Correction code 16014567 FRT 1.02 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

1. 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, The number of bolts on newer vehicles may vary, Early production vehicles may have 28x bolts, T30, 9 Nm

   

2. Remove HVC logic cap
   Note

   1x cap

   

3. Inspect HV insulating gloves
   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

   

4. Put on HV insulating gloves and leather over gloves
   Note

   Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves

   

5. Remove ancillary cover from HV battery

   

6. Remove battery pyro and shunt insulators
   Note

   2x insulators, Make sure to wear proper PPE from this step onward until the ancillary cover has been secured

   

7. Remove bolts securing pyro disconnect to ancillary bay
   Note

   2x patch bolts, 13mm, 9 Nm, Discard after removal

   

8. Remove pyro disconnect from ancillary bay
   Note

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

   

9. Lift HV Controller up to access fuse insulator
   Note

   Setup seatbelt to hold HVC assembly and tray in upward position

   

10. Install HVC logic cap
    Note

    1x cap

    

11. Install insulator for DC input assembly to both fastcharge busbars inlet side
    Note

    1x insulator

    

12. Install negative AC inlet terminal cover
    Note

    1x cover, 3x clips, Use caution as the clips are very easy to damage

    

13. Install positive AC inlet terminal cover
    Note

    1x cover, 3x clips, Use caution as the clips are very easy to damage

    

14. Install HVC logic cap
    Note

    1x cap

    

15. Install pyro disconnect dummy

    

16. Use bungee to secure HVC in an upwards position
    Note

    Wrap bungee around RH headrest

    

17. Remove the nuts securing the 700VDC 63A compressor fuse
    Note

    2x patch nuts, 8mm, 2.5 Nm, Discard after removal

    

18. Remove the 700VDC 63A PCS output fuse from AWD bus and dist assembly
    Note

    1x fuse

    

19. Remove the nuts securing the 700VDC 63A PCS output fuse
    Note

    2x patch nuts, 8mm, 2.5 Nm, Discard after removal

    

20. Remove the 700VDC 63A compressor fuse from AWD bus and dist assembly
    Note

    1x fuse

    

21. Remove nut securing the HV battery ancillary positive busbar
    Note

    1x nut, 10mm, 14Nm

    

22. Remove the HV battery ancillary positive busbar from AWD bus and dist assembly

    

23. Remove nut securing negative AC harness to negative HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm

    

24. Remove nuts securing PTC negative harness
    Note

    2x nut, 8mm, 4.5 Nm

    

25. Disconnect HV carrier connector
    Note

    1x connector

    

26. Remove screw securing HV carrier assembly
    Note

    1x screw, T20, 3 Nm

    

27. Remove HV carrier assembly

    

    

28. Install two upside-down M5 nuts on the ancillary tray.
    
29. Position the heat shrink sleeve on the new HV carrier wire as illustrated (green rectangle).
    
30. Attach the 2 HV carrier terminals together using an M4 nut and bolt (torque 2.5 Nm).
    
31. Slide the heat shrink sleeve over the fastened terminals, and then install the sleeve with a heat gun.
    Warning

    Use caution and if necessary, PPE such as protective gloves when handling the heat gun.
    
32. Install HV carrier assembly

    

    

    

    

33. Install screw securing HV carrier assembly
    Note

    1x screw, T20, 3 Nm

    

34. Connect HV carrier connector
    Note

    1x connector

    

35. Install nuts securing PTC negative harness
    Note

    2x nut, 8mm, 4.5 Nm

    

36. Install nut securing negative AC harness to negative HV battery DC link busbar
    Note

    1x nut, 8mm, 4.5 Nm

    

37. Install the HV battery ancillary positive busbar to AWD bus and dist assembly

    

38. Install the nut securing the HV battery ancillary positive busbar
    Note

    1x nut, 10mm, 4.5 Nm

    

39. Perform Hioki resistance test at 63A fuse input joint
    Note

    55 μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

40. Install 700VDC 63A PCS output fuse to AWD bus and dist assembly
    Note

    1x fuse

    

41. Install nuts securing the 700VDC 63A PCS output fuse
    Note

    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque

    

42. Perform Hioki resistance test at 63A fuse input joint
    Note

    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

43. Install the 700VDC 63A compressor fuse to AWD bus and dist assembly
    Note

    1x fuse

    

44. Install the nuts securing the 700VDC 63A compressor fuse
    Note

    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts

    

45. Perform Hioki resistance test at 63A fuse out joint
    Note

    1x HV joint, 145 μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

46. Perform Hioki resistance test at 63A fuse in joint
    Note

    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

47. Install fuses access insulator
    Note

    3x clips

    

48. Remove pyro disconnect dummy

    

49. Clean mating surface of pyro
    Note

    Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner

    

    

    

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

    

51. Position pyro disconnect to ancillary bay for installation
    Note

    1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way

    

    

52. Install bolts securing pyro disconnect to ancillary bay
    Note

    2x patch bolts, 13mm, 9 Nm, Install new patch bolts

    

53. Measure resistance from module 2 busbar to pyro disconnect
    Note

    1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

54. Measure resistance from pyro disconnect to shunt
    Note

    1x HV joint, 45μΩ or less

    

    

55. Install battery pyro and shunt insulators
    Note

    2x insulators

    

56. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
    Note

    Ensure no plastisol residue on ancillary bay or HVC, Remove plastisol residue if necessary, Fastener count may vary on new vehicles, Allow 1 minute for IPA to dry

    

    

57. Wipe penthouse with IPA to clean surface
    Note

    Allow to 1 minute dry time

    

58. Inspect penthouse 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 penthouse wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused

    

59. Inspect penthouse cover seal to confirm it has no visual damage
    Note

    Image up close for clarity, Delaminated and torn seals cannot be reused

    

    

    

    

60. Remove HVC logic cap
    Note

    1x cap

    

61. Remove ancillary Service Insulator Kit

    

    

    

    

    

    

    

    

62. Position ancillary cover to HV battery for installation

    

63. Install HVC logic cap
    Note

    1x cap

    

64. Install ancillary cover to HV battery
    Note

    18x bolts, E10 5-Lobe, 8 Nm, new SOP change fastener to captive E10 5-Lobe bolts, use E10 5-Lobe socket without magnet, Follow torque sequence per image, The number of bolts on newer vehicles may vary, Early production vehicles may have 28x bolts, T30, 9 Nm