Correction code 1601010302 FRT 4.92 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. Open all four doors

   

2. Lower all four windows

   

3. Raise and support vehicle
   Note

   Ensure vehicle is not charging

   

   

   

4. Place vehicle in service mode plus
   Note

   Using Vehicle Ops mobile app enter last six digits of VIN then select vehicle from list then swipe to the left and select "Enable Service Mode Plus"Vehicle Ops mobile app can be downloaded at: https://mobile.tesla.com/AppStore/Home/AppDetails?appId=6

   

   

   

5. Unlock vehicle gateway
   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

   

   

   

   

6. Run Thermal Fill Drain (Coolant Only) through the UI
   Note

   Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has 50 minutes time limit, After 50 minutes routine must be performed again

   

   

   

   

7. Move LH front seat forward

   

8. Move RH front seat forward

   

9. Open hood

   

   

10. Remove rear underhood apron
    Note

    14x clips

    

    

11. Power off vehicle from center display
    Note

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

    

    

12. Disconnect LV battery and First Responder Loop
    Note

    2x connectors, 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

    

    

    

    

    

    

13. Release 2nd row seat cushion and disconnect harness
    Note

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

    

    

    

    

    

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

    

15. 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

    

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

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

17. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

    

18. Remove ancillary bay probe lid cover from ancillary bay cover

    

    

19. Verify no high voltage
    Note

    Make 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

    

    

    

20. Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
    Note

    Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time

    

    

21. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners

    

22. Remove HV insulating gloves

    

23. Raise vehicle fully and lower lift onto locks
    Note

    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects

    

    

24. Remove bolts securing front aero shield
    Note

    7x bolts, 10mm, 5 Nm

    

25. Remove front aero shield from studs
    Note

    2x nuts, 15mm, 5 Nm

    

    

26. Remove both LH and RH bolts securing wheel liners to front skid plate
    Note

    2x blots, 10mm, 5 Nm

    

27. Remove front skid plate
    Note

    4x bolts, EP10, 13 Nm, 2x tabs, Move foward to remove

    

    

    

    

28. Position coolant drain container below HV battery hose

    

29. Disconnect RH manifold tube from LH manifold tube
    Note

    1x spring clip, 2x plugs, Plug both side hose end

    

    

30. Remove coolant drain container from underneath vehicle

    

31. Remove bolt securing FDU HV harness to FDU
    Note

    1x bolt, 10mm, 10 Nm

    

32. Disconnect FDU HV harness connector
    Note

    1x clip, 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 FDU header are not damaged

    

    

33. Release HV connector mount bracket from stud on LH side of firewall
    Note

    1x mount bracket

    

34. Disconnect AC compressor HV harness connector
    Note

    1x locking connector, 3 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, depress yellow tab and pull the connector backward then depress the green tab to release

    

    

    

35. Remove ancillary harness bracket from front of HV battery
    Note

    2x barrel clips

    

    

36. Remove rear aero shield clips
    Note

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

    

    

37. Remove rear aero shield
    Note

    11x bolts, 10mm, 5 Nm

    

    

38. Release LH side hose clip from rear battery skid plate enclosure
    Note

    1x fir tree clip

    

39. Release RH side hose clips from rear battery skid plate enclosure
    Note

    2x fir tree clips

    

40. Remove lower bolts securing HV battery rear skid plate enclosure
    Note

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

    

41. Remove upper nut securing HV battery rear skid plate enclosure
    Note

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

    

42. Remove upper bolts securing HV battery rear skid plate enclosure
    Note

    4x bolts, 13mm, 35 Nm

    

43. Remove HV battery rear skid plate enclosure

    

44. Position coolant drain underneath RH rear of HV battery

    

45. Disconnect RH coolant hose from rear of HV battery
    Note

    1x spring clip, 2x plugs, Plug both the coolant hose and passthrough

    

    

46. Release clips securing HV battery return tube from rear of HV battery
    Note

    2x clips

    

47. Remove coolant drain container from underneath vehicle

    

48. Disconnect AC HV harness connector from right rear of HV battery
    Note

    1x connector, 2 stage connector, Release the red tab before releasing the black locking lever

    

    

    

49. Disconnect FDU HV harness connector 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 FDU header are not damaged

    

    

    

50. Remove center ski cover from HV battery
    Note

    6x bolts, EP14, 34 Nm, Recommend assistance, Short bolts at both ends, Long bolts in the middle

    

    

51. Use a spring loaded center punch to mark locations for drilling
    Note

    Use a center punch to create a small dimple in the centre of each spot weld

    

    

52. Use spot weld cutters to remove the Front Skid Plate Bracket
    Note

    Use 3/8" size spot weld cutter,Use chiselling technique at high speed to allow the chips to fly out as the cut exits the aluminium, or clean the cutter manually after short drilling, Drill to a depth of no more than the thickness of the Skid Plate Bracket approximately 2.5mm,

    

    

    

53. Separate Skid Plate Bracket from HV battery
    Note

    When cutter is deep enough, use 38 mm Scraper or plastic wheel weight removal chisel and light hammer blows to try to separate the skid plate from the battery, If it didn't get off easy, try to drill a little deeper

    

    

54. Apply masking tape
    Note

    Mark mating surface with masking tape

    

55. Clean mating area
    Note

    Use 120 grit sand paper to remove paint on the mating surfaces

    

56. Create a stencil of holes for new skid plate bracket
    Note

    Stick the masking tape on old Skid Plate Bracket along the top edge,Use thin ballpoint pen to mark the holes and Skid Plate Bracket location on a masking tape peace

    

    

57. Mark the location of the new holes
    Note

    Remove a stencil from the old bracket and apply to the new one strictly in the same location,Use center punch to create a small dimple in the centre of each circle

    

58. Drill holes in the new Skid Plate Bracket
    Note

    Secure the new Skid Plate Bracket in a vise,Use 5/16" Spot Weld Cutter this time, Use chiselling technique at high speed to allow the chips to fly out as the cut exits the hole, or clean the cutter manually after short drilling,

    

    

    

59. Remove masking tape

    

60. Clean mating area
    Note

    Use 120 grit sand paper to clean future mating surfaces

    

61. Fit the pieces together
    Note

    Try the Skid Plate Bracket on a HV battery and check that the flat surfaces fit snugly together

    

    

    

62. Clean mating areas with Isopropyl alcohol

    

63. Allow 1 minute dry time

    

64. Apply adhesive

    

    

65. Install the Skid Plate Bracket on a HV battery
    Note

    Install Skid Plate Bracket on a HV batteryUse the long bolt from the ski plate, screw it in by hand in the first hole,Apply slight pressure to the bracket using 2 wedges, slightly zip tie the wedge as shown on pictures

    

    

66. Set up temperature measurement tool
    Note

    Set up the Digital multimeter with thermocouple attached to it, Be careful with the polarity of the plug, Press LPF button to change from °F to C°, Turn switch to Temp position,Check if the temperature readings are real,Attach thermocouple to the skid plate

    

    

67. Use a heat gun to reduce curing time of adhesive
    Note

    WarningWhen force curing adhesive in a repair area near the High Voltage Battery, do not allow the HighVoltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Batteryabove 74°C (165°F) for an extended period could result in injury to personnel and/or damage tothe battery.Attach the Bosch digitally adjustable temperature heat gun to the Transmission Jack with the zip ties, Install it facing the skid plate bracket 10 cm from itCuring▪ 7 days at 23 ± 2 °C▪ 2 hours at 65 ± 2 °C

    

68. Allow adhesive to cure
    Note

    Allow adhesive to cure 2 hours

    

69. Allow adhesive to cure
    Note

    Allow adhesive to cure 2 hours

    

70. Remove wedges
    Note

    Cut the zip tie and remove wedges, Remove bolt from the center ski cover first hole

    

    

71. Touch Up bare metal spots
    Note

    Touch Up bare metal spots

    

72. Install center ski cover onto HV battery
    Note

    6x bolts, EP14, 34 Nm, Recommend assistance, Short bolts at both ends, Long bolts in the middle

    

    

73. Connect FDU HV harness connector 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

    

    

    

    

74. Connect AC HV harness connector to right rear of HV battery
    Note

    1x connector, Hold connector level with header and secure with even upward force, Rotate lever arm and secure locking tab, Verify that the latch is fully secured and not damaged

    

    

    

75. Install clip securing RH coolant hose to HV battery
    Note

    1x clip

    

76. Position coolant drain underneath RH rear of HV battery

    

77. Connect RH inner coolant hose onto rear of HV batter
    Note

    1x spring clip, 2x plugs, Remove plugs from the coolant hose and passthrough, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

    

    

78. Remove coolant drain container from underneath vehicle

    

79. Position HV battery rear skid plate enclosure onto HV battery for installation
    Note

    Recommend assistance if needed

    

    

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

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

    

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

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

    

82. Install lower bolts securing HV battery rear skid plate enclosure
    Note

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

    

83. Torque bolts securing HV battery rear skid plate enclosure to vehicle
    Note

    4x bolts, 13mm, 35 Nm

    

84. Torque upper nut securing HV battery rear skid plate enclosure
    Note

    1x nut, 10mm, 13 Nm

    

85. Install RH side hose clips to HV battery rear skid plate enclosure
    Note

    2x fir tree clips

    

86. Install LH side hose clip to HV battery rear skid plate enclosure
    Note

    1x clip

    

87. lnstall rear aero shield
    Note

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

    

    

88. Install LH and RH clips securing rear aero shield to wheel house liner
    Note

    2x clips

    

    

89. Install ancillary harness bracket to front of HV battery
    Note

    2x barrel clips

    

    

90. Connect AC compressor HV harness connector
    Note

    1x locking connector, 3 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector, Engage locking tab

    

    

91. Install HV connector mount bracket to stud on LH side of firewall
    Note

    1x mount bracket

    

92. Install FDU HV harness connector to FDU
    Note

    1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU then remove HV connector lever lock before fully latching 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

    

    

    

93. Install bolt securing FDU HV harness to FDU
    Note

    1x bolt, 10mm, 10 Nm

    

94. Position coolant drain container below HV battery hose

    

95. Connect RH manifold tube onto LH manifold tube
    Note

    1x spring clip, 1x plug, Remove plug from HV battery, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

    

    

96. Remove coolant drain container from underneath vehicle

    

97. Install front skid plate
    Note

    4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation

    

    

    

    

98. Apply Loctite 222 onto front wheel liner bolts and install bolts securing front wheel liners to front skid plate
    Note

    2x blots, 10mm, 5 Nm, Apply Loctite 222 onto front wheel liner bolts

    

99. Position front aero shield onto vehicle
    Note

    2x nuts, 15mm, 5 Nm, Hand-tighten the nuts to temporarily hold the panel in place

    

    

100. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
     Note

     7x bolts, 10mm, 5 Nm

     

     

101. Lower vehicle fully
     Note

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

     

     

     

102. 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

     

     

     

103. Remove coolant bottle cap

     

104. Fill coolant to proper level
     Note

     Ensure that the fluid level filled to the Max line

     

105. 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

     

     

     

     

     

106. Move RH front seat to original position

     

107. Move LH front seat to original position

     

108. Access Thermal System routines using UI
     Note

     Select Service mode > Thermal

     

     

109. Select "Coolant Purge Start" using UI
     Note

     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

     

     

     

     

110. Inspect coolant level and top off as necessary
     Note

     Ensure that fluid level is at Max line

     

111. Install coolant bottle cap

     

112. Install rear underhood apron
     Note

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

     

     

113. Close hood

     

114. Raise all windows

     

115. Close all four doors

     

116. Remove lift arms from below vehicle
     Note

     Lower rack arms fully and remove them from under vehicle