2025-08-11

HV Battery (AWD) (Remove and Install)

Correction code 16010201 FRT 6.55 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.

2025-08-11: Updated entire procedure to latest validation.
2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
2024-09-18: Updated to latest time study.
2024-08-20: Added steps to install backbone harness guide if the guide is not present.
2024-08-09: Added PN of anti-abrasion tape.
2024-07-15: Updated rear interior HV battery bolt steps: in addition to the 13 mm bolts, some vehicles might also have 15 mm bolts.
2024-06-10: Updated entire procedure according to latest time study.

Warning

DO NOT SKIP the steps to remove the tonneau slats. Work on or around the ancillary bay REQUIRES the removal of the tonneau slats. Failure to remove the tonneau slats while working on or around the ancillary bay will result in conditions that may cause personal injury.

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.

Special tools required for this procedure:

1134523-00-B - Battery Alignment Rods
1065131-00-A - Battery Coolant Drain Kit
1135762-00-A - Coolant Hose Plug Kit
1080568-00-A - Fluid Catcher
1076927-00-A - Hioki tester
1020566-00-F - HV Battery Table
1076928-00-A - Test Probes - Hioki 9461
1936724-00-A - Universal Lift Pad adapters
1050448-00-B - Vacuum Refill Tool
1479505-00-A - Vacuum Fill Adapter -
1879451-99-A - LV ABRASION STICKER,XM,HVB,CTSB

Remove

Open all the doors and lower all the windows.
Use a pocket screwdriver to manually latch all the doors to prevent lockout.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
Open the tailgate.
Open the tonneau cover.
Release LH sail applique

Note
6x tabs, Release rear portion of LH sail applique and support with inflatable airbag
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
6x tabs, Release rear portion of RH sail applique and support with inflatable airbag
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
Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Toolbox: (link)via Service Mode: Closures ➜ Tonneau ➜ Calibrate Tonneau
Release tonneau chain from motors

Note
Recommend assistance, Press close button until both motors have audibly released all links, Frame TPN: 1999662-00-A
Manually guide remaining tonneau slats and chain out of bed rails

Note
Recommend assistance, 2x pins, Remove pins then move powertrain table away from vehicle and guide slats out, Frame TPN: 1999662-00-A
Move vehicle onto lift

Note
Ensure positioning allows rear doors to open
Move the LH front seat fully rearward.
Remove bolts securing front of LH front seat tracks to risers

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Move the LH front seat fully forward.
Remove bolts securing rear of LH front seat tracks to the floor panel

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Adjust position of LH front seat for easy removal

Note
Move seat to middle of track at most upright position with seat fully up off floor
Move the RH front seat fully rearward.
Remove bolts securing front of RH front seat tracks to risers

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Move the RH front seat fully forward.
Remove bolts securing rear of RH front seat tracks to the floor panel

Note
2x patch bolts, T45P, 34 Nm, Discard after removal
Adjust position of RH front seat for easy removal

Note
Move seat to middle of track at most upright position with seat fully up off floor
Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT
via Toolbox: (link)via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
window will appear, Select 'Run'
Note
Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
Open the powered frunk.
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
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Remove front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Remove rear skid plate

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
Verify no HV - Install amp clamp to RDU HV harness

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
Remove leather over gloves and HV insulating gloves
Disconnect EPB harness connector from LH rear brake caliper

Note
1x connector, Release locking tab
Release the LH rear parking brake with EPB release tool

Note
1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete
Connect LH rear EPB harness

Note
1x connector, Engage locking tab
Disconnect RH rear EPB harness

Note
1x connector, Release locking tab
Release the RH rear parking brake with EPB release tool

Note
1x connector, Connect EPB release tool to brake caliper then press release button to disengage park brake, Disconnect EPB release tool once complete
Connect RH rear EPB harness

Note
1x connector, Engage locking tab
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
Position wheel chocks fore and aft of RH rear wheel
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle,
Roll vehicle rearward

Note
Position vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position
Release LH front seat belt from pretensioner

Note
Unlock the linkage by rotating the lock screw counterclockwiseA light audible click will be heard, and the screw should remain horizontalDo not rotate clockwise to avoid damage to the mechanism
Disconnect LH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove LH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Release RH front seat belt from pretensioner

Note
Unlock the linkage by rotating the lock screw counterclockwise A light audible click will be heard, and the screw should remain horizontal Do not rotate clockwise to avoid damage to the mechanism
Disconnect RH seat

Note
1x connector, 2 stage locking tab, Release yellow locking tab, then release black lever to disconnect
Remove RH front seat from vehicle

Note
Recommend assistance, Use caution to not damage other components, Lift seat off risers, Rotate sideways and remove out back door opening
Remove center console front panel

Note
10x clips
Release HV outlet from front console panel

Note
2x screws, T20, 1 Nm, 1x clip
Remove front bolts securing center console to riser

Note
4x bolts, 10mm, 5 Nm
Disconnect center console harness connectors

Note
2x connectors
Remove center console back panel

Note
10x clips, 3x connectors, 3x harness clips
Remove rear bolts securing center console to riser

Note
2x bolts, 10mm, 5 Nm
Remove center console

Note
Lift up to release from riser
Remove RH outboard riser bolt cover

Note
Lift from outer edge then pull away
Remove RH seat riser assembly from vehicle

Note
4x bolts, 13mm, 40 Nm, 2x clips, release cabin MV harness and air duct from riser assembly
Remove LH outboard riser bolt cover

Note
Lift from outer edge then pull away
Remove LH seat riser assembly from vehicle

Note
4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, release cabin HV outlet harness, and air duct from riser assembly
Remove footwell cover

Note
3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether
Remove LH front floor mat
Remove LH mid A-pillar trim

Note
1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
Remove LH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Remove LH center floor rail

Note
4x clips, 3x datums, Pull upwards to release
Remove accelerator pedal side trim

Note
3x clips, Lift from forward edge then slide over accelerator pedal
Remove accelerator pedal

Note
2x nuts, 13mm, 10 Nm, 1x connector, Release locking tab
Fold back LH front cabin carpet
Remove LH carpet support foam

Note
Lift up from rear edge
Remove LH front interior HV Battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Remove RH front floor mat
Remove RH mid A-pillar trim

Note
1x clip, 3x tabs, Release tabs then slightly bend live hinge and release clip
Remove RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Release sill plate, Pull rearward then upward
Remove RH center floor rail

Note
4x clips, 3x datums, Pull upwards to release
Remove center floor trim

Note
17x clips, Release upper section first
Fold back RH carpet

Note
8x clips, 4x datums
Remove RH carpet support foam

Note
Lift up from rear edge
Remove RH interior front HV battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Fold up 2nd row 60 seat

Note
Pull tether to release then lift up until locked in place
Remove 2nd row floor mat
Partially release LH lower C-pillar trim

Note
1x clip, 1x datum
Fold up 2nd row 40 seat

Note
Pull tether to release then lift up until locked in place
Partially release RH lower C-pillar trim

Note
1x clip, 1x datum
Remove rear wall lower trim

Note
2x push clips, 4x clips, Remove outermost push clips, then pull straight forward to release inner clips
Remove LH rear carpet duct bezel

Note
4x clips
Remove rear carpet RH duct bezel

Note
4x clips
Release HV cabin outlets harness from foam

Note
Slide outwards out of groove
Remove rear carpet assembly

Note
4x clips, 17x stands, 6x datums, Release stands around LH and RH floor ducts then release stands at center console, Fold back carpet and stands from forward edge, Fold rear carpet and foam forwards then pull center of carpet and foam upwards to remove, Remove clips if they remain on pack side
Remove RH subwoofer

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards center of vehicle to release outer port from body
Remove RH rear interior HV battery mounting bolts

Note
4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
Remove LH subwoofer

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards RH of vehicle to release outer port from body, Release locking tab
Remove LH rear interior HV battery mounting bolts

Note
4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
Remove interior HV harness bulkhead cover

Note
3x nuts, 10mm, 9 Nm
Release LH MV controller dry side locking cover

Note
1x bolt, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover are fully released before attempting to release any MV connectors, Plastic Locking CoverUse hand tools on any plastic locking covers, The locking cover may release crooked causing it to get stuck, secure bolt a few turns to loosen the tension then release bolt while assisting plastic locking cover by gently prying on the side that's stuck, Metal Locking CoverYou can use power tools, Quickly disconnecting locking cover helps connectors remove symmetrically, Video uses rear controller for demonstration purposes only
Release floor harness from LH MV controller

Note
1x connector, 1x clip, Depress tabs to release connector housing from locking cover
Release RH MV controller connector lower locking cover

Note
1x bolt, 8mm, 6 Nm, Do not remove locking covers, Loosen until bolts spins freely, Double check that bolts and locking covers are fully released before attempting to release any MV connectorsPlastic Locking Cover Use hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, secure bolts a few turns to loosen the tension then release bolts while assisting plastic locking covers by gently prying on the stuck sidesMetal Locking Cover You can use power tools, Quickly disconnecting locking covers helps connectors remove symmetrically
Release cabin floor and backbone harnesses from RH MV controller

Note
1x connector, 1x backbone cable, 2x edge clips, 3x harness clips, Pull from edges of connector housing, Do not pull backbone cable, Avoid bending cable at a tight radius
Disconnect rear display connector from car computer

Note
1x connector
Release front section of backbone

Note
3x harness clips, Pass connector under cabin floor harness
Disconnect backbone harness from rear MV controller

Note
1x connector, 1x bolts, 8mm, 6 Nm, Do not remove locking cover, Loosen until bolt spins freely, Double check that bolt and locking cover has fully released before attempting to release any MV connectors, Depress tabs on connector housing to releasePlastic Locking CoverUse hand tools on any plastic locking covers, The locking covers may release crooked causing them to get stuck, Thread bolt a few turns to avoid damage then gently pry stuck edges of locking coverMetal Locking CoverYou can use power tools, Quickly disconnecting locking covers helps connectors release evenly
Partially release aft section of LH front fender flare cover

Note
11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
Remove LH front rocker fastener from step reinforcement

Note
1x bolt, 10mm, 4 Nm
Remove clip securing LH front wheel liner to rocker cover

Note
1x clip
Partially release fore section of LH rear fender flare cover

Note
13x clips, 3x datums total, Release as needed for clearance, Full removal not required
Remove LH rear rocker fastener from step reinforcement

Note
1x bolt, 10mm, 4 Nm
Remove clip securing LH rocker cover to rear wheel liner

Note
1x clip
Remove rocker cover fasteners from LH side ski

Note
6x bolts, 10mm, 10 Nm
Release LH rocker cover from rocker carrier

Note
11x clips, 1x datum, Remove any clips that remained on carrier
Remove front LH rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm, 2x datums
Remove rear LH rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm
Partially release aft section of front RH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Release as needed for clearance, Full removal not required
Remove RH front rocker fastener from step reinforcement

Note
1x bolt, 10mm, 4 Nm
Remove clip securing RH rocker cover to front wheel liner

Note
1x clip
Partially release fore section of rear RH fender flare cover

Note
13x clips, 3x datums total, Release as needed for clearance, Full removal not required
Remove RH rear rocker fastener from step reinforcement

Note
1x bolt, 10mm, 4 Nm
Remove clip securing RH rocker cover to rear wheel liner

Note
1x clip
Remove rocker cover fasteners from RH side ski

Note
6x bolts, 10mm, 10 Nm
Release RH rocker cover from rocker carrier

Note
11x clips, 1x datum, Remove any clips that remained on carrier
Remove front RH rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm, 2x datums
Remove rear RH rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm
Roll vehicle forward

Note
Remove fore wheel chock, Move vehicle to position necessary to place onto lift
Move vehicle onto lift

Note
Ensure positioning allows rear doors to open
Install Universal Lift Pad adapters

Note
4x Adapters, Remove original lift pads from lift arms then install respective adapter, Remove plugs from BIW holes, Align pins with lift point holes on body
Raise and support vehicle

Note
Set air suspension to "Jack Mode", Align lift adapter pins with lift point holes on body
Remove fastener covers from bed floor assembly

Note
6x covers
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 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
Remove bolts securing HV battery to RUB

Note
4x bolts, 21mm, 119 Nm, Break free before using power tools, Tonneau slats must be closed or removed to access forward bolts, Shown without tonneau for clarity
Disconnect ancillary bay MV connector

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
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
Support HV Busbar assembly

Note
Suspend assembly to maintain clearance
Disconnect HV ancillary harnesses

Note
2x connectors, Release red locking tab then slide open black lever to remove, Push cabin harness into interior
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Position coolant drain container underneath RH rear of HV battery
Remove RH rear wheel

Note
6x nuts, 21mm, 205 Nm
Secure RH rear wheel liner aside
Disconnect RDU return hose from PT return hose

Note
1x spring clip, 1x clamp clip, Move wheel liner aside as needed, Plug coolant connections as needed
Disconnect RDU supply hose

Note
1x spring clip, Plug hoses
Move coolant drain container to front right of HV battery
Remove RH front wheel

Note
6x nuts, 21mm, 205 Nm
Secure RH front wheel liner aside
Disconnect PT supply and return hoses

Note
2x spring clips, Plug hoses
Disconnect battery coolant supply and return hoses

Note
2x spring clips, Use caution with pick near HV harness, Plug Hoses, Position coolant drain as needed
Remove coolant drain container from underneath vehicle
Disconnect pressurized pack lines

Note
2x VOSS fittings, 12mm, 8Nm
Release clips securing LH pressurized pack line

Note
3x clips
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
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
Release FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Move harness clear of subframe
Position battery table

Note
Ensure table is level
Remove front exterior HV Battery mounting bolts and ground strap

Note
6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm, Ensure ground strap is clear of battery
Remove side exterior HV battery mounting bolts from LH and RH side

Note
16x bolts, 15mm, 62 Nm
Raise vehicle away from HV battery

Note
Ensure no coolant hoses, harnesses, or brake lines are caught while lifting, If lift is shorter then remove rear wheels as needed
Remove HV battery from underneath vehicle

Note
Recommend assistance
Install HV battery alignment rods

Note
4x alignment rods, Hand tight, Install 2x larger rods onto front casting, Install 2x smaller rods onto seat stancion mounting holes on pack, New battery packs may not yet have threads in the required holes. Suggest installing bolt to create threads prior to rod installation, It is not recommended to use any holes other than instructed
Position HV battery beneath vehicle

Note
Recommend assistance
Lower vehicle onto HV battery

Note
Ensure no coolant hoses, harnesses, or brake lines are caught while lowering, Recommend assistance to ensure good alignment whilst lowering
Install side exterior HV battery mounting bolts to LH and RH side

Note
16x bolts, 15mm, 60 Nm
Install front exterior HV Battery mounting bolts and ground strap

Note
6x bolts, 18mm, 115 Nm, 1x bolt, 10mm, 10 Nm
Raise vehicle away from battery table

Note
Set to a comfortable working height, Ensure lift is lowered onto a lock
Remove battery table from under vehicle
Remove HV battery alignment rods from front casting

Note
2x alignment rods
Install FDU HV harness

Note
1x connector, 1x bolt, 10mm, 10 Nm, Ensure locking tab engages
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
Install RDU HV harness

Note
1x connector, 1x harness clip, Ensure locking tab is engaged
Install clips securing pressurized pack line

Note
3x clips
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
Position coolant drain container underneath RH rear of HV battery
Connect RDU return hose to PT return hose

Note
1x spring clip, Remove coolant plugs, Pull back wheel liner as required, Perform a push-pull-push test to ensure hose is engaged
Connect RDU supply hose

Note
1x spring clip, Remove coolant plugs, Perform a push-pull-push test to ensure hose is engaged
Move coolant drain container to front right of HV battery
Connect PT supply and return hoses

Note
2x spring clips, Remove plugs, Perform a push-pull-push test to ensure hose is engaged
Connect battery supply and return coolant hoses

Note
2x edge clips, 2x spring clips, Remove plugs, Secure edge clips to casting, Perform a push-pull-push test to ensure hose is engaged
Remove coolant drain container from underneath vehicle
Install Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Install front skid plate

Note
8x nuts, 15mm, 50 Nm, 2x bolts, 11mm, 50 Nm
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Install RH front wheel

Note
6x nuts, 21mm, 205 Nm
Install RH rear wheel

Note
6x nuts, 21mm, 205 Nm
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
Torque RH front wheel nuts

Note
6x nuts, 21mm, 205 Nm
Torque RH rear wheel nuts

Note
6x nuts, 21mm, 205 Nm
Install bolts securing HV battery to RUB

Note
4x bolts, 21mm, 115 Nm, Tonneau must be closed or removed to access forward bolts, Shown without tonneau for clarity
Clean HV connector contact surface of residual Penetrox

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
Install busbar onto HV header and install bolts

Note
2x bolts, 10mm, 9 Nm
Connect HV ancillary harnesses

Note
2x connectors, Pull through rear wall opening, Slide black lever to engage then push in red locking tab
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
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
Remove leather over gloves and HV insulating gloves
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
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
Install forward bed panel

Note
6x bolts, 15mm, 85 Nm, Recommend assistance to lift panel into bed
Install fastener covers to forward bed panel

Note
6x covers
Position wheel chocks fore and aft of RH rear wheel
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle,
Roll vehicle rearward

Note
Position vehicle so front doors can be fully opened, Chock wheels once vehicle is in desired position
Inspect for presence of backbone harness guide at front casting

Note
Ensure backbone harness guide is installed, If backbone harness guide not installed refer to: https://pds.tesla.com/pdsui/procedure/edit/6662075b96d4ad4adcc17441Add correction code: PLACEHOLDER for https://pds.tesla.com/pdsui/procedure/edit/6662075b96d4ad4adcc17441
Secure front section of backbone

Note
3x clips, Route connector under cabin floor harness
Inspect for any misalignment at rear ribs and apply abrasion tape if missing

Note
Ensure cable is lying flat without twist, Ensure cable is secured correctly to rib, Apply surface protection at seam of rearmost rib under backbone cable if missing
Connect backbone harness to rear MV controller

Note
1x connector, 1x bolt, 8mm, 6 Nm, Push backbone connector housing into plastic locking cover, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors too while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt are seated fully
Connect rear display connector to car computer

Note
1x connector
Secure cabin floor and backbone harnesses onto RH MV controller

Note
1x connector, 1x backbone cable, 2x edge clips, 3x harness clips, Push from edges of connector housing, Avoid bending ribbon cable at a tight radius
Secure RH MV controller connector locking cover

Note
1x bolt, 8mm, 6 Nm, Ensure connector housing is secured to locking frame with a push-pull-push test, Ensure connectors are aligned before securing bracket, Secure locking cover bolt by hand initially to prevent thread stripping Plastic Locking Cover Use hand tools on any plastic locking covers, The locking cover may secure crooked causing it to get stuck, release bolt a few turns to loosen the tension then secure bolt while assist plastic locking cover by gently pushing on the side that's stuck, Push connectors while driving the locking cover bolt to ensure correct seating Metal Locking Cover You can use power tools, Slowly drive locking cover, Ensure locking cover and bolt
Secure floor harness onto LH MV controller

Note
1x connector, 1x clip, Secure in locking cover
Secure left MV controller connector locking frame

Note
1x bolt, 8mm, 4 Nm, Ensure connectors are aligned before tightening center bolt
Install RH interior front HV battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Install RH carpet support foam

Note
Seat at rear edge
Install LH front interior HV Battery mounting bolts

Note
3x bolts, 24mm, 160 Nm
Install LH carpet support foam

Note
Seat at rear edge
Install accelerator pedal

Note
2x nuts, 13mm, 10 Nm, 1x connector, Secure locking tab
Unfold RH front cabin carpet into position
Unfold LH front cabin carpet into position
Secure HV cabin outlets harness to foam

Note
Tuck harness into groove
Install rear carpet assembly

Note
4x clips, 6x datums, Secure center foams and datums, Secure stands at center console then secure stands around LH and RH floor ducts, Fully tuck carpet under risers and trim, Replace any missing or damaged clips
Install LH seat riser assembly

Note
4x bolts, 13mm, 40 Nm, 8x clips, release cabin MV harness, attach cabin HV outlet harness and air duct to seat riser
Install LH outboard riser bolt cover
Install RH seat riser assembly

Note
4x bolts, 13mm, 40 Nm, 2x clips, Attach cabin MV harness and air duct to riser assembly
Install RH outboard riser bolt cover
Install LH rear carpet duct bezel

Note
4x clips, Replace any missing or damaged clips
Install rear carpet RH duct bezel

Note
4x clips, Replace any missing or damaged clips
Install center console

Note
Lower onto riser
Connect center console harness connectors

Note
2x connectors
Install front bolts securing center console to riser

Note
4x bolts, 10mm, 5 Nm
Secure HV outlet onto front console panel

Note
2x screws, T20, 1 Nm, 1x clip
Install center console front panel

Note
10x clips, Replace any missing or damage clips
Install rear bolts securing center console to riser

Note
2x bolts, 10mm, 5 Nm
Secure HV outlet onto rear console panel

Note
3x screws, T20, 1 Nm, 2x clips
Install center console rear panel

Note
10x clips, 3x connectors, 3x harness clips, Replace any missing or damaged clips
Install LH front seat into vehicle

Note
Recommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
Connect LH front seat harness

Note
1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
Install RH front seat into vehicle

Note
Recommend Assistance, Be cautious not to damage surrounding components while lifting the seat into the vehicle
Connect RH front seat harness

Note
1x connector, 2 stage locking tabs, Make connection and engage black lever, then engage yellow locking tab
Remove HV battery alignment rods from stancion mounting holes on pack

Note
2x alignment rods
Install RH rear interior HV battery mounting bolts

Note
4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
Install RH subwoofer

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards outside of vehicle to secure port
Install LH rear interior HV battery mounting bolts

Note
4x bolts, 13mm, 60 Nm, Bolts on both sides of stanchion, Some vehicles may have a mix of 13mm and 15mm bolts
Install LH subwoofer

Note
1x connector, 2x bolts, 13mm, 8 Nm, Slide towards LH of vehicle to secure outer port to body, Engage locking tab
Install rear wall lower trim

Note
2x push clips, 4x clips
Secure LH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 60 seat

Note
Pull tether to release then pivot down until locked in place
Secure RH lower C-pillar trim

Note
1x clip, 1x datum
Fold down 2nd row 40 seat

Note
Pull tether to release then pivot down until locked in place
Install 2nd row floor mat
Reconnect MV power. See Disconnect MV Power (Modify).
Remove Universal Lift Pad adapters

Note
4x Adapters, Install original lift pads, Install plugs back into holes in BIW
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
Install front RH rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm, 2x datums
Install rear RH step reinforcement

Note
3x bolts, 10mm, 15 Nm
Install RH rocker cover to rocker carrier

Note
11x clips, 1x datum
Install rocker cover fasteners to RH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing RH rocker cover to rear wheel liner

Note
1x clip
Install RH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of rear RH fender flare cover

Note
13x clips, 3x datums total, Ensure no clips are damaged, Replace clips as required
Install clip securing RH rocker cover to front wheel liner

Note
1x clip
Install RH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of front RH fender flare cover

Note
11x clips, 3x datum, 1x connector total, Ensure no clips are damaged, Replace clips as required
Secure RH front seat belt to pretensioner

Note
Ensure the lock screw is in the horizonal position. If it is not, unlock it by following the linkage removal instructions.Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.
Move the RH front seat fully rearward.
Install bolts securing RH front seat front tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install center floor trim

Note
17x clips, Replace any missing or damaged clips, Install lower section first
Install RH center floor rail

Note
4x clips, 3x datums
Install RH lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs
Install RH mid A-pillar trim

Note
1x clip, 3x tabs, Replace any missing or damaged clips
Install RH front floor mat
Move the RH front seat fully forward.
Install bolts securing RH front seat rear tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install LH front rocker step reinforcement

Note
3x bolts, 10mm, 15 Nm, 2x datums
Install rear LH step reinforcement

Note
3x bolts, 10mm, 15 Nm
Install LH rocker cover to rocker carrier

Note
11x clips, 1x datum, Replace any missing or damaged clips
Install rocker cover fasteners to LH side ski

Note
6x bolts, 10mm, 10 Nm
Install clip securing LH rear wheel liner to rocker cover

Note
1x clip
Install LH rear rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure fore section of LH rear fender flare cover

Note
13x clips, 3x datums total, Replace any missing or damaged clips
Install clip securing LH front wheel liner to rocker cover

Note
1x clip
Install LH front rocker fastener to step reinforcement

Note
1x bolt, 10mm, 4 Nm
Secure aft section of LH front fender flare cover

Note
11x clips, 3x datum, 1x connector total, Replace any missing or damaged clips
Secure LH front seat belt to pretensioner

Note
Ensure the lock screw is in the horizonal position. If it is not, unlock it by following the linkage removal instructions.Slide the linkage onto the pretensioner cable, an audible click will be heard, and the screw should rotate to the locked position. Verify there are no twists in the webbing from the upper trim to the pretensioner. Perform a firm pull test with at least 15 pounds of force.
Move the LH front seat fully rearward.
Install bolts securing both LH front seat front tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Install LH center floor rail

Note
4x clips, 3x datums
Install accelerator pedal side trim

Note
3x clips, Replace any missing or damaged clips
Install footwell cover

Note
3x clips, 3x magnets, 1x bolt, 10mm, 3 Nm, Bolt is captive to tether, Replace any missing or damaged clips or magnets
Install LH Lower A-pillar trim

Note
7x clips, 3x datums, 2x tabs, Replace any missing or damaged clips
Install LH mid A-pillar trim

Note
1x clip, 3x tabs, Replace any missing or damaged clips
Install LH front floor mat
Move the LH front seat fully forward.
Install bolts securing LH front seat rear tracks to vehicle

Note
2x patch bolts, T45P, 34 Nm, Install new bolts
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Install vacuum refill cap onto coolant bottle assembly
Place empty coolant container into front storage area

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
Fill container with at least 15L of coolant
Place filled coolant container onto coolant drain & fill cart

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
Setup coolant refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose to refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open the refill valve to allow coolant to be drawn into the system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once the gauge reads zero, close the coolant refill valve
Remove shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove vacuum refill cap from coolant bottle assembly
Remove coolant refill tool from vehicle

Note
Move coolant drain & fill cart away from vehicle
Remove coolant container from inside underhood area
Run ODIN routine
PROC_EGGRIGHT3_X_THERMAL-FILL-DRAIN-STOP
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Select "Start Coolant Air Purge" using the UI

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
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
Close the powered frunk.
Perform Thermal Performance through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow toolbox article 206000
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
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
Secure RH sail applique

Note
6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut same length tape and apply
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
Secure rear LH sail applique

Note
6x tabs, 6x tabs, Remove inflatable air bag, Clean off double sided tape from sail and applique, Clean with IPA wipes and allow 1 minute dry time, Cut double sided tape to length and apply
Close tailgate
Run ODIN routine PROC_EGGREAR1_TONNEAU-CALIBRATEvia Toolbox: (link)via Service Mode: Closures ➜ Tonneau ➜ Calibrate Tonneau
Open the tonneau cover.
Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox: (link)
Raise all the windows and close all the doors.

Cybertruck Service Manual

HV Battery (AWD) (Remove and Install)

Remove

Figure 1

Figure 2

Figure 3