Correction code NEW NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

1. Open all four doors

   

2. Lower all four windows

   

3. Move LH front seat forward

   

4. Move RH front seat forward

   

5. Power off vehicle from center display
   Note

   Via Controls > Safety > Power Off, Select Power Off button at warning dialog box

   

   

6. Open hood

   

   

7. Remove rear apron
   Note

   14x clips

   

   

8. Disconnect LV battery and first responder loop
   Note

   2x connectors, Ensure that one minute has passed after window movement before performing the power-off, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

   

   

   

   

9. Verify operation of multimeter
   Note

   Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

   

10. Raise vehicle fully, lower lift onto locks
    Note

    Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to side if both locks are not engaged

    

    

11. Remove rear aero shield clips
    Note

    2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

    

    

12. Remove rear aero shield
    Note

    11x bolts, 10mm, 5 Nm

    

    

13. Release clips securing coolant hose to LH side of HV battery rear skid plate
    Note

    1x fir tree clip

    

14. Release clips securing coolant hose to RH side of HV battery rear skid plate
    Note

    2x fir tree clips

    

15. Remove lower bolts securing HV battery rear skid plate
    Note

    2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count

    

16. Remove upper nut securing HV battery rear skid plate
    Note

    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles

    

17. Remove upper bolts securing HV battery rear skid plate
    Note

    4x bolts, 13mm, 35 Nm

    

18. Remove rear skid plate from HV battery

    

19. Install amp clamp to RDU HV harness
    Note

    Verify meter is zeroed out before performing measurement, Measure single cableIf 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 downIf the current is within the range of -0.5 A to 0.5 A, Continue to the next step, Disconnect and check voltage at HV plug on the battery side If the measurement is still outside the range of -0.5 A to 0.5 A, Do not disconnect any HV harness, Escalate for assistance

    

    

20. Remove nut securing RDU HV cable bracket from HV battery
    Note

    1x nut, 10mm, 10 Nm, Number of fasteners may vary

    

21. Remove all items from pockets and ensure not wearing metal items
    Note

    This includes: rings, watches, bracelets, necklaces, earrings, piercings, phones, badges, metal belt buckles, airpods and headphones

    

22. 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.tesla.com/en-US/documents

    

23. Put on HV insulating gloves and leather over gloves
    Note

    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configurationhttps://service.tesla.com/en-US/documents

    

24. Disconnect RDU HV cable from HV battery
    Note

    1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged

    

    

    

25. Verify no high voltage at RDU HV header
    Note

    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, 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

    

    

    

26. Connect RDU HV cable to HV battery
    Note

    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position

    

    

27. Remove HV insulating gloves

    

28. Install RDU HV cable bracket to HV battery
    Note

    1x nut, 10mm, 10 Nm, Number of fasteners may vary

    

29. Position rear battery enclosure skid plate to HV battery for installation
    Note

    Recommend assistance if needed

    

    

30. Install upper bolts securing HV battery rear skid plate hand tight
    Note

    4x bolts, 13mm, 35 Nm, Torque at later step

    

31. Install upper nut securing HV battery rear skid plate hand tight
    Note

    1x nut, 10mm, 13 Nm, Torque at later step

    

32. Install lower bolts securing HV battery rear skid plate hand tight
    Note

    2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts

    

33. Torque upper bolts securing HV battery rear skid plate and HV battery to vehicle
    Note

    4x bolts, 13mm, 35 Nm

    

34. Torque upper nut securing HV battery rear skid plate
    Note

    1x nut, 10mm, 13 Nm

    

35. Install clips securing coolant hose to RH side of HV battery rear skid plate
    Note

    2x fir tree clips

    

36. Install clip securing coolant hose to LH side of HV battery rear skid plate
    Note

    1x fir tree clip

    

37. Install rear aero shield
    Note

    11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts before installing

    

    

    

38. Install rear aero shield
    Note

    2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

    

    

39. Lower vehicle until tires are touching ground
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

    

    

    

40. Release 2nd row seat cushion and disconnect harness connectors
    Note

    2x clips, 2x connectors, Press tabs backward then pull front edge up

    

    

    

    

    

41. Disconnect HVC logic connector and install logic cap
    Note

    1x connector, 1x cap, Release locking tab then push the handle downward to release connector

    

    

    

42. Remove bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

43. Remove bolts securing ancillary bay cover to HV battery
    Note

    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

    

    

44. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf

    

45. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear electrical protective gloves any time Hioki tester is used

    

46. Remove HVC logic cap
    Note

    1x cap

    

47. Remove ancillary bay cover from HV battery

    

    

48. Install HVC logic cap
    Note

    1x logic cap

    

49. Inspect ancillary bay for any missing insulators
    Note

    Install service insulator kit before continuing to next step

    

    

    

    

    

50. Remove bolts securing pyro disconnect to ancillary bay
    Note

    1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal

    

    

51. Remove pyro disconnect from ancillary bay
    Note

    1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay

    

    

52. Install pyro disconnect dummy

    

53. Use rubber bands to secure HVC to vehicle body

    

    

54. Remove insulators for fuse and bolts
    Note

    2x insulators

    

55. Remove 700V DC 63A PCS2 output fuse
    Note

    1x fuse, 2x nuts, 8mm, 4.5 Nm, Discard nuts after removal

    

    

56. Remove nut securing negative output harness from negative HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm, Discard after removal

    

57. Remove 700V DC 63A compressor fuse
    Note

    1x fuse, 2x nuts, 8mm, 4.5 Nm, Discard nuts after removal

    

    

58. Remove ancillary positive busbar bracket form positive HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm, Discard after removal

    

    

    

59. Disconnect PCS2 lite HV DC harness HV connector
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

60. Remove bolt securing RH ancillary bay bus cover
    Note

    1x bolt, T25, 3 Nm

    

61. Lift up DC link busbar cover
    Note

    1x clip, Be careful not to damage cover when lifting, It is recommended to assist

    

    

62. Remove PCS2 lite HV DC harness from ancillary bay
    Note

    3x harness slots, 1x hook, First, remove the terminals from the studs, and then remove harness outward, It is not allowed to damage the insulation layer of the harness, If it is damaged, it must be replaced.

    

    

    

    

    

    

63. Install PCS2 lite HV DC harness to ancillary bay
    Note

    3x harness slots, 1x hook, It is not allowed to damage the insulation layer of the harness, If necessary use a HV insulated 90 degree hook to assist, Ensure that harness is not pinched, Then install the harness terminals onto the studs.

    

    

    

    

    

    

    

64. Install DC link busbar cover
    Note

    1x clip

    

    

65. Install bolt securing RH ancillary bay bus cover
    Note

    1x bolt, T25, 3 Nm

    

66. Connect PCS2 lite DC busbar HV connector
    Note

    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

    

67. Install nut securing negative output harness to negative HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm, Install new nut, Mark after torque

    

68. Perform Hioki resistance test at negative output harness terminal to negative HV battery DC link busbar
    Note

    55μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

69. Install ancillary positive busbar bracket to positive HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm, Install new nut, Mark after torque

    

    

    

70. Perform Hioki resistance test at ancillary positive busbar bracket to positive HV battery DC link busbar
    Note

    60μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

71. Install 700V DC 63A PCS2 output fuse
    Note

    1x fuse, 2x nuts, 8mm, 4.5 Nm, Install new nuts, Mark after torque

    

    

72. Perform Hioki resistance test at 63A PCS fuse input joint
    Note

    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

73. Perform Hioki resistance test at 63A PCS fuse output joint
    Note

    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

74. Install 700V DC 63A compressor fuse
    Note

    1x fuse, 2x nuts, 8mm, 4.5 Nm, Install new nuts, Mark after torque

    

    

75. Perform Hioki resistance test at 63A compressor fuse input joint
    Note

    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

76. Perform Hioki resistance test at 63A compressor fuse output joint
    Note

    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

77. Position HVC and skylite hinge to PCS2 Lite
    Note

    Release bungee

    

    

78. Install insulators for fuse and bolts
    Note

    2x insulators

    

79. Remove pyro disconnect dummy

    

80. Clean mating surface of pyro
    Note

    Allow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, Busbar, And the pyrotechnic battery disconnect, If the insulation protective cover is removed

    

    

    

81. Set multimeter to "LoZ" (low impedance) mode
    Note

    For Fluke 110/113/114/115/116/117 LoZ setting:start with selector switch in 'off position', press the range button and rotate the selector switch to 'diode test' then let go of the range button, press the yellow button right under the display briefly, and the display should now indicate that the LoZ function (low impedance measurement) has been activated

    

    

82. Measure voltage between busbar and shunt
    Note

    Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points

    

    

83. Position pyro disconnect to ancillary bay for installation
    Note

    1x connector, Measure voltage between busbar and shunt for at least 10 seconds, while still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation, Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars, After the second person places the pyro down on the HV bus, the first person should continue to measure the voltage for another 10 seconds

    

    

    

    

    

84. Install bolts securing pyro disconnect to ancillary bay
    Note

    2x bolts, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Install new fasteners, Mark with paint pen

    

85. Measure resistance from module 2 busbar to pyro disconnect
    Note

    1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

86. Measure resistance from pyro disconnect to shunt
    Note

    1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

87. Inspect ancillary bay walls for damage
    Note

    Any dent or depression in the seal that causes it to not be flat will result in a leak, And cannot be reused, Any paint that comes off the ancillary bay wall, Whether or not it sticks to the seal, Will require enclosure leak test when reassembled, It can still be reused

    

88. Inspect ancillary bay cover seal to confirm it has no visual damage
    Note

    Image up close for clarity, Delaminated and torn seals cannot be reused, If installing new parts, Skip this step

    

    

    

    

    

89. Remove service insulator kit

    

    

    

    

90. Remove HVC logic cap
    Note

    1x logic cap

    

91. Position ancillary bay cover to HV battery for installation
    Note

    Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered

    

    

92. Remove leather over gloves and HV insulating gloves
    Note

    HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded

    

93. Install bolts securing ancillary bay cover to HV battery
    Note

    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

    

    

94. Install bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

95. Remove logic cap and connect HVC logic connector
    Note

    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

    

    

96. Connect 2nd row seat harness and secure cushion
    Note

    2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test

    

    

    

97. Connect first responder loop and LV battery
    Note

    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

    

    

    

98. Move RH front seat to original position

    

99. Move LH front seat to original position

    

100. Install rear apron
     Note

     14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips

     

     

101. Close hood

     

102. Raise all four windows

     

103. Close all four doors