Correction code 16309000 3.18 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.

1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
2. Open the LH front door and lower the LH front window.
3. Place the vehicle into Service Mode. See Service Mode.
4. Unlock the vehicle Gateway. See Gateway (Unlock).
5. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
6. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
7. Disconnect MV power. See Disconnect MV Power.
8. 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

   

   

9. Remove the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
10. Disconnect pressurized pack lines
    Note

    2x VOSS fittings, 12mm, 8Nm, Discard and replace

    

11. Remove VOSS fitting from pressurized pack air lines
    Note

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

    

    

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

    

13. 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

    

14. Put on HV insulating gloves and leather over gloves

    

15. 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

    

    

    

    

    

    

16. Secure RDU header connector to ancillary
    Note

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

    

    

17. Remove Pyro Fuse Access cover
    Note

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

    

18. Remove primary pyro fuse
    Note

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

    

    

19. Remove secondary pyro fuse
    Note

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

    

    

20. Remove leather over gloves and HV insulating gloves

    

21. 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

    

    

22. 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

    

    

    

23. Release RH tonneau NVH cover
    Note

    6x bolts, 10mm, 5Nm, 2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal

    

    

24. Remove RH tonneau NVH cover
    Note

    Release rearward then slide over LH side NVH cover before removing upward

    

    

    

25. Release LH tonneau NVH cover
    Note

    5x bolts, 10mm, 5Nm

    

    

26. Remove LH tonneau NVH cover
    Note

    Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material

    

    

27. Remove tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm

    

    

28. Clean all debris from ancillary cover
    Note

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

    

29. Release pressurized pack air line to Ancillary
    Note

    1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.

    

30. Remove VOSS fitting from pressurized pack air line to Ancillary
    Note

    1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal

    

    

31. Release pressurized pack valve block from air suspension reservoir
    Note

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

    

    

32. Release air suspension valve block
    Note

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

    

    

    

33. Release air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

34. Place air suspension reservoir in service position then install Ancillary Access Bench
    Note

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

    

    

    

35. 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

    

    

    

    

    

36. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

38. Release HV connector from DC FC header
    Note

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

    

39. Support HV Busbar assembly
    Note

    Suspend assembly to maintain clearance

    

40. Remove fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

41. Release low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

42. Release fasteners securing ancillary cover to HV battery
    Note

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

    

    

    

43. Remove ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

44. 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

    

45. Put on HV insulating gloves and leather over gloves

    

46. Verify voltage across both terminals of the HV battery positive contactor
    Note

    Set the multimeter to measure the voltage across both terminals of the HV battery positive and DC link,Ensure to probe the busbar on the side of the fastener location through the small cutout shown on image, instead of the fasteners, HV fasteners have an insulated top,If the measured voltage is outside the range of -0.1V to 0.1V, then the HV battery positive contactor is not seized,If the measured voltage is between -0.1V and 0.1V, Set the multimeter to measure resistance and measure the resistance across the HV battery positive contactor terminals,If the measured resistance is greater than 1M Ohm (1000K Ohm), then the HV battery positive contactor is not seized,If the measured resistance is lower than 1M Ohm, then the HV battery positive contactor might be seized, Discontinue procedure and replace the device cluster assembly and retest

    

    

    

47. Verify voltage across both terminals of the HV battery negative contactor
    Note

    Set the multimeter to measure the voltage across both terminals of the HV battery negative and DC link,Ensure to probe the busbar on the side of the fastener location through the small cutout shown on image, instead of the fasteners, HV fasteners have an insulated top,If the measured voltage is outside the range of -0.1V to 0.1V, then the HV battery negative contactor is not seized,If the measured voltage is between -0.1V and 0.1V, Set the multimeter to measure resistance and measure the resistance across the HV battery negative contactor terminals,If the measured resistance is greater than 1M Ohm (1000K Ohm), then the HV battery negative contactor is not seized,If the measured resistance is lower than 1M Ohm, then the HV battery positive contactor might be seized, Discontinue procedure and replace the device cluster assembly and then retest

    

    

    

48. Install ancillary cover
    Note

    Use suction cup and maneuver around busbar and tonneau cage

    

    

    

    

49. Secure fasteners of cover to HV battery
    Note

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

    

    

    

50. Secure low voltage header
    Note

    2x bolts, 10mm, 6 Nm

    

51. Secure fast charger header doubler
    Note

    2x bolts, E10 5 Lobe Torx, 10Nm

    

    

52. 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

    

53. 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

    

54. 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

    

55. Position busbar connector and lower onto HV header
    Note

    Release bungee cord

    

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

    2x bolts, 10mm, 9 Nm

    

57. 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

    

    

58. Remove leather over gloves and HV insulating gloves

    

59. Install bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

60. Connect Ancillary bay MV connector
    Note

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

    

    

    

    

    

61. Secure tonneau coverbox cross supports
    Note

    8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners

    

    

62. Install LH tonneau NVH cover
    Note

    Ensure busbar clearance during install to avoid damage to NVH material

    

    

63. Secure LH tonneau NVH cover
    Note

    5x bolts, 10mm, 5Nm

    

    

64. Install RH tonneau NVH cover

    

    

    

65. Secure RH tonneau NVH cover
    Note

    6x bolts, 10mm, 5Nm

    

    

66. Remove Ancillary Access Bench then place air suspension reservoir into position for installation
    Note

    Ensure air lines are not twisted, Ensure no harnesses are caught

    

    

    

67. Secure air suspension reservoir
    Note

    2x nuts, 13mm, 33 Nm, 2x fir tree clips

    

    

68. Secure air suspension valve block
    Note

    3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation

    

    

    

69. Install new VOSS air fitting to pressurized pack valve block at ANC circuit
    Note

    1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line is installed

    

    

70. Secure pressurized pack air line from Ancillary to valve block
    Note

    1x line, Remove plastic cap from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test

    

    

71. Secure pressurized pack valve block to air suspension reservoir
    Note

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

    

    

72. Install bed floor assembly
    Note

    10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance

    

    

    

73. Raise vehicle fully

    

74. Put on HV insulating gloves and leather over gloves

    

75. Clean mating surface of the pyro
    Note

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

    

    

    

    

76. Install secondary pyro fuse
    Note

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

    

    

77. Install primary pyro fuse
    Note

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

    

    

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

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

    

    

    

79. Remove leather over gloves and HV insulating gloves
80. Install new Voss fittings and nut to pyro cover
    Note

    2x VOSS fittings, 12mm, 8 Nm, Do not remove VOSS plastic plug until SCUBA line install

    

    

81. Install Pyro Fuse Access cover
    Note

    4x bolts, E-Torx 5 lobe, 10Nm, Ensure seal is fully seated and undamaged

    

    

82. Install pressurized pack lines
    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

    

    

    

83. Install the mid aeroshield. See Undertray - Mid Aeroshield (Remove and Install).
84. Reconnect MV power. See Disconnect MV Power.
85. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
86. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
87. Exit Service Mode. See Service Mode.
88. Raise the LH front window and close the LH front door.
89. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.