Tube (Powertrain) - Rear Powertrain Return
Correction code 1830010152 FRT 2.3 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.
- 1139807-00-A Skt, 1/2" Dr, 20EP Torx Plus External
- 1133768-00-C Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
- 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
- 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
- 1065131-00-A Kit, Battery Coolant Drain
- 1473522-00-A Coolant Drain and Fill Adapters
- 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
- 1053600-00-D Pressure Test Fixture
- 1133570-00-A Skt, 3/8in Dr, 14EP Torx Plus External
Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
---|---|---|---|---|
LH and RH front footwell HV battery bolts (x4) |
|
|
Reuse | |
LH and RH rear HV battery interior bolts (x2) |
|
|
Reuse | |
Bolt that secures the charge port busbar access door Bolts that attach the charge port busbar kit to the HV header |
|
|
Reuse | |
Nut that attaches the positive LV output to the power conversion system (PCS) cable |
|
|
Replace | |
Bolts (x2) that attaches the LH and RH front wheel liners to skid plate |
|
|
Reuse | |
Nut that attaches the rear drive unit HV cable bracket to the HV battery |
|
|
Reuse | |
Middle bolts (x4) that secure the HV battery center ski cover |
|
|
Reuse | |
Bolts (x8) that attach the LH and RH front support brackets to vehicle |
|
|
Reuse | |
LH and RH bolts (x16) that attach the HV battery to vehicle |
|
|
Reuse |
Remove
- Remove the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Open all doors and lower all windows.
- Move the LH front seat backward.
- Remove the LH front floor mat.
- Remove the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
- Remove the lower A-pillar assembly. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Remove the driver side footwell cover. See Cover - Footwell - Driver (Remove and Replace).
- Remove the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
-
Remove the LH front main cabin carpet
clips (x2).
NoteNumber of clips on new vehicles may vary.
-
Fold the LH front main cabin carpet
aside for access.
NoteDead pedal and foam block are parts of the carpet.
-
Remove the LH front footwell HV
battery bolts (x2).
Tip: Use of the following tool(s) is recommended:
- Torx Plus EP20 socket - 1139807-00-A
- Cordless Ratchet/Impact Driver
- 3/8in to 1/2in Adapter
- 3 in extension
- Ratchet/torque wrench
- Move the LH front seat forward and the RH front seat backward.
-
Repeat step 4 to 8 to the RH side.
NoteFor the passenger side footwell cover, see Cover - Footwell - Front Passenger (Remove and Replace).
-
Remove the clip that attaches the RH
front main carpet to vehicle.
NoteNumber of clips on new vehicles may vary.
-
Fold the RH front main cabin carpet
aside for access.
NoteLift the center piece and pull the carpet back, release the seat harness from clips (x2) to allow the carpet to fold back more.
-
Remove the RH front footwell HV
battery bolts (x2).
Tip: Use of the following tool(s) is recommended:
- Torx Plus EP20 socket - 1139807-00-A
- Cordless Ratchet/Impact Driver
- 3/8in to 1/2in Adapter
- 3 in extension
- Ratchet/torque wrench
- Move the RH front seat forward, and close the RH front door.
- Remove the 2nd row floor mat from vehicle.
- Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
- Pull back the rear carpet to access the rear interior battery bolts.
-
Remove the LH and RH rear HV battery
interior bolts (x2).
NoteLift up the carpet for access.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
- Close the LH and RH rear door latches manually.
- Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
-
Place the vehicle in Service Mode
Plus.
NoteIn Vehicle Ops mobile app, enter the last six digits of VIN, and 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.
- Unlock the vehicle gateway. See Gateway Unlock.
-
On the touchscreen, tap Run, and allow the routine to complete.
, tap NoteThermal Fill Drain routine has a 5 hour time limit. After 5 hours, the routine must be performed again.
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
-
Remove the bolt that secures the
charge port busbar access door.
Tip: Use of the following tool(s) is recommended:
- Insulated tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm 12-point deep socket
- Electrical Protective Gloves
- Tohnichi Torque Wrench
- Insulated tools:
-
Remove the bolts (x2) that attach the
charge port busbar kit to the HV header.
Tip: Use of the following tool(s) is recommended:
- Insulated tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm 12-point deep socket
- Electrical Protective Gloves
- Tohnichi Torque Wrench
- Insulated tools:
-
Lift and remove the charge
port busbar connector from the HV header.
NoteWiggle the connector back and forth to ease removal.WarningThe video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
- Remove the HV insulating gloves.
-
Disconnect the HVC logic connector and
install the logic cap.
NoteRelease the locking tab then push the handle downward to release the connector.
- Remove the DCDC ground busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
-
Remove and discard the nut that
attaches the positive LV output to the power conversion system (PCS) cable, and then
move the cable aside.
Tip: Use of the following tool(s) is recommended:
- 4 in extension
- Cordless Ratchet/Impact Driver
- 13 mm socket
- 13 mm 12-point deep socket
- Ratchet/torque wrench
- Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
- Remove the push clips (x3) that attach the lower rear edge of LH front wheel liner to vehicle for access to coolant hose.
-
Remove the bolt that attaches the LH
front wheel liner to skid plate.
Tip: Use of the following tool(s) is recommended:
- 10mm Deep Magnetic Nutsetter
- Cordless Ratchet/Impact Driver
- 10 mm deep socket
- Ratchet/torque wrench
- Hex Driver
- Use bungee strap to pull back the LH front wheel liner and secure it to the subframe.
- Position a coolant drain container underneath the LH front of the HV battery.
- Attach the hose extension to the coolant drain hose for extra length.
- Connect the battery flush fitting adapter to the coolant cart drain hose.
- Disconnect the spring clip that attaches the HV battery return hose to LH side of vehicle, and connect the battery flush fitting to the male side.
-
Attach the battery drain fitting
adapter to the female side of HV battery return tube.
NoteMake sure valve is set to closed. Perform a push-pull test to verify that the adapter is fully engaged.
- Attach the battery drain fitting adapter to the coolant cart pressure hose.
- Turn the valve knob to vertical position to open the valve on the battery drain fitting adapter.
-
Slowly open the valve on pressure
regulator, and allow coolant to drain out of the HV battery return tube.
NoteClose the valve on the pressure regulator once no coolant is draining from HV battery return hose.
- Disconnect the compressed air from the coolant cart.
-
Release the spring clip, and then
remove the battery drain fitting adapter from the female side of the HV battery return
tube.
NoteSet the valve knob to closed position.
-
Release the spring clip, and then
remove the battery flush fitting adapter from the male side of the HV battery return
tube.
NotePlug the hose once the adapter is removed.
- Repeat step 37 to 40 to the RH side.
-
Release the spring clip to disconnect
the powertrain supply hose from the powertrain supply tube.
NotePlug hoses as required.
-
Release the spring clip to disconnect
the powertrain return hose from the powertrain return tube.
NotePlug hoses as required.
-
Disconnect the HV battery manifold
hose.
NotePlug hoses as required.
- Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
-
Disconnect the A/C compressor HV
harness connector.
NoteUnlock by pulling back the red tab, then pushing the orange lip and pulling back the connector at the same time, and then pushing the green lip and pulling back the connector again to disconnect the connector.
- Remove the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Position a coolant drain container underneath the LH rear of the HV battery.
-
Disconnect the LH coolant hose from
the rear of HV battery.
NotePlug the coolant hose and the passthrough.
- Remove the fir tree clip that attaches the coolant hose to the rear subframe shear plate.
-
Disconnect the rear drive unit
inverter inlet tube from the LH rear of HV battery.
NotePlug the hose connections as needed. Coolant loss greater than 1L requires vacuum fill.
-
Attach the coolant drain hose adapter
to the power conversion system (PCS) outlet hose coupling.
NoteUse the adapter with 90 degree angle. Make sure that the locking tab is fully seated.
- Attach the coolant drain hose adapter to the coolant hose extension.
-
Attach the coolant hose extension to
the coolant drain hose.
WarningUse caution as coolant may spill. Make sure to wear safety glasses.
- Position the coolant drain container underneath the RH rear of vehicle.
-
Disconnect the rear powertrain supply
hose from the rear of HV battery.
NotePlug the hose connections as needed. Coolant loss greater than 1L requires vacuum fill.
-
Attach the coolant pressure tester to
the power conversion system (PCS) inlet hose coupling.
NoteThis adapter is connected to regulated air line adapter. Make sure the locking tab is fully seated.
- Attach the coolant pressure tester to the pressure fitting adapter.
- Connect the compressed air to the coolant pressure tester.
-
Open the regulator valve, then slowly
adjust the regulator to 50 psi.
WarningUse caution as coolant may spill. Make sure to wear safety glasses.
-
Open the 2nd valve slowly.
WarningUse caution as coolant may spill. Make sure to wear safety glasses.
- Set timer for 1 minute and select start. Once the timer is complete, select Stop Reset.
- Close the regulator valve.
- Disconnect the compressed air from coolant pressure tester.
- Remove the coolant pressure tester from the power conversion system (PCS) inlet hose coupling.
- Position the coolant drain container underneath the LH rear of HV battery.
- Remove the coolant drain adapter with hose from the power conversion system (PCS) outlet hose coupling.
-
Disconnect the rear drive unit outlet
hose from powertrain return tube and plug both hose ends.
NoteLower hose located at RH rear of HV battery. Use a shop towel to clean any residue coolant if necessary. Coolant loss greater than 1L requires vacuum fill.
- Remove the LH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
- Hand tighten the bolt that attaches the LH side of subframe to body.
- Remove the RH shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
- Hand tighten the bolt that attaches the RH side of subframe to body.
- Remove the support stand from under the vehicle.
-
Remove the nut that attaches the rear
drive unit HV cable bracket to the HV battery.
NoteNumber of fasteners may vary.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 10mm Deep Magnetic Nutsetter
-
Disconnect the connector that connects
the rear drive unit HV cable and HV battery.
NoteRelease 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 rear drive unit header are not damaged.
-
With assistance, place the HV battery
table into position, and lower the vehicle to support the HV battery.
NoteLine up the table so the middle 4 bolts are accessible through the opening in table. Adjust the final battery table position using adjustable caster jacks on the table.
-
Remove the middle bolts (x4) that
secure the HV battery center ski cover.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 6 in extension
- Socket 3/8in Dr EP14 - 1133570-00-A
-
Remove the bolts (x8) that attach the
LH and RH front support brackets to vehicle.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 6 in extension
- 16 mm socket
- 3 in extension
- Ratchet/torque wrench
-
Remove the LH and RH bolts (x16) that
attach the HV battery to vehicle.
Tip: Use of the following tool(s) is recommended:
- 3 in extension
- 13 mm socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- Flex head ratchet/flex head torque wrench
- With assistance, raise the vehicle free of HV battery.
- With assistance, remove the battery from under the vehicle.
- Lower the table, and release the clips (x5) to remove the powertrain return tube from the RH side of HV battery.
Install
- Install the powertrain return tube to the RH side of HV battery, and secure the clips (x5).
-
Install HV battery alignment rods
(x4).
NoteInstall 2 rods to the body at front of vehicle and the other 2 rods to battery near the ancillary bay.
- With assistance, position the HV battery under the vehicle.
-
With assistance, lower the vehicle
onto the HV battery and align the holes.
NoteUse alignment rods. Be sure that the coolant hoses do not get caught on the alignment rods. Caution not to damage HV cable. Do not fully lower the vehicle onto battery (this will help with installing battery bolts).
-
Set the LH and RH bolts (x16) that
attach the HV battery to vehicle with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down the bolts. Do not over tighten bolts. Fully torque at later step.
- Remove the HV battery alignment rods.
-
Set the bolts (x8) that attach the LH
and RH front support brackets to vehicle with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down bolts. Do not over tighten the bolts. Fully torque at later step.
-
Set the middle bolts (x4) that attach
the HV battery center ski cover with cordless impact.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting. Flush down bolts. Do not over tighten the bolts. Fully torque at later step.
-
Hand-tighten the bolts (x4) that
attach the HV battery to body at LH and RH shear plate area.
NoteTorque at later step.
-
Connect the rear drive unit HV cable
to HV battery.
NoteMake sure the connector lock is 90 degrees from the connector before beginning to secure the connector. Use one hand to support the connector while the other latching the locking tab. Once installed, verify that the latch is not damaged and is fully secured in the latched position.
-
Install the nut that attaches the rear
drive unit HV cable bracket to the HV battery.NoteNumber of fasteners may vary.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 10mm Deep Magnetic Nutsetter
-
Remove the hose plugs and connect the
rear drive unit outlet hose to powertrain return tube.
NotePerform a push-pull-push test to make sure hose is fully engaged. Use shop towel to clean any coolant residue if necessary. Coolant loss greater than 1L requires vacuum fill.
-
Remove the plugs and connect the rear
drive unit inverter inlet hose to the LH rear of HV battery.
NotePerform a push-pull-push test to make sure the hose is fully engaged. Coolant loss greater than 1L requires vacuum fill.
- Install the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Lower vehicle onto pack completely.
-
Torque the LH and RH bolts (x16) that
attach the HV battery to vehicle.Tip: Use of the following tool(s) is recommended:
- 3 in extension
- 13 mm socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- Flex head ratchet/flex head torque wrench
-
Torque the bolts (x8) that attach the
LH and RH front support brackets to vehicle.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 6 in extension
- 16 mm socket
- 3 in extension
- Ratchet/torque wrench
-
Torque the middle bolts (x4) that
secure the HV battery center ski cover.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 6 in extension
- Socket 3/8in Dr EP14 - 1133570-00-A
-
With assistance, raise the vehicle and
lower it onto locks, then remove the battery table from under the vehicle.
NoteSet vehicle to comfortable working height. Make sure there's an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to the side.
- Support the front portion of rear subframe.
- Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
- Remove the plugs and connect the HV battery manifold hose.
-
Remove the plugs and connect the
powertrain supply hose.
NotePerform a push-pull-push test to make sure the hose is fully engaged. Coolant loss greater than 1L requires vacuum fill.
-
Remove the plugs and connect the
powertrain return hose.
NotePerform a push-pull test to verify hoses are fully engaged. Coolant loss greater than 1L requires vacuum fill.
- Install the LH and RH front skid plates. See Skid Plate - HV Battery - Front (Remove and Replace).
- Connect the HV battery return hose.
-
Connect the A/C compressor HV harness
connector.
NoteEngage the locking tab.
- Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
- Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
-
Position the busbar kit connector and
lower it onto the HV header.
NoteShift the rear end of busbar assembly upward to help ease installation. If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
-
Install the bolts that attach the
charge port busbar kit to the HV header.Tip: Use of the following tool(s) is recommended:
- Insulated tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm 12-point deep socket
- Electrical Protective Gloves
- Tohnichi Torque Wrench
- Insulated tools:
-
Install the bolt that secures the
charge port busbar access door.Tip: Use of the following tool(s) is recommended:
- Insulated tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm 12-point deep socket
- Electrical Protective Gloves
- Tohnichi Torque Wrench
- Insulated tools:
- Install the DCDC ground busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
-
Install a new nut that attaches the positive LV output to the power conversion system
(PCS) cable.NoteMake sure the rubber boot is not pinched between the cable terminal and the pass through.Tip: Use of the following tool(s) is recommended:
- 4 in extension
- Cordless Ratchet/Impact Driver
- 13 mm socket
- 13 mm 12-point deep socket
- Ratchet/torque wrench
-
Remove the logic cap and connect the
HVC logic connector.
NoteAlign the connector then pull the handle to locking position. Get the connector fully seated.
- Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
- Remove the lift arms from below the vehicle, and move the vehicle away from the lift.
- On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap , and then allow the routine to complete.
-
Inspect the coolant level, top off as
necessary.
NoteEnsure that the coolant level is at the "Max" line.
-
Select Run, and then allow the routine to complete.
, click Note
- The routine will last for a while after the stop message displays. The coolant pumps are audible.
- The test lasts for approximately 10 mins. Do not start another routine during this time.
- Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
- The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
- If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
-
Install the LH and RH rear HV battery
interior bolts (x2).NoteLift up the carpet for access.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Install the push clips (x2) that
secures the rear carpet section.
NoteTuck the corners under the lower C pillar trim.
- Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
-
Close the LH and RH rear doors.
NoteRelease the latches before closing if manually latched.
- Open the LH front door.
-
Install the LH front footwell HV
battery bolts (x4).Tip: Use of the following tool(s) is recommended:
- Torx Plus EP20 socket - 1139807-00-A
- Cordless Ratchet/Impact Driver
- 3/8in to 1/2in Adapter
- 3 in extension
- Ratchet/torque wrench
-
Install the push clips (x2) that
attach the LH front main cabin carpet to vehicle.
NoteNumber of clips on new vehicles may vary.
- Install the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
- Install the driver side footwell cover. See Cover - Footwell - Driver (Remove and Replace).
- Install the lower A-pillar assembly. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Install the LH instrument panel end cap. See End Cap - Instrument Panel - LH (Remove and Replace).
- Install the LH front floor mat.
-
Repeat step 45 to 52 for the RH side.
NoteFor the passenger side footwell cover, see Cover - Footwell - Front Passenger (Remove and Replace).
- Close the RH front door.
-
Inspect coolant level and top off as
necessary, and then install the coolant bottle cap.
NoteEnsure that the fluid level is at Max line.
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Install the LH and RH rocker panel lower covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Disable Service Mode. See Service Mode.
- Raise all windows and close the LH front door.