Correction code 1630012122 FRT 1.14 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.NOTE: See Ergonomic Precautionsfor 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. Open hood

   

   

6. Remove rear underhood apron
   Note

   14x clips

   

   

7. Power off vehicle from center display
   Note

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

   

   

8. 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

   

   

   

   

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

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

   

   

   

   

   

10. Verify operation of multimeter
    Note

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

    

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

    

12. 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

    

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

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

    

14. Remove bolts securing ancillary bay probe lid cover from ancillary bay cover
    Note

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

    

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

    

    

16. 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

    

    

    

    

17. 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

    

    

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

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

    

19. Remove HV insulating gloves

    

20. Disconnect HVC logic connector and install logic cap
    Note

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

    

    

    

21. Remove bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

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

    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

    

    

23. 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

    

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

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

    

25. Remove HVC logic cap
    Note

    1x cap

    

26. Remove ancillary bay cover from HV battery

    

    

27. Install HVC logic cap
    Note

    1x cap

    

28. Inspect ancillary bay for any missing insulators
    Note

    Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary

    

    

    

    

    

    

    

    

    

29. Remove bolts securing pyro disconnect to ancillary bay
    Note

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

    

30. Remove pyro disconnect from ancillary bay
    Note

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

    

    

31. Install pyro disconnect dummy

    

32. Lift HV Controller up to gain access to fuse insulator
    Note

    Setup seatbelt to hold HVC assembly and tray in upward postition

    

33. Disconnect PCS to DC bus HV connector
    Note

    1x connector, Release locking tab then disconnect

    

34. Disconnect PCS logic connector from PCS
    Note

    1x connector

    

35. Disconnect PCS LV connector from PCS
    Note

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

    

36. Disconnect ancillary bay harness connectors from positive pack contactor
    Note

    2x connectors

    

37. Remove HV PCS to DC Bus harness clip from positive pack contactor
    Note

    1x clip

    

38. Remove HV joint insulators from positive HV switch
    Note

    2x insulators

    

39. Remove bolt securing positive pack contactor to positive busbar
    Note

    1x patch bolt, 13mm, 9 Nm, Discard after removal

    

40. Remove nut securing positive pack contactor to module 4 rear terminal
    Note

    1x patch nut, 13mm, 9 Nm, Discard after removal

    

41. Remove nuts securing positive pack contactor to ancillary bay
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

    

42. Remove positive pack contactor from ancillary bay
    Note

    2x guide pins

    

    

    

43. Position positive pack contactor to ancillary bay for installation
    Note

    2x guide pins

    

    

    

44. Install nuts securing positive pack contactor to ancillary bay
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary

    

45. Install bolt securing positive pack contactor to positive busbar
    Note

    1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque

    

46. Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
    Note

    1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

    

47. Measure resistance from HV joint between HV battery positive contactor and center of HV battery positive terminal
    Note

    1x HV joint, 110μΩ or less

    

    

48. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
    Note

    1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

    

    

49. Install ancillary bay harness clip to positive pack contactor
    Note

    1x clip

    

50. Connect ancillary bay harness connectors to positive pack contactor
    Note

    2x connectors

    

51. Connect PCS LV connector to PCS
    Note

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

    

52. Connect PCS logic connector to PCS
    Note

    1x connector

    

53. Connect PCS to DC bus HV connector
    Note

    1x connector, Connect then secure locking tab

    

54. Lower HV Controller back into place

    

55. Remove harness clip from FC contactor cover
    Note

    1x clip

    

56. Disconnect ancillary bay harness connectors from negative pack contactor
    Note

    2x connectors

    

57. Remove HV joint insulators from negative pack contactor
    Note

    2x insulators

    

58. Remove bolt securing negative pack contactor to DC link busbar joint
    Note

    1x patch bolt, 13mm, 9 Nm, Discard after removal

    

59. Remove nut securing negative pack contactor to HV battery tall silicon terminal
    Note

    1x patch nut, 13mm, 9 Nm, Discard after removal

    

60. Remove nuts securing negative pack contactor to penthouse
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

    

61. Remove negative pack contactor from penthouse
    Note

    2x guide pins

    

    

62. Position negative pack contactor to penthouse for installation
    Note

    Align the 2x guide pins

    

    

63. Install nuts securing negative pack contactor to penthouse
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary, Mark after torque

    

64. Install bolt securing negative pack contactor to DC link busbar joint
    Note

    1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque

    

65. Install nut securing negative pack contactor to HV battery tall terminal
    Note

    1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

    

66. Perform Hioki impedance test at HV joint of negative pack contactor to negative DC link busbar
    Note

    1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

    

    

67. Perform Hioki impedance test at negative pack contactor to module 1 rear terminal
    Note

    1x HV joint, 110μΩ or less

    

    

68. Install HV joint insulators to negative pack contactor
    Note

    2x insulators

    

69. Connect ancillary bay harness connectors to negative pack contactor
    Note

    2x connectors

    

70. Install ancillary bay harness clip around negative pack contactor area
    Note

    1x clip

    

71. Remove pyro disconnect dummy

    

72. Clean mating surfaces
    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

    

    

73. Set multimeter to "LoZ" (low impedance) mode

    

74. Measure voltage between busbar and shunt
    Note

    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

    

    

75. Position pyro disconnect to ancillary bay for installation
    Note

    1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way

    

    

    

76. Install bolts securing pyro disconnect to ancillary bay
    Note

    2x patch bolts, 13mm, 9 Nm

    

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

    1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

78. Measure resistance from pyro disconnect to shunt
    Note

    1x HV joint, 45μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

79. Remove service insulator kit

    

    

    

    

    

    

    

    

80. 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

    

81. 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

    

    

    

    

    

82. Wipe ancillary bay cover with IPA to clean surface
    Note

    Allow to 1 minute dry time

    

83. 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.

    

    

84. Remove HV insulating gloves

    

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

    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

    

    

86. Install bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

87. 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

    

    

88. 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

    

    

    

89. 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

    

    

    

90. Install rear underhood apron
    Note

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

    

    

91. Close hood

    

92. Move RH front seat to original position

    

93. Move LH front seat to original position

    

94. Raise all four windows

    

95. Close all four doors