Model 3 Service Manual

01/08/2024 02:26:11

Correction code

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.

Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning

If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.

Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

2024-07-29: Added information on installing a recycling warning label with CE marking and manufacturer information, if this was present on the ancillary bay cover being replaced.
2023-11-08: Added/updated HV insulating glove steps.
2023-05-22: Added caution for correct positive DC cable connection.

Additional part that may be required for this operation (for Europe only):

1108781-BB-F: LABEL - RECYCLING WARNING - EU or
1108781-SH-F: LABEL - RECYCLING WARNING - EU

Remove

Warning

When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.

Open all four doors
Lower all four windows
Move LH front seat forward
Partially remove LH rear door seal
Remove LH 7s Lower C-Pillar Trim

Note
8x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
Fold 60 seat into down position
Disconnect logic connector at LH seat frame

Note
1x connector
Move 60 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove 60 seat rear outboard track fastener

Note
1x patch bolt, 11mm, 37 Nm, Discard after removal
Remove 60 seat rear inboard track fasteners

Note
2x patch bolts, 11mm, 37 Nm, Discard after removal
Move 60 seat fully rearward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove 60 seat outboard track cover

Note
1x clip, Slide covers forward to release from 60 seat tracks
Remove center track cover from 2nd row seats

Note
2x clips, Slide covers forward to release from 2nd row seat tracks
Release cabin carpet from 60 seat

Note
Pull cabin carpet towards front of vehicle
Remove 60 seat front inboard track fasteners

Note
1x bolts, 11mm, 37 Nm, Discard after removal
Remove 60 seat front outboard track fasteners

Note
1x bolts, 11mm, 37 Nm, Discard after removal
Remove 2nd row 60 seat assembly from vehicle

Note
Recommend assistance
Move RH front seat forward
Partially remove RH rear door seal

Note
Pillar and sill trim have tabs seated underneath seal
Remove RH rear sill trim

Note
8x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
Remove 40 seat outboard track cover

Note
1x clip, Slide cover forward to release from 40 seat track
Release cabin carpet from 40 seat

Note
Pull cabin carpet towards front of vehicle
Remove bolts securing 40 seat podium to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
Fold 40 seat into down position
Disconnect 40 frame connector

Note
1x connector
Move 40 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove bolts securing 40 seat inner and outer tracks to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
Move 40 seat fully rearward using towel bar

Note
With one hand on towel bar pull up and slide the seat rearward with your other hand
Remove 40 seat from vehicle

Note
Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
Remove 3rd row seat cushion and disconnect harness

Note
1x connector, Pull LH and RH release lever under 3rd row seat cushion to release seat cushion
Remove 3rd row RH seat cushion bolster

Note
1x bolt, 13mm, 37 Nm, Slide RH cushion bolster towards front of vehicle to remove
Remove 3rd row LH seat cushion bolster

Note
1x bolt, 13mm, 37 Nm, Slide LH seat cushion bolster towards front of vehicle to remove
Release clip securing 3rd row carpet to LH support bracket

Note
1x clip
Make a slit in 3rd row carpet around LH seat belt

Note
Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
Remove 3rd row carpet from under LH trunk side trim
Release clip securing RH body harness to body
Make a slit in 3rd row carpet around RH seat belt

Note
Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
Remove 3rd row carpet from under RH trunk side trim
Remove 3rd row carpet from vehicle
Open the hood.
Remove the rear apron.
Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
Disconnect the HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove 3rd row NVH insulator
Empty all pockets and remove all metal objects such as watches and jewelery.
Inspect the HV insulating gloves for any damage.
Put on the HV insulating gloves and leather over gloves.
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present, Replace gasket if damage is found
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Release positive 12V output cover from PCS cable

Note
1x cover
Remove nut securing positive 12V output from PCS cable and move cable aside

Note
1x nut, 13mm, 15 Nm, Discard after removal
Remove fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Discard after removal, Newer vehicles may be equipped with 3x bolts
Put on HV insulating gloves and leather over gloves.

Warning
Continue to wear the gloves until instructed to remove them.
Remove bolts securing ancillary bay cover to HV battery

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

Note
1x cap
Remove ancillary bay cover from HV battery

Note
Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step

Install

For Europe only: Check the ancillary bay cover that is being replaced for the presence of a recycling warning label that includes a CE marking and manufacturer information.

Figure 1. 1108781-BB-F shown, 1108781-SH-F similar
- If the recycling warning label with CE marking and manufacturer information is not present on the ancillary bay cover being replaced, continue to the next step.
- If the recycling warning label with CE marking and manufacturer information is present on the ancillary bay cover being replaced:
  1. Note the area where the recycling warning label is affixed on the ancillary bay cover being replaced.
  2. Clean the corresponding area on the new ancillary bay cover with an IPA wipe and allow 1 minute dry time.
  3. Install a new recycling label with CE marking and Manufacturing Information (part number 1108781-BB-F or 1108781-SH-F) on the new ancillary bay cover.
    Note
    For the correct part number, refer to the part number printed on the label that is attached to the ancillary bay cover being replaced.
Inspect ancillary bay walls for damage

Note
Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
Inspect ancillary bay cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Position the ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Install HVC logic cap

Note
1x cap
Install bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
Remove HV insulating gloves.
Install fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Install new bolts, Newer vehicles may be equipped with 3x bolts
Install positive 12V output from PCS cable and torque nut securing it

CAUTION
Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.

Note
1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque, Make sure rubber boot is not pinched between cable terminal and pass through
Install positive 12V output cover to PCS cable

Note
1x cover
Install 3rd row NVH insulator
Remove logic cap and connect the HVC logic connector

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
Install 3rd row carpet into vehicle
Install 3rd row carpet under RH trunk side trim
Install clip securing RH body harness to body

Note
1x clip
Install 3rd carpet under LH trunk side trim
Install clip securing 3rd row carpet to LH support bracket

Note
1x clip
Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
Install 3rd row LH seat cushion bolster

Note
1x bolt, 13mm, 37 Nm, Slide LH seat cushion bolster into seat frame assembly
Install 3rd row RH seat cushion bolster

Note
1x bolt, 13mm, 37 Nm, Slide RH seat cushion bolster into seat frame assembly
Install 3rd row seat cushion and connect harness

Note
1x connector, Secure 3rd row seat cushion into RH and LH latches
Install 40 seat into vehicle

Note
Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
Connect 40 seat frame connector to body harness

Note
1x connector
Install bolts securing 40 seat podium to vehicle hand tight

Note
2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step
Move 40 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Install bolts securing 40 seat inner and outer tracks to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Install new bolts
Move 40 seat to original position
Torque bolts securing 40 seat podium to vehicle

Note
2x patch bolts, 11mm, 37 Nm
Install cabin carpet to 40 seat
Install 40 seat outboard track cover

Note
1x clip
Install RH rear sill trim

Note
8x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips
Reseat RH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Move the RH front seat to its original position.
Install 2nd row 60 seat assembly

Note
Recommend assistance
Connect logic connector at LH 60 seat frame

Note
1x connector
Install fasteners securing 60 seat frame to body

Note
5x patch bolts, 11mm, 37 Nm, Install new patch bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
Secure cabin carpet to 60 seat

Note
Strap velcro on
Move 60 seat to original position
Install 60 seat outboard track cover

Note
1x clip
Install center track cover to 2nd row seats

Note
2x clip, Slide cover straight on to clip to 2nd row seat tracks
Install LH 7s Lower C-Pillar Trim

Note
8x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
Reseat LH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Move LH front seat to original position
Raise all four windows
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing

Remove

Install

Figure 1

Figure 2

Figure 3