2026-03-05

Cover - Ancillary Bay (Swap) (Battery On Table)

Correction code 16300107 0.36 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. See Ergonomic Precautions for safe and healthy working practices.

Informational PurposesAn informational icon, calling your attention
Note
This procedure is to be performed if the HV battery has been removed and components must be reworked or swapped between old and new HV batteries. Add this correction code as a separate activity.
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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.
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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.
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Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

Torque Specifications

Table 1. Torque Specifications: Cover - Ancillary Bay (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the positive 12V output cable to the DCDC passthrough
9 Nm (6.6 lbs-ft)
  • 13 mm 12-point deep socket
Replace
Informational PurposesAn informational icon, calling your attention
Note
Mark the fastener with a paint pen after torquing.
Bolt that attaches the ancillary bay cover to the high voltage controller
5 Nm (3.7 lbs-ft) +30 deg
  • External Torx E10
Reuse
Bolt attaches the ancillary bay cover to the HV battery
8 Nm (5.9 lbs-ft)
  • External Torx E10 5-Lobe
Reuse
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
Informational PurposesAn informational icon, calling your attention
Note
Torque these fasteners in the sequence specified in the installation step.
Informational PurposesAn informational icon, calling your attention
Note
These bolts are attached to the ancillary bay cover.

Remove

  1. With the HV battery removed from the vehicle, remove the bolts that attach the high voltage controller internally to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
    Figure 1. 4-Bolt HVC Ancillary Bay Cover
    Figure 2. 3-Bolt HVC Ancillary Bay Cover
  2. Put on HV insulating gloves and leather over gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Continue to wear the gloves until instructed to remove them.
  3. Loosen the bolts that attach the ancillary bay cover to the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive to the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  4. Remove the logic connector cap from the high voltage controller connector.
  5. Remove the ancillary bay cover from the HV battery.
  6. Repeat steps 1 to 5 on the replacement HV battery.

Install

  1. Visually inspect the condition of the ancillary bay cover gasket and the new HV battery mating surface for cracks, cuts, gouges, abrasions, or any damage that could affect the seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the damage to the gasket is severe, replace the ancillary bay cover gasket. If there is minor damage (including paint) that might affect the seal, perform an ancillary bay air leak test when instructed to do so.
  2. Use an IPA wipe to clean any residue from the high voltage controller mounting bolt holes and both the inside and outside of the ancillary bay cover at the bolt holes.
  3. Install the ancillary bay cover on the new HV battery, and then hand-tighten the bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Different ancillary bay cover revisions have 28, 18, or 16 bolts.
  4. Remove HV insulating gloves.
  5. Reinstall the logic connector cap onto the high voltage controller connector.
  6. Torque the ancillary bay cover bolts in the sequence shown, and mark each with an orange paint pen as they are torqued.
    8 Nm (5.9 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Figure 3. 28-Bolt Ancillary Bay Cover Torque Sequence
    Figure 4. 18-Bolt Ancillary Bay Cover Torque Sequence
    Figure 5. 16-Bolt Ancillary Bay Cover Torque Sequence
  7. Install and hand-tighten the bolts that attach the high voltage controller internally to the ancillary bay cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not remove the LH upper A-pillar trim tether from the body side. If removed from the body side, the tether will have to be replaced.
    Figure 6. 5-Bolt HVC Ancillary Bay Cover
    Figure 7. 4-Bolt HVC Ancillary Bay Cover
    Figure 8. 3-Bolt HVC Ancillary Bay Cover
  8. Torque the high voltage controller to ancillary bay cover bolts in the sequence shown, and mark each bolt with an orange paint pen as they are torqued.
    5 Nm (3.7 lbs-ft) +30 deg
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Insufficient torque of bolts 1 and 2 opens the high voltage interlock loop circuit.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
    Figure 9. 5-Bolt HVC Ancillary Bay Cover
    Figure 10. 4-Bolt HVC Ancillary Bay Cover
    Figure 11. 3-Bolt HVC Ancillary Bay Cover
  9. Repeat steps 2 to 8 on the old HV battery to be shipped.
  10. If damage was found on the ancillary bay cover gasket or the HV battery mating surface, or if the aluminum tape retrofit patch was replaced, or if another procedure instructed to perform an ancillary bay air leak test, do that now. See Ancillary Bay Air Leak Test.
    Informational PurposesAn informational icon, calling your attention
    Note
    If an ancillary bay air leak test is performed, add correction code 16100400 as a separate activity to the Service Visit.