13/06/2024 09:57:07

HV Battery (AWD) (3-Phase) (Remove and Replace)

Correction code 16010222 4.74 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.

  • 2024-06-13: Updated lift pad adapter PNs.
  • 2023-12-01 Updated HV insulating glove guidance when removing the old HV battery.
  • 2023-11-21: Added new lift pad instructions.
  • 2023-11-06: Updated UI steps.
  • 2023-08-23: Updated EPB Service Mode reference.
  • 2023-07-11: Reorganized steps to accommodate service while standing.
  • 2023-07-06: Added step to perform a charge port voltage check.
  • 2023-05-22: Added conspicuous discharge warning table.
  • 2023-03-16: Updated Discharge section and added steps to configure the HV battery.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be surface shipped must have a State of Charge (SoC) of less than 50%. HV batteries to be air shipped must have a SoC of less than 30%. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977, to determine if the HV battery parameters are within safe limits for shipment or storage.
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Note
If possible, perform the discharge procedure before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians..
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Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians..
  1. For Front of House and Service Advisors
  2. Identify the vehicle SOC.
    • If the SOC is less than the specified values, proceed with removal. See Remove.
    • If the SOC is greater than the specified values, lower all of the vehicle windows and turn on the climate control system to maximum defrost. This setting will discharge the battery by approximately 10% SOC every hour.
  3. Move the vehicle to a location where it can safely continue to discharge the battery unattended.
  4. Identify the vehicle SOC every half-hour.
  5. When the SOC is below 50% for surface transport, or below 30% for air transport, turn off the climate control system, raise the windows, and then move the vehicle to the service bay.
  6. For Service Technicians
  7. Identify the vehicle SOC Max value.
    • If the SOC Max value is less than the specified values, proceed with removal. See Remove.
    • If the SOC Max value is greater than the specified values, continue to the next step.
  8. Move the vehicle to a location where it can safely discharge the battery unattended.
  9. Enable Service Mode Plus. See Service Mode Plus.
  10. On the vehicle touchscreen, touch Lightning Bolt icon > HV System.
  11. Touch Start HV Discharge, and then in the window that opens, touch Run.
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    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  12. After discharge is complete, move the vehicle to the service bay.

Remove

  1. Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See Software Update.
  2. Remove bolts securing LH rocker panel lower cover to body.
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    Note
    4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
  3. Remove clips securing the LH rocker panel lower cover to wheel liners.
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    Note
    4x push clips.
  4. Remove LH rocker panel lower cover.
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    Note
    10x clips.
  5. Remove bolts securing RH rocker panel lower cover to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary.
  6. Remove clips securing the RH rocker panel lower cover to wheel liners.
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    Note
    4x push clips.
  7. Remove RH rocker panel lower cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips.
  8. Open all four doors.
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    Note
    If vehicle is being powered down, Latch rear doors to prevent accidental closure.
  9. Lower all four windows.
  10. Open hood.
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    Note
    Press "Open" button on the touchscreen to release the latch, Lift the lid manually.
  11. Remove rear apron.
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    Note
    12x clips, Only store rear apron visible face upwards .
  12. Remove cabin intake upper duct assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Heat pump vehicles have 3x clips.
  13. Move LH front seat backward.
  14. Remove LH IP end cap.
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    Note
    3x clips.
  15. Remove LH mid A-pillar assembly.
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    Note
    1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove.
  16. Remove clip for LH lower A-pillar trim.
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    Note
    1x push clip.
  17. Remove LH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 3 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
  18. Remove screw and clips securing LH footwell cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x screw, T20, 2.5 Nm.
  19. Remove connectors from LH footwell cover and remove from vehicle.
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    Note
    3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected.
  20. Remove LH front floor mat.
  21. Remove LH console side panel carpet.
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    Note
    12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips.
  22. Move RH front seat backward.
  23. Remove RH IP end cap.
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    Note
    3x clips.
  24. Remove RH mid A-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Release upper clip then pull mid A-pillar upward to remove from vehicle.
  25. Remove clip for RH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  26. Remove RH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet.
  27. Remove clips securing RH footwell assembly.
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    Note
    4x push clips.
  28. Disconnect RH foot well assembly connectors and remove from vehicle.
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    Note
    2x electrical connectors.
  29. Remove RH front floor mat.
  30. Remove RH console side panel carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips.
  31. Move RH front seat forward.
  32. Move LH front seat forward.
  33. Remove 2nd row floor mat from vehicle.
  34. Remove 2nd row seat cushion and disconnect harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 2x connectors, Press tab toward vertical backward of vehicle on each side to release front edge of seat cushion.
  35. Fold the 40 seat in down position.
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    Note
    Protect the seat cushion.
  36. Remove RH side bolster.
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    Note
    1x clip, 1 tab, Pull outward then slightly upward to remove.
  37. Remove and discard bolster plastic bracket from RH side.
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    Note
    2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
  38. Fold the 40 seat into vertical position.
  39. Remove the RH rear door sill trim panel.
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    Note
    3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
  40. Release clips securing the RH upper B-pillar assembly and move aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top of trim to release the remaining clips.
  41. Remove the RH lower B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
  42. Fold the 60 seat in down position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion.
  43. Remove LH side bolster.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1 tab, Pull outward then slightly upward to remove.
  44. Remove and discard bolster plastic bracket from LH side.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal.
  45. Fold the 60 seat into vertical position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat protection.
  46. Remove the LH rear door sill trim panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Pull upward at the lower corner of sill trim to release clip from lower B-pillar, then remove the remaining clips by pulling away from the body.
  47. Release clips securing the LH upper B-pillar assembly and move aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Pull the bottom of the upper B-pillar toward inside of the car, then pull the top to release the remaining clips.
  48. Remove the LH lower B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 6x clips, Remove the front push clip from lower B-pillar, then pull the top of B-pillar to release top clips then work your way to bottom clips.
  49. Remove clips securing rear main cabin carpet to vehicle.
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    Note
    4x push clips, Velcro strips, The number of clips on newer vehicles may vary.
  50. Move LH front seat backward.
  51. Remove clips securing LH front main carpet to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Number of clips on new vehicles may vary.
  52. Fold the LH front main cabin carpet aside for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    Dead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more.
  53. Remove LH front footwell HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm.
  54. Remove LH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access.
  55. Move RH front seat backward.
  56. Remove clips securing RH front main cabin carpet to footwell area.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, Number of clips may vary on older vehicles.
  57. Fold RH front main cabin carpet aside for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more.
  58. Remove RH front footwell HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm.
  59. Remove RH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access.
  60. Place wheel chocks to keep vehicle from moving.
  61. Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
  62. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  63. Select ‘Actions/Autodiag’ and search for ‘Thermal’.
  64. Select "Start Thermal Fluid Fill/Drain (Coolant only)", click Run and allow routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete, Verify vehicle is in Series via Garage > Vitals > Thermal tab > Coolant loops, Thermal Fluid Fill/Drain routine has a 5 hour limit, After 5 hours routine must be performed again.
  65. Remove laptop from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close Toolbox 3.0, we will need to resume later.
  66. Power off vehicle from center display.
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box.
  67. Disconnect 12V negative terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V.
  68. Remove 12V cap from ancillary bay.
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    Note
    1x cap.
  69. Disconnect HVC logic connector and install logic cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector.
  70. Remove all items from pockets and ensure not wearing metal items.
  71. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf.
  72. Put on HV insulating gloves and leather over gloves.
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    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
  73. Perform a charge port voltage check. See Charge Port Voltage Check.
  74. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover.
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    Note
    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal.
  75. Remove ancillary bay probe lid cover from ancillary bay cover.
  76. Verify no high voltage.
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    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.
  77. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover.
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    Note
    Confirm no damage is present, Seal can be re-used.
  78. Install bolts securing ancillary bay probe lid cover to ancillary bay cover.
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    Note
    2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners.
  79. Remove HV cap from ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap.
  80. Remove edge support bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm, 1x clip.
  81. Remove fastener securing busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm.
  82. Remove bolts securing charge port busbar to HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm.
  83. Lift charge port busbar connector to remove from HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal.
  84. Disconnect 3PH charge port inlet harness from HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release red locking tab and rotate lever arm to release.
  85. Remove HV insulating gloves.
  86. Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm.
  87. Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm.
  88. Remove nut securing DCDC ground busbar to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
  89. Remove bolt securing DCDC ground busbar to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 20 Nm.
  90. Remove DCDC ground busbar.
  91. Remove positive 12V output cover from PCS cable.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover.
  92. Remove nut securing positive 12V output from PCS cable and move cable aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal.
  93. Close all four doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down.
  94. Push vehicle onto lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed.
  95. Install Universal Lift Pad Adapters (1936724-00-A).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT use any other lift pad adapters.
    Informational PurposesAn informational icon, calling your attention
    Note
    Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model 3 (1453419-00-A. Use only the Universal Lift Pad Adapters and discard any other versions of lift pad adapters.
    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed. Do Not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black liftpad is toward the vehicle.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  96. Raise vehicle fully and lower lift onto locks.
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    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.
  97. Remove outer fasteners securing front aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm.
  98. Remove remaining nuts and remove front aero shield from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm.
  99. Remove the clips securing the front LH and RH wheel liners to the front skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips.
  100. Remove bolts securing front skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP10, 13 Nm.
  101. Remove skid plate from HV battery.
  102. Release connector from bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector.
  103. Put on HV insulating gloves.
  104. Disconnect A/C compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x Red locking tab, 2 stage push release, Unlock by pulling back red tab, Push orange lip and pull back ''stage 1'', Push green lip and pull back to disconnect.
  105. Remove bolt securing FDU HV harness to FDU.
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    Note
    1x bolt, 10mm, 10 Nm.
  106. Disconnect the FDU HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    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.
  107. Remove the FDU HV harness connector from the FDU and move aside.
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    Note
    1x connector.
  108. Remove HV insulating gloves.
  109. Remove bolt securing FDU ground strap to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm.
  110. Release FDU ground strap harness clip from FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip.
  111. Remove FDU ground strap bolt from HV battery and remove ground strap from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm.
  112. Remove push clip securing LH front wheel liner to LH rocker panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  113. Remove push clip securing RH front wheel liner to RH rocker panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  114. Use bungee strap to pull back LH front wheel liner.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure to subframe.
  115. Use bungee strap to pull back RH front wheel liner.
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    Note
    Secure to subframe.
  116. Position coolant drain container underneath RH front of HV battery.
  117. Disconnect PT return hose at RH side of vehicle and plug female side of hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip.
  118. Attach PT drain fitting adapter to male PT return hose.
  119. Attach hose extension to coolant drain hose for extra length.
  120. Attach PT drain fitting adapter to coolant cart drain hose.
  121. Disconnect PT supply tube and plug male side of hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Upper hose located on RH front of HV battery.
  122. Attach PT flush fitting adapter to female side of PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull test to verify adapter is fully engaged.
  123. Attach PT flush fitting adapter to coolant pressure tester with cart flush hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pressure regulator is not adjustable (set at 20 psi).
  124. Attach compressed air line to coolant pressure tester.
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    Note
    Verify valve is in closed position.
  125. Open valve on PT drain fitting adapter.
  126. Slowly open valve on pressure regulator and allow coolant to drain out of PT return hose.
  127. Close valve on pressure regulator .
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    Note
    Turn valve knob horizontal when coolant is no longer visibly draining.
  128. Disconnect compressed air from coolant pressure tester.
  129. Remove PT flush fitting adapter from female side of PT supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug PT supply hose.
  130. Remove PT drain fitting adapter from male side of PT return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug the PT return hose.
  131. Remove PT drain fitting adapter from cart drain hose.
  132. Remove PT flush fitting adapter from cart pressure hose.
  133. Position coolant drain container underneath LH front of HV battery.
  134. Disconnect HV battery return hose at LH side of vehicle and plug male side of hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip.
  135. Attach battery drain fitting adapter to female side of HV battery return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Make sure valve is set to closed, Perform push-pull test to verify adapter is fully engaged.
  136. Attach battery drain fitting adapter to coolant cart drain hose.
  137. Disconnect HV battery front manifold hose and plug female side of hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip.
  138. Release HV battery front manifold hose from body.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  139. Attach Battery flush fitting adapter to male side of HV battery supply hose.
  140. Attach battery flush fitting adapter to coolant cart pressure hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pre-set pressure regulator valve.
  141. Attach compressed air line to coolant pressure tester.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify valve is in closed position.
  142. Open valve on battery drain fitting.
  143. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Close valve on pressure regulator once no coolant is draining from HV battery return hose.
  144. Disconnect compressed air from coolant cart.
  145. Remove battery drain fitting adapter from female side of HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug HV battery return hose.
  146. Remove battery flush fitting adapter from male side of HV battery front manifold hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug HV battery front manifold hose.
  147. Remove coolant drain container from underneath vehicle.
  148. Remove battery drain fitting adapter from cart drain hose.
  149. Remove battery flush fitting adapter from cart pressure hose.
  150. Remove mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    13x bolts, 10mm, 5 Nm.
  151. Support front portion of rear subframe.
  152. Release clips securing coolant hoses to LH shear plate.
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    Note
    2x fir tree clips.
  153. Remove smaller fasteners securing LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  154. Remove large bolt securing LH shear plate and subframe to body and remove shear plate.
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    Note
    1x bolt, 21mm, 130 Nm, Discard after removal.
  155. Hand tighten bolt securing LH side of subframe to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm.
  156. Release clips securing coolant hoses to RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  157. Remove smaller fasteners for RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  158. Remove large bolt securing RH shear plate and subframe to body and remove shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Discard at later step.
  159. Hand tighten bolt securing RH side of subframe to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm.
  160. Remove support stand from under vehicle.
  161. Release LH side hose clip from rear battery skid plate enclosure.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles.
  162. Release RH side hose clips from rear battery skid plate enclosure.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  163. Remove lower bolts securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Older VINs may be equipped with additional fastener count.
  164. Remove upper nut securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles.
  165. Remove upper bolts securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  166. Remove HV battery rear skid plate enclosure .
  167. Position coolant drain container underneath LH rear of HV battery.
  168. Disconnect RDU inverter inlet tube from LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Plug HV battery and hose, Coolant loss greater than 1 L will require vacuum fill.
  169. Position coolant drain container underneath RH rear of vehicle.
  170. Disconnect RDU outlet hose from PT return tube and plug both hose ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
  171. Remove coolant drain container from underneath vehicle.
  172. Remove nut securing RDU HV cable bracket to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Number of fasteners may vary.
  173. Put on HV insulating gloves.
  174. Disconnect RDU HV cable from HV battery.
    Informational PurposesAn informational icon, calling your attention
    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.
  175. Remove HV insulating gloves.
  176. Place HV battery table into position and lower vehicle to support HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table.
  177. Remove central bolts securing HV battery center ski cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm.
  178. Remove bolts securing LH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  179. Remove bolts securing RH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  180. Remove front bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary.
  181. Remove LH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  182. Remove RH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  183. Raise vehicle free of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  184. Remove battery from under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  185. Remove Flexitol adjustable elements from the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, Hand tight, Reverse threads, Hardware will be installed onto new pack.
  186. Disconnect LH inner coolant hose from front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Use shop towel to clean any residue coolant if necessary.
  187. Remove LH manifold tube from LH front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Plug HV battery.
  188. Remove RH manifold tube from front of HV battery and plug both ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs.
  189. Remove RH manifold tube from RH front of HV battery and remove hose assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Plug HV battery side.
  190. Remove PT return tube from RH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Lower hose location.
  191. Remove PT supply hose from RH rear of HV battery and plug both ends.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Use shop towel to clean any residue coolant if necessary.
  192. Remove PT supply tube from RH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Upper hose location, Remove plugs from each end of hose and allow coolant to fully drain if discarding .
  193. Attach HV battery H-frame to gantry and raise into position.
  194. Position HV battery under gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, If original pack is RWD and supplied pack is DM, Center ski transfer will be needed.
  195. Lower H-frame onto HV battery and secure H-frame to battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen, Later production packs only use 6x bolts.
  196. Raise HV battery off of battery table.
  197. Position gantry over pallet.
  198. Lower HV battery onto pallet.
  199. Remove H-frame from old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen.
  200. Raise gantry and H-frame from old HV battery.
  201. Remove logic cap from old battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap.
  202. Open the crate top housing the new HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Confirm part number specific to vehicles configuration https://epcadmin.teslamotors.com/epcadmin .
  203. Remove nuts securing new HV battery to crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 15mm.
  204. Position gantry over new HV battery crate and secure H-frame to battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen, Hand tight.
  205. Lift new HV battery out of crate.
  206. Move gantry away from HV battery crate and over HV battery table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  207. Lower HV battery onto battery table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Make sure to align HV battery onto center ski.
  208. Release H-frame from HV battery and raise gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen, Hand tight.
  209. Remove HV battery from under gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  210. Position gantry over old HV battery.
  211. Lower H-frame onto old HV battery and secure H-frame to battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen.
  212. Raise old HV battery above height of HV battery crate.
  213. Position HV battery crate underneath old HV battery.
  214. Lower old HV battery into crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to align the 4 studs and not damage the battery.
  215. Remove H-frame from old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 8mm Allen, Hand tight.
  216. Raise gantry and H-frame from old HV battery.
  217. Lower gantry and remove HV battery H-frame from gantry.
  218. Install nuts securing HV battery to crate hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, 15mm.
  219. Close crate top housing old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.

Install

  1. Install logic cap onto the new battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap.
  2. Remove lower bolts securing rear battery enclosure skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, EP10, 13 Nm.
  3. Remove upper nut securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles.
  4. Remove upper bolts securing rear battery enclosure skid plate from HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  5. Remove rear battery enclosure skid plate from HV battery pack.
  6. Remove nuts securing RDU HV cable bracket to HV battery and remove RDU HV cable.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 10 Nm, Number of fasteners may vary on newer vehicles.
  7. Disconnect RDU HV cable from HV battery.
    Informational PurposesAn informational icon, calling your attention
    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.
  8. Disconnect RDU inverter inlet hose from rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip.
  9. Install PT supply tube to RH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Upper hose location, Loss of coolant greater than 1L requires coolant vacuum fill.
  10. Install PT supply tube to RH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Use shop towel to clean any residue coolant if necessary, Perform push-pull-push test to make sure hose is fully seated. Loss of coolant greater than 1L requires coolant vacuum fill.
  11. Install PT return tube to RH side of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x clips, Lower hose location.
  12. Install front hose assembly onto HV battery and secure RH outer coolant hose connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Use shop towel to clean any residue coolant if necessary, Make sure the locking clip is fully seated. Loss of coolant greater than 1L requires coolant vacuum fill.
  13. Install RH manifold tube to front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 1x plug, Remove plug from HV battery, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
  14. Connect LH outer coolant hose to front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Use shop towel to clean any residue coolant if necessary, Make sure the locking clip is fully seated. Loss of coolant greater than 1L requires coolant vacuum fill.
  15. Connect LH inner coolant hose to front of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Use shop towel to clean any residue coolant if necessary, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
  16. Install Flexitol adjustable elements onto the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x nuts, Reverse thread, Hand tight.
  17. Install ancillary bay perimeter seal onto HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped.
  18. Install HV battery alignment rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
  19. Position HV battery under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  20. Lower vehicle onto HV battery and align holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts).
  21. Set RH bolts securing HV battery to vehicle with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  22. Set LH bolts securing HV battery to vehicle with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  23. Install front bolts securing HV battery to vehicle hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, Reinstall fastener unless the body is patched or no hole exists, Patch the body if HV battery doesn't have these holes.
  24. Remove HV battery alignment rods.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay.
  25. Set bolts securing RH front support bracket to vehicle with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  26. Set bolts securing LH front support bracket to vehicle with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  27. Set central bolts securing HV battery center ski cover with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, EP14, 34 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  28. Install bolts securing HV battery to body at LH shear plate area hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step.
  29. Install bolts securing HV battery to body at RH shear plate area hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm, Torque at later step.
  30. Open LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components.
  31. Set LH rear HV battery interior bolt with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  32. Close LH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch.
  33. Open LH front door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components.
  34. Set LH front footwell HV battery bolts with cordless impact .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  35. Close LH front door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch.
  36. Open RH rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components.
  37. Set RH rear HV battery interior bolt with cordless impact.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up carpet for access, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  38. Close RH rear door.
  39. Open RH front door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution while working around this area not to damage any components.
  40. Set LH front footwell HV battery bolts with cordless impact .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm, Ensure smooth thread engagement and bolts are not cross threaded into pack, Flush down bolts, Do not over tighten bolts, Fully torque at later step.
  41. Close RH front door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not latch.
  42. Lower vehicle onto pack completely.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.
  43. Torque RH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  44. Torque LH bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 13mm, 35 Nm.
  45. Torque front bolts securing HV battery to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, The number of fasteners on newer vehicles may vary, If joint is found loose, note the VIN, joint location, take pictures and escalate via toolbox session.
  46. Torque bolts securing RH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  47. Torque bolts securing LH front support bracket to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 16mm, 110 Nm.
  48. Raise vehicle and lower onto locks, then remove battery table from under vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, 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.
  49. Support front portion of rear subframe.
  50. Remove smaller fasteners for LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, 13mm, 35 Nm.
  51. Remove smaller fasteners for RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolt, 13mm, 35 Nm.
  52. Install LH front bolt and shear plate to rear subframe hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
  53. Install bolts securing LH shear plate to HV battery hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  54. Install RH front bolt and shear plate to rear subframe hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
  55. Install bolts securing RH shear plate to HV battery hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 35 Nm.
  56. Torque bolts securing shear plates to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  57. Torque bolt securing subframe and LH shear plate to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
  58. Torque bolt securing subframe and RH shear plate to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
  59. Remove support stand from under vehicle.
  60. Install clips securing coolant hoses to RH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  61. Install clips securing coolant hoses to LH shear plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  62. Connect RDU HV cable to HV battery.
    Informational PurposesAn informational icon, calling your attention
    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.
  63. Install nut securing RDU HV cable bracket to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Number of fasteners may vary.
  64. Remove hose plugs and connect RDU outlet hose to PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary, Loss of coolant greater than 1L requires coolant vacuum fill.
  65. Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  66. Position HV battery rear skid plate enclosure onto HV battery for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance if needed.
  67. Install upper bolts securing HV battery rear skid plate enclosure hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm, Torque at later step.
  68. Install upper nut securing HV battery rear skid plate enclosure hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm, Torque at later step.
  69. Install lower bolts securing HV battery rear skid plate enclosure hand tight.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts.
  70. Torque bolts securing HV battery rear skid plate enclosure to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 35 Nm.
  71. Torque upper nut securing HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 13 Nm.
  72. Torque lower bolts securing rear battery enclosure skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts.
  73. Install RH side hose clips to HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips.
  74. Install LH side hose clip to HV battery rear skid plate enclosure .
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, Clip quantity may vary on older vehicles.
  75. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    13x bolts, 10mm, 5 Nm.
  76. Position coolant drain container underneath LH front of HV battery.
  77. Install HV battery front manifold hose clips to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  78. Remove plugs then connect male side to female side of HV battery front manifold hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, 1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
  79. Remove plugs then connect female side to male side of HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x plugs, 1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
  80. Position coolant drain container underneath RH front of HV battery.
  81. Remove plugs then connect PT supply tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
  82. Remove plugs then connect PT return tube.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 2x plugs, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.
  83. Remove coolant drain container from underneath vehicle.
  84. Release RH front wheel liner from bungee strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle.
  85. Release LH front wheel liner from bungee strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove strap from vehicle.
  86. Install push clip securing LH front wheel liner to LH front rocker panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  87. Install clip securing RH front wheel liner to RH rocker panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  88. Install FDU ground strap and bolt to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm.
  89. Secure FDU ground strap harness clip to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip.
  90. Install bolt securing FDU ground strap to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 6 Nm.
  91. Install FDU HV harness connector to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever.
  92. Secure FDU HV harness connection to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and engage red locking tab, Do not damage connector or header.
  93. Install bolt securing FDU HV harness to FDU.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm.
  94. Remove plastic bracket securing HV connectors to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips.
  95. Connect A/C compressor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
  96. Connect PTC HV connector to HV cable then reinstall bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 2 stage lock tab, Apply abrasion tape to harness if not present.
  97. Install front skid plate onto HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Slide tabs onto front of HV battery.
  98. Install the bolts securing the front skid plate to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, E10, 13 Nm.
  99. Install the clips securing the front LH and RH wheel liners to the front skid plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips.
  100. Position front aero shield to vehicle and install nuts.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm.
  101. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 5 Nm.
  102. Lower vehicle fully and move rack arms away from vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove M3 lift adapters from body and install body plugs.
  103. Push vehicle away from lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Chock wheels.
  104. Open all four doors.
  105. Install positive 12V output from PCS cable and torque nut.
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    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nut, Mark nut after torque, Make sure rubber boot is not pinched between cable terminal.
  106. Install positive 12V output cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover.
  107. Install DCDC ground busbar.
  108. Install bolt securing DCDC ground busbar to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 20 Nm.
  109. Install nut securing DCDC ground busbar to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut.
  110. Install bolts securing RH inner ancillary bay rail to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm.
  111. Install bolts securing LH inner ancillary bay rail to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T40, 24 Nm.
  112. Connect 3PH charge port inlet harness to HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Rotate lever arm and secure locking tab.
  113. Clean HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector.
  114. Apply Penetrox onto HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered.
  115. Position charge port busbar connector to HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x guide tabs, Recommend assistance, Shift 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.
  116. Clean busbar HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar.
  117. Install bolts securing charge port busbar connector to HV header.
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    Note
    2x bolts, 10mm, 9 Nm.
  118. Install edge support bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm, 1x clip.
  119. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf.
  120. Put on HV insulating gloves and leather over gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
  121. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step.
  122. Remove HV insulating gloves.
  123. Install fastener securing busbar cover access door.
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    Note
    1x bolt, 10mm, 9 Nm.
  124. Install HV cap to ancillary bay.
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    Note
    1x cap.
  125. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  126. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  127. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  128. Enable Service Mode Plus. See Service Mode Plus.
  129. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  130. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  131. Under High-Voltage-Battery, touch High Voltage Battery Replacement.
  132. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
  133. Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
  134. Disable Service Mode Plus. See Service Mode Plus.
  135. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  136. Close RH rear door.
  137. Close LH rear door.
  138. Close LH front door.
  139. Remove lift arms from below vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle.
  140. Open all four doors.
  141. Torque LH rear HV battery interior bolt.
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    Note
    1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary.
  142. Move LH front seat backward.
  143. Torque LH front footwell HV battery bolts.
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    Note
    2x bolts, EP20, 136 Nm.
  144. Fold the LH front main cabin carpet back to original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move front edge down and slide back section up to ease positioning, Install seat harness into clip.
  145. Install clips securing LH front main cabin carpet to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, Number of clips on newer vehicles may vary.
  146. Move LH front seat forward.
  147. Torque RH rear HV battery interior bolt.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary.
  148. Move RH front seat backward.
  149. Torque RH front footwell HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, EP20, 136 Nm.
  150. Unfold RH front main cabin carpet back to original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move front edge down and slide back section up to ease positioning, Install seat harness into clips.
  151. Install clips securing the RH front main cabin carpet to footwell area.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, Number of clips may vary on older vehicles.
  152. Move RH front seat forward.
  153. Install clips and secure Velcro holding rear main cabin carpet to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, The number of clips on newer vehicles may vary.
  154. Install the LH lower B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
  155. Install the LH upper B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
  156. Install the LH rear door sill trim panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Align the guiding tab to slot, Then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim. Newer vehicles may not be equipped with metal bracket and a foam insert will be present the bottom of trim piece.
  157. Fold the 60 seat in down position.
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    Note
    Protect the seat cushion if necessary.
  158. Install bolster plastic bracket to LH side bolster.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Install new bolster bracket.
  159. Install LH side bolster.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push inward to install.
  160. Fold the 60 seat into vertical position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection.
  161. Install the RH lower B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 6x clips, Align the bottom guide tab to its slot then press the bottom clips, Work your way to top clips, Install the front push clip then make sure the seal correctly overlaps the trim.
  162. Install the RH upper B-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Lower the seat belt slider to align it with the B-pillar panel, Insert top portion of upper B-pillar under the headliner to align the clips, Press the bottom to fully seat upper B-pillar to lower B-pillar, Make sure the seal correctly overlaps the trim.
  163. Install RH rear door sill trim panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x guide tab, Align the guiding tab to slot, then push downward to install the clips after aligning them, Make sure the seal sits overlapping the trim.
  164. Fold the 40 seat in down position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Protect the seat cushion if necessary.
  165. Install bolster plastic bracket to RH side bolster.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Install new bolster bracket.
  166. Install RH side bolster.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push inward to install.
  167. Fold the 40 seat into vertical position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection.
  168. Connect 2nd row seat cushion harness and install 2nd row seat cushion.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, 2x clips, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips.
  169. Install 2nd row floor mat into vehicle.
  170. Move RH front seat backward.
  171. Install RH console side panel carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
  172. Install RH front floor mat.
  173. Connect RH footwell assembly connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors.
  174. Install clips securing RH footwell assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips .
  175. Install RH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 2 guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar.
  176. Install clip for RH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  177. Install RH mid A-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align bottom tab then push on top clip to fully seat mid A-pillar, Make sure seal seat on top of trim.
  178. Install RH IP end cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips.
  179. Move LH front seat backward.
  180. Install LH console side panel carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear.
  181. Install LH front floor mat.
  182. Install connectors to LH footwell cover and position for installation, securing front tabs to driver air bag assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector.
  183. Install screw and clips securing LH footwell cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips, 1x screw, T20, 2.5 Nm.
  184. Install LH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clip, 3 guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim.
  185. Install clip for LH lower A-pillar trim.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip.
  186. Install LH mid A-pillar assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim.
  187. Install LH IP end cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips.
  188. Move LH front seat to original position.
  189. Move RH front seat to original position.
  190. Install cabin intake upper duct assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Heat pump vehicles have 3x clips.
  191. Install rear apron.
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips .
  192. Close hood.
  193. Raise all windows.
  194. Close all four doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Unlatch rear doors before closing.
  195. Install RH rocker panel lower cover into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips.
  196. Install clips securing the RH rocker panel lower cover to wheel liners.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips.
  197. Install bolts securing RH rocker panel lower cover to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.
  198. Install LH rocker panel lower cover into position.
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips.
  199. Install clips securing the LH rocker panel lower cover to wheel liners.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips.
  200. Install bolts securing LH rocker panel lower cover to body.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary.