23/07/2024 17:25:27

Ancillary Components - Last Mile Busbar Assembly (Remove and Install)

Correction code 1630010151 1630010152 FRT 3.24 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.

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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.
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Warning
Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.
  1. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Set air suspension to "Jack Mode"
  2. Place vehicle in service mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Via UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
  3. Unlock vehicle gateway
    Informational PurposesAn informational icon, calling your attention
    Note
    After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
  4. Access thermal system routines using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select quick controls > Service mode > Thermal > Actions
  5. Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAINSearch for routine in ToolboxStart Thermal Fluid Fill/DrainDrive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/DrainThermal ➜ Actions ➜ Start Thermal Fill/DrainThermal ➜ Coolant System ➜ Start Coolant Fill/DrainThermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain-COOLANT window will appear, Select 'Run'
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
  6. Remove bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
  7. Release RH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 5 Nm, 2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal
  8. Remove RH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Release rearward then slide over LH side NVH cover before removing upward
  9. Release LH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 5 Nm
  10. Remove LH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
  11. Remove tonneau coverbox cross supports
    Informational PurposesAn informational icon, calling your attention
    Note
    8x screws, T25, 5 Nm
  12. Clean all debris from ancillary cover
    Informational PurposesAn informational icon, calling your attention
    Note
    During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay
  13. Release pressurized pack air line to Ancillary
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.
  14. Remove VOSS fitting from pressurized pack air line to Ancillary
    Informational PurposesAn informational icon, calling your attention
    Note
    1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
  15. Release pressurized pack valve block from air suspension reservoir
    Informational PurposesAn informational icon, calling your attention
    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
  16. Release air suspension valve block
    Informational PurposesAn informational icon, calling your attention
    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
  17. Release air suspension reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 33 Nm, 2x fir tree clips
  18. Place air suspension reservoir in service position then install Ancillary Access Bench
    Informational PurposesAn informational icon, calling your attention
    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
  19. Open powered front trunk
    Informational PurposesAn informational icon, calling your attention
    Note
    Via exterior switch or UI
  20. Power down vehicle via UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
  21. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips
  22. Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release
    Informational PurposesAn informational icon, calling your attention
    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
  23. Verify operation of multimeter
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
  24. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  25. Remove Mid-aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  26. Disconnect pressurized pack lines
    Informational PurposesAn informational icon, calling your attention
    Note
    2x VOSS fittings, 12mm, 8Nm, Discard and replace
  27. Remove VOSS fitting from pressurized pack air lines
    Informational PurposesAn informational icon, calling your attention
    Note
    2x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
  28. Position coolant drain container underneath RH rear of HV battery
  29. Disconnect rear PT supply and RDU supply hoses
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clip, Plug hoses immediately to prevent excess coolant loss, Allow PCS coolant to drain as much as possible before plugging
  30. Release PCS coolant header from ancillary floor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 6Nm
  31. Remove coolant drain container from underneath vehicle
  32. Remove all items from pockets and ensure not wearing metal items
  33. 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
  34. Put on HV insulating gloves and leather over gloves
  35. Verify no HV - Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    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
  36. Remove Pyro Fuse Access cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E-Torx 5 lobe, 10 Nm
  37. Remove primary pyro fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
  38. Remove secondary pyro fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
  39. Release connectors at 2x4 header (AC compressor and Charger headers)
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Fully release red lock tab, Pull black latch down to release connector
  40. Release 2x4 header assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 5-lobe 10mm, 6 Nm
  41. Release drive unit connectors from ancillary headers
    Informational PurposesAn informational icon, calling your attention
    Note
    3x connectors, Release blue lock tab, Rotate black latch
  42. Remove bolts securing HC-Stak HV Headers for LHRDU, FDU, RHRDU from ancillary flange
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 5-lobe 10mm, 10 Nm
  43. Remove LHRDU, FDU, RHRDU headers from ancillary flange
    Informational PurposesAn informational icon, calling your attention
    Note
    3x headers, No tools required, inspect header seals, Replace header if damaged
  44. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  45. Disconnect ancillary bay MV connector
    Informational PurposesAn informational icon, calling your attention
    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
  46. Remove bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 9 Nm
  47. Remove bolts securing HV connector to DC FC header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  48. Release HV connector from DC FC header
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
  49. Support HV Busbar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Suspend assembly to maintain clearance
  50. Remove fast charger header doubler
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5 Lobe Torx, 10 Nm
  51. Release low voltage header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  52. Release fasteners securing ancillary cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    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
  53. Remove ancillary cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Use suction cup and maneuver around busbar and tonneau cage
  54. Remove DC header
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide header off DC bus links, Inspect seal, Replace header if damaged
  55. Disconnect PCS MV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Slide red lock off of lever, Rotate lever to release connector
  56. Release PCS MV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm, 1x clip
  57. Release MV header
    Informational PurposesAn informational icon, calling your attention
    Note
    4x datums, 1x edge clip, 1x fir tree clip
  58. Release HVC connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harnessIf RTV is present at 2 connectors, using a ceramic knife cut through and remove RTV until connector can be disconnected
  59. Release BMB passthrough connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness
  60. Release ACJB LV connector & ACJB to device cluster HV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness
  61. Remove MV ancillary harness
  62. Release HVC harness from PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connectors, Release connector lock, Depress lever and pull at connector, Do not pull at harness
  63. Release device cluster busbar fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
  64. Remove device cluster assembly fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10 5 Lobe Torx, 6Nm
  65. Remove device cluster from ancillary tray
    Informational PurposesAn informational icon, calling your attention
    Note
    Place device cluster on stand to protect headers at bottom of assembly, Remove lifting/install tool, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component
  66. Release PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    6x captured bolts, 8mm, 6Nm
  67. Remove PCS from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x suction cup, Secure suction cup to center of PCS, Remove PCS with coolant hoses attached and plugs secured at header
  68. Remove last mile busbar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees
  69. Install last mile busbar assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 10 Nm, 3x captive bolts, T55, 5 Nm + 60 degrees
  70. Install PCS to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x suction cup, Secure suction cup to center of PCS, Install PCS with coolant hoses attached and plugs secured at header
  71. Secure PCS to ancillary
    Informational PurposesAn informational icon, calling your attention
    Note
    6x captured bolts, 8mm, 6Nm
  72. Install device cluster to ancillary tray
    Informational PurposesAn informational icon, calling your attention
    Note
    Align datums and headers to ancillary and slowly lower into place, Avoid contact of drive unit headers to ancillary tray, Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component
  73. Secure device cluster assembly fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10 5 Lobe Torx, 6Nm
  74. Secure device cluster busbar fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Captured bolts with insulated covers
  75. Perform Hioki measurements from device cluster assembly and busbar bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolts, E10 5 Lobe Torx, 6Nm, 4x bolts, Torx Plus 55, 5Nm + 60 Degrees, Perform zero adjust to Hioki meter prior to testingUse diagram in images to find probing locations and the reading specifications to look forLSL means: Lower Specification LimitUSL means: Upper Specification Limit1020_301 | T1 LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1020_304 | POS Contactor LSL 0.002 mΩ (2 μΩ) - USL 0.05 mΩ (50 μΩ)1010_603 | HVC Ground strap LSL 0.35 mΩ (350 μΩ) - USL 0.78 mΩ (780 μΩ)1020_303 | Shunt2 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)1020_302 | Shunt1 LSL 0.003 mΩ (3 μΩ) - USL 0.05 mΩ (50 μΩ)If readings are lower than the LSL numbers you are not probing correctlyIf readings are higher than USL numbers you have bolts that are not torqued correctly or connectors that may be softset or have internal connector issues
  76. Secure HVC harness to PCS
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connectors, Secure connector lock
  77. Poistion MV ancillary harness for install
  78. Secure ACJB LV and HV connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x connectors, Secure connector locks
  79. Secure BMB passthrough connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure connector locks, Connectors are poke yoked do not force engagement, Ensure locking tabs are facing front of vehicle when connecting
  80. Secure HVC connectors
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 3x connectors, Release connector locks, Depress levers and pull at connector, Do not pull from harness, Apply sealant to connectors at device cluster if it was present during disassembly
  81. Secure MV header
    Informational PurposesAn informational icon, calling your attention
    Note
    4x datums, 1x edge clip, 1x fir tree clip
  82. Secure PCS MV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, E10 5 Lobe, 6 Nm, 1x clip
  83. Connect PCS MV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, PCS header not datumed, Ensure correct orientation and polarity of connection, Harness color red for LV+ and black for LV-, Swing down locking lever, Slide lock fully to engage on top of lever
  84. Install DC header
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide header on to DC bus links, Inspect seal, Replace header if damaged
  85. Install ancillary cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Use suction cup and maneuver around busbar and tonneau cage
  86. Secure fasteners of cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    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
  87. Secure low voltage header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  88. Secure fast charger header doubler
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, E10 5 Lobe Torx, 10Nm
  89. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  90. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  91. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    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
  92. Position busbar connector and lower onto HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Release bungee cord
  93. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  94. 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 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
  95. Install bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, EP10, 9 Nm
  96. Remove leather over gloves and HV insulating gloves
  97. Connect Ancillary bay MV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
  98. Secure tonneau coverbox cross supports
    Informational PurposesAn informational icon, calling your attention
    Note
    8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners
  99. Install LH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure busbar clearance during install to avoid damage to NVH material
  100. Secure LH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    5x bolts, 10mm, 5 Nm
  101. Install RH tonneau NVH cover
  102. Secure RH tonneau NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 5 Nm
  103. Remove Ancillary Access Bench then place air suspension reservoir into position for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure air lines are not twisted, Ensure no harnesses are caught
  104. Secure air suspension reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 33 Nm, 2x fir tree clips
  105. Secure air suspension valve block
    Informational PurposesAn informational icon, calling your attention
    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
  106. Install new VOSS air fitting to pressurized pack valve block at ANC circuit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed
  107. Secure pressurized pack air line from Ancillary to valve block
    Informational PurposesAn informational icon, calling your attention
    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
  108. Secure pressurized pack valve block to air suspension reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Secure reservoir and ancillary air lines at white marked sections
  109. Install bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
  110. Raise vehicle fully
  111. Secure PCS coolant header to ancillary floor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 6Nm
  112. Position coolant drain container underneath RH rear of HV battery
  113. Remove one PCS coolant header plugs & connect leak test adapters
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clips, Leave coolant plugs in supply and return lines, Secure NW22 plug to either coolant header port (Item 6 of kit), Combine NW18 Male testing Couple (Item 5 of kit) to Adapter NW18 180° (Item 1 of kit) and secure to other coolant header port
  114. Attach coolant pressure tester to pressure fitting adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Confirm hose is securely screwed tight
  115. Attach coolant pressure tester to compressed air line
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure valves are closed on pressure regulator
  116. Open the regulator valve then slowly adjust regulator to 50 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as coolant may spill, Make sure to wear safety glasses
  117. Open 2nd valve slowly
    Informational PurposesAn informational icon, calling your attention
    Note
    Slowly open valve on pressure regulator and allow pressure to reach specification
  118. Close the valve and let pressure settle
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait 2 minutes for pressure to settle, Record the reading
  119. Set timer for 2 minutes and select start
    Informational PurposesAn informational icon, calling your attention
    Note
    Once timer is complete, select Stop Reset
  120. Perform the coolant pressure leak test
    Informational PurposesAn informational icon, calling your attention
    Note
    Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
  121. Close both valves
  122. Remove coolant pressure tester from pressure fitting adapter
  123. Remove coolant pressure tester adapter from PCS coolant header
  124. Secure rear PT supply and RDU supply hoses to PCS coolant header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x spring clip, Make sure the locking tabs are fully seated, Perform push-pull-push test
  125. Remove coolant drain container from underneath vehicle
  126. 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
  127. Put on HV insulating gloves and leather over gloves
  128. Install LHRDU, FDU, RHRDU headers to ancillary flange
    Informational PurposesAn informational icon, calling your attention
    Note
    3x headers, No tools required, inspect header seals, Replace header if damaged
  129. Secure bolts to HC-Stak HV Headers for LHRDU, FDU, RHRDU to ancillary flange
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 5-lobe 10mm, 10 Nm
  130. Secure 2x4 header assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 5-lobe 10mm, 6 Nm, Confirm alignment of assembly with fastener openings
  131. Secure connectors at 2x4 header (AC compressor and Charger headers)
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Fully engage red lock tab
  132. Secure drive unit connectors to ancillary headers
    Informational PurposesAn informational icon, calling your attention
    Note
    3x connectors, Rotate black latch, Ensure blue locking tab is fully engaged
  133. Install secondary pyro fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
  134. Install primary pyro fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
  135. Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar
    Informational PurposesAn informational icon, calling your attention
    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
  136. Remove leather over gloves and HV insulating gloves
  137. Install Pyro Fuse Access cover
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged
  138. Install pressurized pack lines
    Informational PurposesAn informational icon, calling your attention
    Note
    2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings, Install new VOSS fittings if re-using 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
  139. Install Mid-aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  140. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  141. Remove coolant bottle cap
  142. Install vacuum refill cap onto coolant bottle assembly
  143. Place empty coolant container into front storage area
    Informational PurposesAn informational icon, calling your attention
    Note
    If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
  144. Fill container with at least 15L of coolant
  145. Place filled coolant container onto coolant drain & fill cart
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
  146. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  147. Install vacuum refill hose to refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  148. Position overflow hose into empty container
  149. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  150. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  151. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  152. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  153. Once the gauge reads zero, close the coolant refill valve
  154. Remove shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  155. Remove coolant refill hose from coolant container
  156. Remove coolant overflow hose from coolant container
  157. Remove vacuum refill hose from refill cap on coolant bottle
  158. Remove vacuum refill cap from coolant bottle assembly
  159. Remove coolant refill tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Move coolant drain & fill cart away from vehicle
  160. Remove coolant container from inside underhood area
  161. Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement
    Informational PurposesAn informational icon, calling your attention
    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
  162. Select "Stop Thermal Fill Drain" through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete, ensure routine is successful
  163. Select "Start Coolant Air Purge" using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
  164. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  165. Install coolant bottle cap
  166. Perform Thermal Performance through the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
  167. Exit Service Mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Via UI > Service > Exit, Press and hold "Exit Service Mode" button
  168. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, Adjust windshield seal as required
  169. Close powered front trunk
    Informational PurposesAn informational icon, calling your attention
    Note
    Via exterior switch or UI
  170. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"