04/09/2024 13:20:02

HV Harness - AC Compressor \(Remove and Install\)

Correction code 4450074051 4450074052 FRT 3.06 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-05-22: Updated connector images and instructions for disconnect/connect.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Open all the doors and lower all the windows.
  2. Use a pocket screwdriver to manually latch all the doors to prevent lockout.
  3. Remove the LH rocker assembly. See Rocker Panel Trim - Rocker Assembly - LH (Remove and Install).
  4. Remove the bolts (x3) that attach the LH front rocker step reinforcement to the vehicle, and then remove the reinforcement from the vehicle.
    15 Nm (11.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  5. Remove the LH rear rocker step reinforcement. See reRocker Panel Trim - Rear Rocker Step Reinforcement - LH (Remove and Install).
  6. Repeat step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-3E50E5B2-D0D1-41DD-8498-90F8DEB0F5A4__GUID-70711676-655C-4F43-9BE6-28A4FACAC74E through step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-3E50E5B2-D0D1-41DD-8498-90F8DEB0F5A4__GUID-6B61E7B2-DE60-4A6B-AAC0-07A5F027AD6F for the RH side of the vehicle.
  7. Remove the 2nd row floor mat.
  8. Fold up the LH 2nd row seat cushion.
  9. Release the clip and datum that attach the lower portion of the LH lower C-pillar trim.
  10. Remove the LH mid A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  11. Remove the LH Lower A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  12. Move the LH front seat fully forward.
  13. Use a flathead screwdriver to rotate the lock mechanism on the front seat belt linkage counterclockwise to release it from the pretensioner, and then slide the linkage off the pretensioner and set it aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT rotate clockwise to avoid damage to the mechanism.
    Informational PurposesAn informational icon, calling your attention
    Note
    The linkage design may vary, but will function the same.
    Informational PurposesAn informational icon, calling your attention
    Note
    The lock screw will remain in the horizontal position when released.
    Informational PurposesAn informational icon, calling your attention
    Note
    A light audible click will be heard when the linkage is released.
  14. Remove and discard the bolts (x2) that attach the rear of the LH front seat tracks to the floor panel.
    34 Nm (25.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx Plus T45 socket
  15. Move the LH front seat fully rearward.
  16. Remove and discard the bolts (x2) that attach the front of the LH front seat tracks to the risers.
    34 Nm (25.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx Plus T45 socket
  17. Move the seat to the middle of track and to the most upright position.
  18. Repeat step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-3E50E5B2-D0D1-41DD-8498-90F8DEB0F5A4__GUID-B22251D0-1FDA-4199-9C31-2D1F8F7E05A2 through step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-3E50E5B2-D0D1-41DD-8498-90F8DEB0F5A4__GUID-67B85AF0-66B7-40D0-B5F0-3F1F9132165F for the RH side of the vehicle.
  19. Remove the RH C-pillar subwoofer. See Audio Speakers - 200mm, Woofer, LH, C-Pillar, Audio (Remove and Install).
  20. Remove the RH rear interior HV battery mounting bolts (x4).
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on both sides of the stanchion.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 18 mm socket
  21. Remove the LH C-pillar subwoofer. See Audio Speakers - 200mm, Woofer, LH, C-Pillar, Audio (Remove and Install).
  22. Remove the LH rear interior HV battery mounting bolts (x4).
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on both sides of the stanchion.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 18 mm socket
  23. Move the vehicle onto a lift. See Raise Vehicle - 2 Post Lift.
  24. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  25. Placeholder - Remove the tonneau NVH cover.
  26. Close the tonneau cover.
  27. Remove the bolts (x4) that attach the HV battery to the RUB.
    115 Nm (84.8 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Break the bolts free before using power tools.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tonneau must be closed to access the forward bolts.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    Figure 1. Bolts shown without tonneau cover for clarity
  28. Open the tonneau cover.
  29. Place the vehicle into Service Mode via the UI. See Service Mode.
  30. On the vehicle touchscreen, tap Start Thermal Fill Drain (Coolant and Refrigerant) and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the routine is successful.
  31. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  32. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  33. Disconnect MV power. See Disconnect MV Power.
  34. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  35. Remove leather over gloves and HV insulating gloves.
  36. Lower the vehicle until the tires are touching the ground.
  37. Release the connector lock, and then disconnect the A/C Compressor HV harness electrical connector from the A/C Compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red locking tab away from the black lever, and then slide the black lever upwards.
  38. Disconnect the ancillary bay MV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connector is double locking. Release the tab, pivot the lever, and then release the second tab to disengage the connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wait 1 second between locking tab release to discharge and prevent arcing.
  39. Remove the bolt that attaches the busbar HV connector lid to the connector.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  40. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  41. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  42. Support the HV Busbar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Suspend the assembly to maintain clearance.
  43. Disconnect the HV ancillary harnesses (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab, and then slide open the black lever to remove.
  44. Remove the LH 1st row seat. See Front Seat Assemblies - 1st Row Seat Assembly - LH Drive - LH - Black (Remove and Install).
  45. Remove the LH front floor mat.
  46. Remove the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
  47. Remove the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  48. Remove the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
  49. Remove the accelerator pedal. See Accelerator Pedal (Remove and Install)
  50. Remove the LH carpet support foam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up from rear edge.
  51. Remove the LH front interior HV battery mounting bolts (x3).
    160 Nm (118.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  52. Release the LH MV controller connector locking frame bolt.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  53. Release the edge clips (x2), and then pull from the edges of the connector housing to disconnect the floor harness connector from the LH MV controller.
  54. Remove the RH 1st row seat. See Front Seat Assemblies - 1st Row Seat Assembly - LH Drive - LH - Black (Remove and Install).
  55. Remove the RH front floor mat.
  56. Remove the RH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  57. Remove the center floor trim. See Passenger Compartment Carpet - Center Floor Trim (Remove and Install).
  58. Fold back the RH carpet.
  59. Remove the RH carpet support foam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up from the rear edge.
  60. Remove the RH interior front HV battery mounting bolts (x3).
    160 Nm (118.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  61. Release the RH MV controller connector locking frame bolt, and then release the clips on the top and bottom of the retaining bracket.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  62. Release the edge clips (x2) on the center console VC right super connector, and then pull the from the edge of the connector house to disconnect the connector and ribbon cable.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not pull the ribbon cable.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid bending the ribbon cable at a tight angle.
  63. Removed the center console assembly. See Center Console - Center Console Assembly (Remove and Install).
  64. Release the VC rear super connector retaining frame bolt, and then release the clips (x4) on the top and bottom of the retaining clip bracket.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  65. Pull from the edges of the ribbon cable connector housing to disconnect the ribbon cable.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not pull the ribbon cable.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid bending the ribbon cable at a tight angle.
  66. Remove the nuts (x3) that attach the interior HV harness bulkhead cover to the vehicle, and then remove the cover from the vehicle.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the harness inside once released.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  67. Raise the vehicle fully.
  68. Remove the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
  69. Remove the fasteners (x10) that attach the front skid plate to the vehicle, and then remove the skid plate from the vehicle.
    50 Nm (36.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 11 mm socket
    • 15 mm socket
  70. Position a coolant drain container underneath the RH rear of HV battery.
  71. Release the spring clip. disconnect the RDU return hose from the PT return hose, and then plug the male and female fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the wheel liner back as needed.
  72. Release the spring clip, disconnect the RDU supply hose, and then plug the male and female fittings.
  73. Move the coolant drain container to the front right of the HV battery.
  74. Release the spring clips, disconnect the PT supply and return hoses, and then plug all the fittings.
  75. Release the spring clips, disconnect the battery inlet and outlet coolant hoses, and then plug all the fittings.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use caution with the pick near the HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the coolant drain container as needed.
  76. Remove coolant drain container from underneath the vehicle.
  77. Pull down the red locking tab and disengage the release lever on the AC compressor HV harness connector, disconnect the connector from the HV battery, and then release the harness clips (x4).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the release lever up.
    Informational PurposesAn informational icon, calling your attention
    Note
    Number of connections may vary by vehicle configuration.
  78. Remove the bolt that attaches the FDU HV harness to the vehicle, and then release the connector lock and disconnect the FDU HV harness connector.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the harness clear of the subframe.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  79. Position battery table underneath the vehicle, and then raise the table to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the table is level.
  80. Remove the bolt that attaches the ground strap to the HV battery.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the ground strap is clear of the battery.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  81. Remove the front exterior HV battery mounting bolts (x6).
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  82. Remove the LH and RH side exterior HV battery mounting bolts (x16).
    62 Nm (45.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
  83. Raise the vehicle away from the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure no coolant hoses, harnesses, or brake lines are caught while lifting.
  84. Release the clips (x11) that attach the AC compressor harness to the vehicle, and then remove the harness from the vehicle.
  85. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Position the AC compressor harness into the vehicle, and then install the clips (x11) that attach the harness to the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the harness routing does not cause any pinching or rubbing.
  2. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  3. Install the battery alignment rods (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install and hand-tighten the two larger rods into the front casting. Install the and hand-tighten the two smaller rods into any of the four seat stanchion mounting holes on the HV battery.
  4. With assistance, lower the vehicle onto the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure no coolant hoses, harnesses, or brake lines are caught while lowering.
  5. Install the LH and RH side exterior HV battery mounting bolts (x16).
    62 Nm (45.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
  6. Remove the battery alignment rods (x4).
  7. Install the front exterior HV battery mounting bolts (x6).
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  8. Install the bolt that attaches the ground strap to the HV battery.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  9. Raise vehicle away from battery table
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Ensure lift is lowered onto a lock
  10. Remove the battery table from underneath the vehicle.
  11. Connect the FDU HV harness connector and secure the connector lock, and then install the bolt that attaches the harness to the vehicle.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab engages.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  12. Secure the clips (x3) that attach the HV harness to the HV battery.
  13. Connect the RDU HV harness connector and secure the connector lock, and then install the harness clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the locking tab is engaged.
  14. Connect the AC compressor HV harness connector to the HV battery, and then secure the connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide down the primary lock, and then engage the red secondary lock.
  15. Position the coolant drain container underneath the RH rear of the HV battery.
  16. Remove the hose plugs, connect the RDU return hose to the PT return hose, and then secure the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to verify the hose is fully engaged.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the wheel liner back as needed.
  17. Remove the hose plugs, connect the RDU supply hose, and then secure the spring clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to verify the hose is fully engaged.
  18. Move the coolant drain container to the front right of the HV battery.
  19. Remove the hose plugs, connect the PT supply and return hoses, and then secure the spring clips.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to verify the hoses are fully engaged.
  20. Remove the hose plugs, connect the HV battery inlet and outlet coolant hoses, and then secure the spring clips.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use caution with the pick near the HV harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the coolant drain container as needed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to verify the hoses are fully engaged.
  21. Remove the coolant drain container from underneath the vehicle.
  22. Position the mid aero shield onto the vehicle, and then install the fasteners (x8) and secure the clips (x6) that attach the aero shield to the vehicle.
    70 Nm (51.6 lbs-ft)
    28 Nm (20.6 lbs-ft)
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The 15mm bolts (x3) are torqued to 70 Nm, 13mm bolts (x3) to 28 Nm, and 10mm bolts (x2) to 6 Nm.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 13 mm socket
    • 10 mm socket
  23. Position the front skid plate to the vehicle, and then install the fasteners (x10) that attach the skid plate to the vehicle.
    50 Nm (36.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Both the nuts (x8) and bolts (x2) are torqued to 50 Nm.
    Tip: Use of the following tool(s) is recommended:
    • 11 mm socket
    • 15 mm socket
  24. Install the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
  25. Lower the vehicle until the tires are touching the ground.
  26. Feed the HV harness through the interior bulkhead cover opening, position the bulkhead cover into the vehicle, and then install the nuts (x3) that attach the cover to the vehicle.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the harness inside once released.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  27. Connect the ribbon cable.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push at edges of connector housing.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid bending the ribbon cable at a tight angle.
  28. With all the connectors properly aligned, install the bolt and secure the clips (x4) on the top and bottom of the retaining clip bracket.
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure all the connectors are aligned before tightening the frame bolt.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  29. Connect the cabin floor harness connector and ribbon cable to the RH MV controller.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push from the edges of the connector housing.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid bending the ribbon cable at a tight angle.
  30. With all the connectors properly aligned, install the RH MV controller connector locking frame bolt.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  31. Install the RH interior front HV battery mounting bolts (x3).
    160 Nm (118.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  32. Install the RH carpet support foam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Start from the rear edge.
  33. Unfold the RH front cabin carpet into position.
  34. Position the center floor trim into the vehicle, and then secure the clips (x4) and datums (x3) that attach the trim to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the lower section first, and then secure the upper section.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid bending the trim beyond what is necessary for clearance.
  35. Install the RH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  36. Install the RH front floor mat.
  37. Close the RH front door.
  38. Connect the floor harness connector to the LH MV controller, and then secure the edge clips (x2) on the connector housing.
  39. With the connectors properly aligned, install the LH MV controller connector locking frame bolt.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  40. Install the LH front interior HV battery mounting bolts (x3).
    160 Nm (118.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 24 mm socket
  41. Install the LH carpet support foam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Start from the rear edge.
  42. Install the accelerator pedal. See Accelerator Pedal (Remove and Install)
  43. Unfold the LH front cabin carpet into position.
  44. Install the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
  45. Install the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
  46. Install the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
  47. Install LH front floor mat.
  48. With assistance, position the LH front seat into the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage surrounding components during installation.
  49. Connect the LH front seat electrical connector, engage the black lever, and then engage the yellow locking tab.
  50. Repeat steps GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-2564314F-BBC6-4031-90ED-7D84FA9CA4A4__GUID-24ACFF39-15A0-4E87-9465-986D271F375C and GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-2564314F-BBC6-4031-90ED-7D84FA9CA4A4__GUID-6146396D-4A62-44B7-BF1B-44FE09734BAB for the RH front seat.
  51. Clean the HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with Penetrox applied to HV connector.
  52. Clean the busbar HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean HV connector during re-use of busbar.
  53. Apply 2 drops of Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Drops of Penetrox should be approximately 5mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  54. Install the HV connector onto the DC FC header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  55. Connect the HV ancillary harnesses (x2), and then secure the connector locks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the black lever to engage, and then push in the red locking tab.
  56. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    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
  57. Put on HV insulating gloves and leather over gloves.
  58. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usage The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. 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
  59. Remove leather over gloves and HV insulating gloves.
  60. Install the bolt that attaches the busbar HV connector lid to the connector.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  61. Connect the ancillary bay MV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connector is double locking. Rotate the lever into 2nd lock. Perform a pull test to ensure the connector is fully engaged.
  62. Connect the AC Compressor HV harness to the AC Compressor, and then secure the connector lock.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the black lever down, and then push the red lock inwards.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the red locking tab is pushed all the way in. The red locking tab should sit flush with the black lever.
    Figure 2. Red locking tab is flush with black lever
    Figure 3. Red locking tab is not fully engaged
  63. Perform coolant system vacuum fill. See Cooling System (Vacuum Refill).
  64. Reconnect MV power. See Disconnect MV Power.
  65. On the vehicle touchscreen, tap Stop Thermal Fill Drain and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the routine is successful.
  66. Tap Start Coolant Air Purge.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait until the coolant pumps stop running (audible noise). "Routine Passed" will appear, but the pumps will run for 10 minutes. Make sure vehicle is not in "Drive". 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.
  67. Install the frunk assembly. See Frunk Assembly (Remove and Install).
  68. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  69. Install the bolts (x4) that attach the HV battery to the RUB.
    115 Nm (84.8 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Break the bolts free before using power tools.
    Informational PurposesAn informational icon, calling your attention
    Note
    The tonneau must be closed to access the forward bolts.
    Tip: Use of the following tool(s) is recommended:
    • 21 mm socket
    Figure 4. Bolts shown without tonneau cover for clarity
  70. Placeholder - Install the tonneau NVH cover.
  71. Open the tonneau cover.
  72. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  73. Remove the Universal Lift Pad adapters.
  74. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  75. Install the RH front seat. See Front Seat Assemblies - 1st Row Seat Assembly - LH Drive - LH - Black (Remove and Install).
  76. Install the RH rear interior HV battery mounting bolts (x4).
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on both sides of the stanchion.
    Informational PurposesAn informational icon, calling your attention
    Note
    Both 15 mm and 18 mm bolts are torqued to 62 Nm.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 18 mm socket
  77. Position the RH subwoofer assembly into the vehicle, slide the subwoofer to the RH side of the vehicle to secure it, connect the electrical connector and engage the connector lock, and then install the bolts (x2) that attach the subwoofer to the vehicle.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  78. Install the RH Lower A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  79. Install the RH mid A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  80. Install the LH front seat. See Front Seat Assemblies - 1st Row Seat Assembly - LH Drive - LH - Black (Remove and Install).
  81. Install the LH rear interior HV battery mounting bolts (x4).
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are located on both sides of the stanchion.
    Informational PurposesAn informational icon, calling your attention
    Note
    Both 15 mm and 18 mm bolts are torqued to 62 Nm.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • 18 mm socket
  82. Install the LH C-pillar subwoofer. See Audio Speakers - 200mm, Woofer, LH, C-Pillar, Audio (Remove and Install).
  83. Secure the clip and datum that attach the LH lower C-pillar trim to the vehicle. Repeat this step for RH lower C-pillar trim.
    Figure 5. LH shown; RH similar
  84. Fold down the 2nd row seat cushions.
  85. Install 2nd row floor mat
  86. Install the LH Lower A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
  87. Install the LH mid A-pillar trim. See A-B-C Positivet Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
  88. Position the LH front rocker step reinforcement to the vehicle, and then install the bolts (x3) that attach the reinforcement to the vehicle.
    15 Nm (11.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  89. Install the LH rear rocker step reinforcement. See Rocker Panel Trim - Rear Rocker Step Reinforcement - LH (Remove and Install).
  90. Install the LH rocker assembly. See Rocker Panel Trim - Rocker Assembly - LH (Remove and Install).
  91. Repeat step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-2564314F-BBC6-4031-90ED-7D84FA9CA4A4__GUID-3E166971-A111-4D23-9117-02D846C3C63B through step GUID-D6F2FED3-46D3-4915-8D55-C47633D5739C.html#GUID-2564314F-BBC6-4031-90ED-7D84FA9CA4A4__GUID-09965776-E5FE-448E-94D0-DEC0C5DCA6D6 for the RH side of the vehicle.
  92. Exit Service Mode. See Service Mode.
  93. Raise all the windows and close all the doors.