Correction code 1630012122 1630012121 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 Precautions for safe and healthy working practices.

1. Disable HV power. See Vehicle HV Disablement Procedure (Test/Adjust)
2. Remove the ancillary cover. See Ancillary Bay Cover (Remove and Replace)
3. Remove bolts securing pyro disconnect to ancillary bay
   Note

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

   

4. Remove pyro disconnect from ancillary bay
   Note

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

   

   

5. Install pyro disconnect dummy

   

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

   Setup seatbelt to hold HVC assembly and tray in upward postition

   

7. Disconnect PCS to DC bus HV connector
   Note

   1x connector, Release locking tab then disconnect

   

8. Disconnect PCS logic connector from PCS
   Note

   1x connector

   

9. 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

   

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

    2x connectors

    

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

    1x clip

    

12. Remove HV joint insulators from positive HV switch
    Note

    2x insulators

    

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

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

    

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

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

    

15. 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

    

16. Remove positive pack contactor from ancillary bay
    Note

    2x guide pins

    

    

    

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

    2x guide pins

    

    

    

18. 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

    

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

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

    

20. 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

    

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

    1x HV joint, 110μΩ or less

    

    

22. 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.

    

    

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

    1x clip

    

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

    2x connectors

    

25. 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

    

26. Connect PCS logic connector to PCS
    Note

    1x connector

    

27. Connect PCS to DC bus HV connector
    Note

    1x connector, Connect then secure locking tab

    

28. Lower HV Controller back into place

    

29. Remove harness clip from FC contactor cover
    Note

    1x clip

    

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

    2x connectors

    

31. Remove HV joint insulators from negative pack contactor
    Note

    2x insulators

    

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

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

    

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

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

    

34. 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

    

35. Remove negative pack contactor from penthouse
    Note

    2x guide pins

    

    

36. Position negative pack contactor to penthouse for installation
    Note

    Align the 2x guide pins

    

    

37. 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

    

38. 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

    

39. 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

    

40. 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.

    

    

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

    1x HV joint, 110μΩ or less

    

    

42. Install HV joint insulators to negative pack contactor
    Note

    2x insulators

    

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

    2x connectors

    

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

    1x clip

    

45. Remove pyro disconnect dummy

    

46. 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

    

    

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

    

48. 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

    

    

49. 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

    

    

    

50. Install bolts securing pyro disconnect to ancillary bay
    Note

    2x patch bolts, 13mm, 9 Nm

    

51. 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

    

    

52. Measure resistance from pyro disconnect to shunt
    Note

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

    

    

53. Remove service insulator kit

    

    

    

    

    

    

    

    

54. 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

    

55. Install the ancillary cover. See Ancillary Bay Cover (Remove and Replace)
56. 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

    

    

    

57. Connect LV power. See LV Power (Disconnect and Connect)
58. Close hood

    

59. Move RH front seat to original position

    

60. Move LH front seat to original position

    

61. Raise all four windows

    

62. Close all four doors