HV components. Electrical safety hooks are used to remove an injured person from a live high voltage circuit without risking additional injury.

Warning

Obey all instructions when using test equipment or servicing a Tesla vehicle or associated high voltage components. If repair instructions are not clear or if there are any questions about how to use the test equipment, escalate a Toolbox session before proceeding.

Warning

If any test equipment fails to operate as expected, do not attempt to diagnose or repair the vehicle. Follow the appropriate lock out – tag out procedure for the equipment, notify your manager.

Warning

When using test equipment, make sure that all cables are connected before turning equipment on or otherwise initiating use.

Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
1130480-00-A Test Probes, Slim, Fluke TP38

Procedure

Open the LH front door and lower the LH front window.
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Connect to vehicle using Toolbox 3. See Toolbox 3 (Connect and Disconnect).
Select "Actions" and search for "diagnostic_path_network.HV_isolationCheck"
Select "HV Isolation Diagnostic Debug", enter VIN, and click run
Read "HV System Global Check Autodiag" question and select "Yes" to continue
Read "HV Awareness" warning and select "Yes" to continue
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
Read "Vehicle Electrical Isolation Procedure" panel and select "Finish Later" to prevent timeout error
Open the powered frunk.
Open the tailgate.
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
Disconnect MV power. See Disconnect MV Power (Modify).
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
Disconnect Toolbox 3 from vehicle and remove laptop. See Toolbox 3 (Connect and Disconnect).
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove the mid-aero shield. See Aeroshield - Mid (Remove and Install).
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
Put on HV insulating gloves and leather over gloves
Remove clips securing AC compressor HV harness

Note
3x clips
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
Select "Resume" to continue to "Vehicle Electrical Isolation Procedure" panel

Note
Read panel and select "Yes" to continue
Read "Rear Left DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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
Select "Resume" to continue to "Rear Left DU + HV Harness Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "Rear Left DU + HV Harness Voltage Check" panel and select "Continue"
Read "Rear Right DU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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
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
Select "Resume" to continue to "Rear Right DU + HV Harness Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "Rear Right DU + HV Harness Voltage Check" panel and select "Continue"
Read "FDU + HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
Disconnect FDU HV harness from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Perform isolation test on FDU HV cable 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 both terminals, Make sure to wear proper PPE, Verify voltage drops below 10V after releasing test button
Select "Resume" to continue to "FDU + HV Harness Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "FDU + HV Harness Voltage Check" panel and select "Continue"
Read "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel and select "Finish Later" to prevent timeout error
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
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
Select "Resume" to continue to "Heat Pump A/C Compressor + HV Harness' Isolation Tests" panel

Note
Read panel and submit resistance to continue
Read CP HV Harness FC contactor question and select "Yes" to continue
Read "CP HV Harness Isolation Test" panel and select "Finish Later" to prevent timeout error
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
Remove bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Remove bolt securing busbar HV connector lid

Note
1x bolt, EP10, 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
Secure CP busbar connector aside

Note
Move connector away from header, Install bags or bungees as needed, Do not open tonneau to prevent damage
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
Select "Resume" to continue to "CP HV Harness Isolation Test" panel

Note
Read panel and submit resistance to continue
Read Ancillary certification question and select "Yes" to continue
Read "PCS2 DC Isolation Test" panel and select "Finish Later" to prevent timeout error
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
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
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
Open tonneau cover

Note
Press forward arrow on LH bed rail
Remove LH sail applique

Note
9x clips, 6x double-sided tape strips, 1x connector, 1x harness clip, Lift rear edge first to remove connector and harness clip, Remove double-sided tape from applique and bed side, Remove any remaining adhesive with IPA wipes, Discard sail applique after removal
Remove LH tonneau water management seal

Note
1x clip, Pull away from rail to release from groove
Release LH tail lamp applique

Note
2x clips
Remove LH tonneau hard stop

Note
3x bolts, 10mm, 9 Nm
Remove LH tonneau slip datum bracket
Remove LH tailgate bumpstop

Note
1x datum, Rotate and release inboard
Remove RH sail applique

Note
9x clips, 6x double-sided tape strips, Remove double-sided tape from applique and bed side, Remove any remaining adhesive with IPA wipes, Discard sail applique after removal
Remove RH tonneau water management seal

Note
1x clip, Pull away from rail to release from groove
Release RH tail lamp applique

Note
2x clips, 2x datums
Remove RH tonneau hard stop

Note
3x bolts, 10mm, 9 Nm
Remove RH tonneau slip datum bracket
Remove RH tailgate bumpstop

Note
1x datum, Rotate and release
Install tonneau transfer frame onto powertrain table

Note
4x bolts, 4x nuts, Frame TPN: 1999662-00-A
Position tonneau transfer frame onto tonneau bed rails

Note
Connect 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

Note
2x pins, Frame TPN: 1999662-00-A
Connect tonneau switch connector

Note
1x connector, Position LH sail applique onto bed
Release tonneau chain from motors

Note
Recommend assistance, Press close button until both motors have audibly released all links, Frame TPN: 1999662-00-A
Secure tonneau floating slats

Note
Slats must be secured to prevent breakdown or shifting, Use tape or bungees as needed
Manually guide remaining tonneau slats and chain out of bed rails

Note
Recommend assistance, 2x pins, Remove pins then move powertrain table away from vehicle and guide slats out, Frame TPN: 1999662-00-A
Remove fasteners securing RH tonneau NVH barrier

Note
6x 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

Note
Vehicles 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

Note
5x 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

Note
Vehicles 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
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
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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
Disconnect pressurized pack lines

Note
2x VOSS fittings, 12mm, 8Nm
Remove VOSS fitting from pressurized pack air lines

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

Note
4x bolts, E-Torx 5 lobe, 10 Nm
Remove primary pyro fuse

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

Note
2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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
Remove rear tonneau cover box cross supports

Note
8x screws, T25, 5 Nm
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
Release pressurized pack air line to Ancillary

Note
1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.
Remove VOSS fitting from pressurized pack air line to Ancillary

Note
1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
Release pressurized pack valve block from air suspension reservoir

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

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

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips
Place air suspension reservoir in service position then install Ancillary Access Bench

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

Note
Suspend assembly to maintain clearance
Remove fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10 Nm
Release low voltage header

Note
2x bolts, 10mm, 6 Nm
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
Remove ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
Disconnect PCS2 DC HV connector

Note
1x connector, Release locking tab, Gently pull up
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
Select "Resume" to continue to "PCS2 DC Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "ACJB Isolation Test" panel and select "Finish Later" to prevent timeout error
Release ancillary bay MV connector header

Note
4x tabs, Move aside as needed
Disconnect HVC logic connector

Note
1x connector
Disconnect negative pack contactor sense connectors

Note
2x connectors
Disconnect positive pack contactor sense connectors

Note
2x connectors
Disconnect ACJB HV connector

Note
1x connector, Release locking tab, Gently pull up
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
Select "Resume" to continue to "ACJB Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "External Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error
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
Select "Resume" to continue to "External Side DC Link Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "Internal Side DC Link Isolation Test" panel and select "Finish Later" to prevent timeout error
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
Select "Resume" to continue to "Internal Side DC Link Isolation Test" panel

Note
Read panel and submit resistance to continue
Read "Warm Heat Pump A/C Compressor Isolation Test" panel and select "Finish Later" to prevent timeout error
Connect ACJB HV connector

Note
1x connector, Secure locking tab
Connect positive pack contactor sense connectors

Note
2x connectors
Connect negative pack contactor sense connectors

Note
2x connectors
Connect HVC logic connector

Note
1x connector
Secure ancillary bay MV connector header

Note
4x tabs
Connect PCS2 DC HV connector

Note
1x connector, Secure locking tab
Install ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
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
Secure low voltage header

Note
2x bolts, 10mm, 6 Nm
Secure fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10Nm
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
Position busbar connector and lower onto HV header

Note
Release bungee cord
Install bolts securing charge port busbar kit to HV Header

Note
2x bolts, 10mm, 9 Nm
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
Install bolt securing busbar HV connector lid

Note
1x bolt, EP10, 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
Secure rear tonneau cover box cross supports

Note
8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners
Position LH tonneau NVH barrier

Note
Vehicles 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

Note
5x 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

Note
Vehicles 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

Note
6x 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 Ancillary Access Bench then place air suspension reservoir into position for installation

Note
Ensure air lines are not twisted, Ensure no harnesses are caught
Secure air suspension reservoir

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips
Secure air suspension valve block

Note
3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation
Install new VOSS air fitting to pressurized pack valve block at ANC circuit

Note
1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed
Secure pressurized pack air line from Ancillary to valve block

Note
1x line, Remove plastic cap from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
Secure pressurized pack valve block to air suspension reservoir

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

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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
Install secondary pyro fuse

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

Note
2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
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
Remove HV insulating gloves
Install new Voss fittings and nut to pyro cover

Note
2x VOSS fittings, 12mm, 8 Nm, Do not remove VOSS plastic plug until SCUBA line install
Install Pyro Fuse Access cover

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged
Install pressurized pack lines

Note
2x 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
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
Connect FDU HV harness to HV battery

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
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
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
Install clips securing AC compressor HV harness

Note
3x clips
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
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
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
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
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
Turn off the AC and blower motor
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 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
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
Select "Resume" to continue to "Warm Heat Pump A/C Compressor Isolation Test" panel

Note
Read panel and submit resistance to continue
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
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
Install rear underhood apron

Note
9x clips, Adjust windshield seal as required
Close powered front trunk

Note
Via exterior switch or UI
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Position tonneau transfer frame onto tonneau bed rails

Note
Lay 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

Note
Recommend 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
Release tonneau floating slats

Note
Slats must be secured to prevent breakdown, Use tape or bungees as needed
Secure tonneau chain onto motors

Note
Recommend 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

Note
Disconnect air supply, Lower and adjust angle on powertrain table as needed, Frame TPN: 1999662-00-A
Install RH tailgate bumpstop

Note
1x datum, Rotate and secure
Install RH tonneau slip datum bracket
Install RH tonneau hard stop

Note
3x 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

Note
2x clips, 2x datums
Install RH tonneau water management seal

Note
1x clip, Push seal into rail groove
Install the RH sail applique. See Sail Applique - RH (Remove and Replace).
Secure LH tailgate bumpstop

Note
1x datum, Rotate and secure
Install LH tonneau slip datum bracket
Install LH tonneau hard stop

Note
3x 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

Note
2x clips 2x datums
Install LH tonneau water management seal

Note
1x clip, Push seal into rail groove
Install the LH sail applique. See Sail Applique - LH (Remove and Replace).
Close the tonneau cover.
Close the tailgate.
Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
Raise the LH front window and close the LH front door.

Cybertruck Service Manual

Isolation/Insulation Test (Test/Adjust)

Procedure

Figure 1

Figure 2

Figure 3