Hose - Return - Powertrain (Heat Pump) (Remove and Replace)
Correction code 18303112 3.24 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.
Remove
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Remove bolts securing LH rocker panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
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Remove clips securing the LH rocker panel lower cover to wheel liners
Note4x push clips
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Remove LH rocker panel lower cover
Note10x clips
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Remove bolts securing RH rocker panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
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Remove push clips (x4) securing the RH rocker panel lower cover to wheel liners
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Remove RH rocker panel lower cover
Note10x clips
- Open all doors and lower all windows.
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Open hood
NotePress "Open" button on touchscreen to release latch, Lift lid manually
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Remove rear apron
Note12x clips, Only store rear apron visible face upwards
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Remove cabin intake upper duct assembly
Note3x clips, Some configurations may come with 4x clips
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Move LH front seat backward
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Remove LH IP end cap
Note3x clips
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Remove LH mid A-pillar assembly
Note1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
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Remove clip for LH lower A-pillar trim
Note1x push clip
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Remove LH lower A-pillar trim
Note2x clips, 3 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
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Remove screw and clips securing LH footwell cover
Note2x push clips, 1x screw, T20, 2.5 Nm
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Remove connectors from LH footwell cover and remove from vehicle
Note3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected
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Remove LH front floor mat
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Remove LH console side panel carpet
Note12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips
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Remove clips securing LH front main carpet to vehicle
Note3x clips, Number of clips on new vehicles may vary
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Fold the LH front main cabin carpet aside for access
NoteDead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more
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Remove LH front footwell HV battery bolts
Note2x bolts, EP20, 136 Nm
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Move RH front seat backward
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Remove RH IP end cap
Note3x clips
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Remove RH mid A-pillar assembly
Note1x clip, 1x tab, Release upper clip then pull mid A-pillar upward to remove from vehicle
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Remove clip from RH lower A-pillar trim
Note1x push clip
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Remove RH lower A-pillar trim
Note1x clip, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
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Release RH footwell assembly from IP
Note4x push clips
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Remove RH footwell assembly
Note2x connectors
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Remove RH front floor mat
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Remove RH console side panel carpet
Note12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips
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Remove clips securing RH front main cabin carpet to footwell area
Note3x push clips, Number of clips may vary on older vehicles
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Fold RH front main cabin carpet aside for access
Note2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more
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Remove RH front footwell HV battery bolts
Note2x bolts, EP20, 136 Nm
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Move RH front seat forward
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Move LH front seat forward
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Remove 2nd row floor mat from vehicle
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Remove 2nd row seat cushion and disconnect harness
Note2x tabs, 2x connectors, Slide locking tabs to left of vehicle while lifting up seat bench. Newer models have connectors on both sides of bench, Older models have 2x connectors on one side of bench
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Fold the 40 seat in down position
NoteProtect the seat cushion
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Remove RH side bolster
Note1x clip, 1 tab, Pull outward then slightly upward to remove
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Remove and discard bolster plastic bracket from RH side
Note2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
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Fold the 40 seat into vertical position
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Remove the RH rear door sill trim panel
Note3x 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
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Fold the 60 seat in down position
NoteProtect the seat cushion
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Remove LH side bolster
Note1x clip, 1 tab, Pull outward then slightly upward to remove
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Remove and discard bolster plastic bracket from LH side
Note2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
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Fold the 60 seat into vertical position
NoteRemove seat protection
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Remove the LH rear door sill trim panel
Note3x 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
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Remove clips securing rear main cabin carpet to vehicle
Note2x push clips
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Remove LH rear HV battery interior bolt
Note1x bolt, 16mm, 66 Nm, Lift up carpet for access
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Remove RH rear HV battery interior bolt
Note1x bolt, 16mm, 66 Nm, Lift up carpet for access
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Place wheel chocks to keep vehicle from moving
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Connect to vehicle using Toolbox 3.0
NoteVehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
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Enter EPB Service Mode through toolbox 3
NoteSelect ‘Actions’ tab and search for 'EPB Enter Service Mode', Select PROC_EPB_X_SERVICE-MODESearch for routine in ToolboxEPB Enter Service ModeChassis / Brakes - EPB Service ModeChassis / Brakes - EPB Service Modehv / Rear Drive Unit Replacement - Release / Re-Engage Emergency Parking BrakeChassis / Brakes - EPB Service Mode, select 'Both' and 'Start', click 'RUN', Hold down brake pedal while performing routine, Caution vehicle may roll freely, Select ‘X’ at top right of window to close once complete
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Enter EPB Service Mode through toolbox 3
NoteSelect ‘Actions’ tab and search for 'EPB Enter Service Mode', Select PROC_EPB_X_SERVICE-MODESearch for routine in ToolboxEPB Enter Service ModeChassis / Brakes - EPB Service ModeChassis / Brakes - EPB Service Modehv / Rear Drive Unit Replacement - Release / Re-Engage Emergency Parking BrakeChassis / Brakes - EPB Service Mode, select 'Both' and 'Start', click 'RUN', Hold down brake pedal while performing routine, Caution vehicle may roll freely, Select ‘X’ at top right of window to close once complete
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Enter EPB Service Mode through toolbox 3
NoteSelect ‘Actions’ tab and search for 'EPB Enter Service Mode', Select PROC_EPB_X_SERVICE-MODESearch for routine in ToolboxEPB Enter Service ModeChassis / Brakes - EPB Service ModeChassis / Brakes - EPB Service Modehv / Rear Drive Unit Replacement - Release / Re-Engage Emergency Parking BrakeChassis / Brakes - EPB Service Mode, select 'Both' and 'Start', click 'RUN', Hold down brake pedal while performing routine, Caution vehicle may roll freely, Select ‘X’ at top right of window to close once complete
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Remove laptop from vehicle
NoteDo not close Toolbox 3.0, we will need to resume later
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Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Disconnect 12V negative terminal
Note1x nut, 10mm, 6 Nm, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
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Disconnect first responder loop
Note1x connector, Release locking tab
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
NoteCheck 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
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
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Remove ancillary bay probe lid cover from ancillary bay cover
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Verify no high voltage
NoteMake 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
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Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
NoteConfirm no damage is present, Seal can be re-used
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Install bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
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Remove HV insulating gloves
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Remove HV cap from ancillary bay
Note1x cap
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Remove edge support bracket
Note2x bolts, 10mm, 10 Nm, 1x clip
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Remove fastener securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Remove bolts securing charge port busbar to HV header
Note2x bolts, 10mm, 9 Nm
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Lift charge port busbar connector to remove from HV header
Note4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal
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Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
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Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
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Remove 12V cap from ancillary bay
Note1x cap
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Disconnect HVC logic connector and install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
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Remove nut securing DCDC ground busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
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Remove bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
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Remove DCDC ground busbar
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Remove positive 12V output cover from PCS cable
Note1x cover
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Remove nut securing positive 12V output from PCS cable and move cable aside
Note1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
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Close all four doors
NoteMake sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down
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Push vehicle onto lift
NoteRecommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
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Raise and support vehicle
NoteRemove body plugs and install M3 lift pad adapters to indicated locations
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Raise vehicle fully and lower lift onto locks
NoteSet 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
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Remove outer fasteners securing front aero shield
Note9x bolts, 10mm, 5 Nm
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Remove remaining nuts and remove front aero shield from vehicle
Note2x nuts, 15mm, 5 Nm
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Remove the clips securing the front LH and RH wheel liners to the front skid plate
Note2x push clips
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Remove bolts securing front skid plate
Note4x bolts, EP10, 13 Nm
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Remove skid plate from HV battery
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Remove bolt securing FDU HV harness to the FDU
Note1x bolt, 10mm, 10 Nm
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Disconnect the FDU HV harness connector
Note1x 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
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Remove the FDU HV harness connector from the FDU and move aside
Note1x connector
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Remove bolt securing FDU ground strap to HV battery
Note1x bolt, 10mm, 10 Nm
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Release FDU ground strap harness clip from FDU
Note1x clip
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Disconnect both AC compressor HV harness connectors on HV battery
Note2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
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Remove push clip securing LH front wheel liner to LH rocker panel
Note1x push clip
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Remove push clip securing RH front wheel liner to RH rocker panel
Note1x push clip
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Use bungee strap to pull back LH front wheel liner
NoteSecure to subframe
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Use bungee strap to pull back RH front wheel liner
NoteSecure to subframe
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Position coolant drain container underneath RH front of HV battery
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Disconnect PT return tube from FDU inverter inlet hose
Note2x clips, 2x plugs, Lower hose located on RH front of HV battery, Plug both hose ends
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Disconnect PT supply tube and plug both hose ends
Note2x clips, 2x plugs, Upper hose located on RH front of HV battery
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Position coolant drain container underneath LH front of HV battery
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Disconnect HV battery return tube from HV battery hose
Note2x clips, 2x plugs, Located on LH front of HV battery, Install cap and plug to both ends, Coolant loss greater than 1 L will require vacuum fill
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Position coolant drain container below HV battery front manifold hose
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Release HV battery front manifold hose from body
Note1x clip
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Disconnect HV battery front manifold hose and plug both hose ends
Note1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill
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Remove coolant drain container from underneath vehicle
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Remove mid aero shield
Note13x bolts, 10mm, 5 Nm
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Release clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Release LH side hose clip from rear battery skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
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Release RH side hose clips from rear battery skid plate enclosure
Note2x fir tree clips
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Release clips securing coolant hoses to RH shear plate
Note2x fir tree clips
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Remove lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Older VINs may be equipped with additional fastener count
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Remove upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
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Remove upper bolts securing HV battery rear skid plate enclosure
Note4x bolts, 13mm, 35 Nm
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Remove HV battery rear skid plate enclosure
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Position coolant drain container underneath LH rear of HV battery
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Disconnect RDU inverter inlet tube from LH rear of HV battery
Note1x spring clip, 2x plugs, Plug HV battery and hose, Coolant loss greater than 1 L will require vacuum fill
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Position coolant drain container underneath RH rear of vehicle
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Disconnect RDU outlet hose from PT return tube and plug both hose ends
Note1x 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
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Remove coolant drain container from underneath vehicle
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Remove nut securing RDU HV cable bracket to HV battery
Note1x nut, 10mm, 10 Nm, Number of fasteners may vary
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Disconnect RDU HV cable from HV battery
Note1x 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
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Support front portion of rear subframe
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Remove smaller fasteners securing LH shear plate
Note2x bolts, 13mm, 35 Nm
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Remove smaller fasteners for RH shear plate
Note2x bolts, 13mm, 35 Nm
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Remove large bolt securing RH shear plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 130 Nm, Discard at later step
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Hand tighten bolt securing RH side of subframe to body
Note1x bolt, 21mm, 130 Nm
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Remove large bolt securing LH shear plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 130 Nm, Discard after removal
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Hand tighten bolt securing LH side of subframe to body
Note1x bolt, 21mm, 130 Nm
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Remove support stand from under vehicle
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Place HV battery table into position and lower vehicle to support HV battery
NoteRecommend 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
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Remove central bolts securing HV battery center ski cover
Note4x bolts, EP14, 34 Nm
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Remove bolts securing RH front support bracket to vehicle
Note4x bolts, 16mm, 110 Nm
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Remove bolts securing LH front support bracket to vehicle
Note4x bolts, 16mm, 110 Nm
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Remove LH bolts securing HV battery to vehicle
Note8x bolts, 13mm, 35 Nm
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Remove RH bolts securing HV battery to vehicle
Note8x bolts, 13mm, 35 Nm
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Raise vehicle free of HV battery
NoteRecommend assistance
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Remove ancillary bay perimeter seal from HV battery pack
NoteDiscard anytime HV battery is removed from vehicle
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Remove PT return tube from RH side of HV battery
Note5x clips, Lower hose location, Remove plugs from both ends of hose and allow coolant to fully drain if discarding
Install
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Install PT return tube to RH side of HV battery
Note5x clips, Lower hose location
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Install ancillary bay perimeter seal onto HV battery pack
NoteThis 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
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Install HV battery alignment rods
Note2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay
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Lower vehicle onto HV battery and align holes
NoteRecommend 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)
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Set RH bolts securing HV battery to vehicle with cordless impact
Note8x 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
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Set LH bolts securing HV battery to vehicle with cordless impact
Note8x 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
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Remove HV battery front alignment rods
Note2x rods
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Set bolts securing RH front support bracket to vehicle with cordless impact
Note4x 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
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Set bolts securing LH front support bracket to vehicle with cordless impact
Note4x 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
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Set central bolts securing HV battery center ski cover with cordless impact
Note4x 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
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Open LH rear door
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Remove HV battery alignment rod from LH rear HV battery interior bolt location
Note1x rod
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Set LH rear HV battery interior bolt with cordless impact
Note1x 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
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Close LH rear door
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Open LH front door
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Set LH front footwell HV battery bolts with cordless impact
Note2x 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
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Close LH front door
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Close RH rear door
NoteDo not latch
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Open RH rear door
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Remove HV battery alignment rod from RH rear HV battery interior bolt location
Note1x rod
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Set RH rear HV battery interior bolt with cordless impact
Note1x 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
-
Close RH rear door
NoteDo not latch
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Open RH front door
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Set LH front footwell HV battery bolts with cordless impact
Note2x 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
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Close RH front door
NoteDo not latch
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Lower vehicle onto pack completely
NoteRecommend assistance
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Torque RH bolts securing HV battery to vehicle
Note8x bolts, 13mm, 35 Nm
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Torque LH bolts securing HV battery to vehicle
Note8x bolts, 13mm, 35 Nm
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Torque bolts securing RH front support bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Torque bolts securing LH front support bracket to vehicle
Note4x bolts, 16mm, 110 Nm
-
Torque central bolts securing HV battery center ski cover
Note4x bolts, EP14, 34 Nm
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Raise vehicle and lower onto locks, then remove battery table from under vehicle
NoteRecommend 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
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Support front portion of rear subframe
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Remove bolt securing LH side of rear subframe to body
Note1x bolt, 21mm, 130 Nm, Discard after removal
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Install bolt and shear plate to LH side of rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
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Install bolts securing LH shear plate to HV battery hand tight
Note2x bolts, 13mm, 35 Nm
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Remove bolt securing RH side of rear subframe to body
Note1x bolt, 21mm, 130 Nm, Discard after removal
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Install RH front bolt and shear plate to rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
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Install bolts securing RH shear plate to HV battery hand tight
Note2x bolts, 13mm, 35 Nm
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Torque bolts securing shear plates to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque bolt securing subframe and LH shear plate to body
Note1x front bolt, 21mm, 130 Nm, Mark bolt after torque
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Torque bolt securing subframe and RH shear plate to body
Note1x front bolt, 21mm, 130 Nm, Mark bolt after torque
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Remove support stand from under vehicle
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Connect RDU HV cable to HV battery
Note1x 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
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Install nut securing RDU HV cable bracket to HV battery
Note1x nut, 10mm, 10 Nm, Number of fasteners may vary
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Position coolant drain container underneath RH rear of vehicle
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Remove hose plug from RDU outlet hose and connect to PT return hose
Note1x spring clip, 1x plug, 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.
-
Position coolant drain container underneath LH rear of HV battery
-
Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery
Note1x spring clip, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
-
Remove coolant drain container from underneath vehicle
-
Position HV battery rear skid plate enclosure onto HV battery for installation
NoteRecommend assistance if needed
-
Install upper bolts securing HV battery rear skid plate enclosure hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
-
Install upper nut securing HV battery rear skid plate enclosure hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
-
Install lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts
-
Torque bolts securing HV battery rear skid plate enclosure to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm
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Install clips securing coolant hoses to RH shear plate
Note2x fir tree clips
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Install RH side hose clips to HV battery rear skid plate enclosure
Note2x fir tree clips
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Install LH side hose clip to HV battery rear skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
-
Install clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Note13x bolts, 10mm, 5 Nm
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Position coolant drain container underneath LH front of HV battery
-
Remove plugs then connect HV battery return tube
Note2x 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.
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Position coolant drain container below HV battery front manifold hose
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Remove plugs then connect HV battery front manifold hose
Note1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
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Secure HV battery front manifold hose to body
Note1x barrel clip
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Position coolant drain container underneath RH front of HV battery
-
Remove plugs then connect PT supply tube
Note2x 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
-
Remove plug and connect PT return tube
Note2x clips, 1x plug, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill.
-
Release RH front wheel liner from bungee strap
NoteRemove strap from vehicle
-
Release LH front wheel liner from bungee strap
NoteRemove strap from vehicle
-
Install push clip securing LH front wheel liner to LH front rocker panel
Note1x push clip
-
Install clip securing RH front wheel liner to RH rocker panel
Note1x push clip
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Connect both AC compressor HV harness connectors on HV battery
Note2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
-
Secure FDU ground strap harness clip to FDU
Note1x clip
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Install FDU ground strap and bolt to HV battery
Note1x bolt, 10mm, 10 Nm
-
Install FDU HV harness connector to FDU
Note1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
-
Secure FDU HV harness connection to FDU
Note1x 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
-
Install bolt securing FDU HV harness to FDU
Note1x bolt, 10mm, 10 Nm
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Install front skid plate onto HV battery
Note2x tabs, Slide tabs onto front of HV battery
-
Install the bolts securing the front skid plate to the HV battery
Note4x bolts, E10, 13 Nm
-
Install the clips securing the front LH and RH wheel liners to the front skid plate
Note2x push clips
-
Position front aero shield to vehicle and install nuts
Note2x nuts, 15mm, 5 Nm
-
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
Note9x bolts, 10mm, 5 Nm
-
Lower vehicle fully and move rack arms away from vehicle
NoteRemove M3 lift adapters from body and install body plugs
-
Push vehicle away from lift
NoteRecommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Chock wheels.
-
Open all four doors
-
Install positive 12V output from PCS cable and torque nut
Note1x nyloc nut, 13mm, 9 Nm, Install new nut, Mark nut after torque, Make sure rubber boot is not pinched between cable terminal
-
Install positive 12V output cover
Note1x cover
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Install DCDC ground busbar
-
Install bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
-
Install nut securing DCDC ground busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
-
Remove logic cap and connect HVC logic connector
Note1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
-
Install 12V cap to ancillary bay
Note1x cap
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Install bolts securing RH inner ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Install bolts securing LH inner ancillary bay rail to the ancillary bay cover
Note2x bolts, T40, 24 Nm
-
Clean busbar HV connector contact surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Clean HV connector contact surface of residual Penetrox
NoteAllow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector
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Apply Penetrox onto HV connector joints
NoteApply 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
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Position charge port busbar connector to HV header
Note4x 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
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Install bolts securing charge port busbar HV header
Note2x bolts, 10mm, 9 Nm
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Install edge support bracket
Note2x bolts, 10mm, 10 Nm, 1x clip
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Inspect HV insulating gloves
NoteCheck 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
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Note2x 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
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Remove HV insulating gloves
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Install fastener securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Install HV cap to ancillary bay
Note1x cap
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Torque LH rear HV battery interior bolt
Note1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary
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Torque RH rear HV battery interior bolt
Note1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary
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Install clips and secure Velcro holding rear main cabin carpet to vehicle
Note2x push clips
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Install the LH rear door sill trim panel
Note3x 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
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Install RH rear door sill trim panel
Note3x 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
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Connect 2nd row seat cushion harness and install 2nd row seat cushion
Note2x connectors, Both connectors are located on LH side of vehicle, 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
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Install 2nd row floor mat into vehicle
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Remove coolant bottle cap
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Install refill tool cap onto coolant bottle assembly
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Setup vacuum refill tool
NoteVerify all valves on refill tool are in the closed position, See image for clarity
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Install vacuum refill hose onto refill cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully engaged
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Place refill hose inside filled coolant container
NoteMake sure hose end is fully submerged into coolant
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Position overflow hose into empty container
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Connect shop air supply to coolant refill tool
NoteIf not already done, Verify refill valve is set to off
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Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
NoteGauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
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Slowly open refill valve to allow coolant to be drawn into system
NoteMake sure hose end of refill hose is fully submerged during entire process
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Once gauge reads zero, close refill valve
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Disconnect shop air supply from coolant refill tool
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Remove coolant refill hose from coolant container
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Remove coolant overflow hose from coolant container
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Remove vacuum refill hose from refill cap on coolant bottle
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Remove coolant refill tool from vehicle
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Remove both coolant containers from inside underhood area
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Connect first responder loop
Note1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer
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Connect 12V negative terminal
Note1x nut, 10mm, 6 Nm
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Move LH front seat backward
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Press and hold park button to release EPB service mode
NoteRemove wheel chocks if necessary
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Torque LH front footwell HV battery bolts
Note2x bolts, EP20, 136 Nm
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Fold the LH front main cabin carpet back to original position
NoteMove front edge down and slide back section up to ease positioning, Install seat harness into clip
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Install clips securing LH front main cabin carpet to vehicle
Note3x push clips, Number of clips on newer vehicles may vary
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Install LH console side panel carpet
Note1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
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Install LH front floor mat
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Install LH lower A-pillar trim
Note2x 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
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Install clip for LH lower A-pillar trim
Note1x push clip
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Install LH mid A-pillar assembly
Note1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
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Install LH IP end cap
Note3x clips
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Install connectors to LH footwell cover and position for installation, securing front tabs to driver air bag assembly
Note3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector
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Install screw and clips securing LH footwell cover
Note1x screw, T20, 2.5 Nm, 2x push clips
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Connect to vehicle using Toolbox 3.0
NoteVehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
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Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete
NoteSelect ‘X’ at top right of window to close once complete
- Select ‘Actions/Autodiag’ tab and search for ‘Purge'
-
Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
NoteMake sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
-
Perform Thermal System Performance Test through toolbox 3
NoteSelect ‘Actions’ tab and search for 'Thermal System Performance Test', Select TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCESearch for routine in ToolboxThermal System Performance TestThermal / Actions - Test Thermal Performancehv / Front Drive Inverter Replacement - Thermal System Testhv / Rear Drive Inverter Replacement - Thermal System Testhv / Rear Left Drive Inverter Replacement - Thermal System Testhv / Rear Right Drive Inverter Replacement - Thermal System Testhv / Front Drive Unit Replacement - Thermal System Testhv / Rear Drive Unit Replacement - Thermal System Test, select 'Complete inflate' click 'RUN'. Select ‘X’ at top right of window to close once complete.
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Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
-
Inspect coolant level and top off as necessary
NoteEnsure that fluid level is at Max line
-
Install coolant bottle cap
-
Install cabin intake upper duct assembly
Note3x clips, Some configurations may come with 4x clips
-
Install rear apron
Note12x clips
-
Close hood
-
Move RH front seat backward
-
Torque RH front footwell HV battery bolts
Note2x bolts, EP20, 136 Nm
-
Unfold RH front main cabin carpet back to original position
NoteMove front edge down and slide back section up to ease positioning, Install seat harness into clips
-
Install clips securing the RH front main cabin carpet to footwell area
Note3x push clips, Number of clips may vary on older vehicles
-
Install RH console side panel carpet
Note1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
-
Install RH front floor mat
-
Install RH lower A-pillar trim
Note1x 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
-
Install clip for RH lower A-pillar trim
Note1x push clip
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Install RH mid A-pillar assembly
Note1x 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
-
Install RH IP end cap
Note3x clips
-
Position RH footwell assembly
Note2x connectors
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Install RH footwell assembly onto IP
Note4x push clips
-
Move RH front seat to original position
-
Move LH front seat to original position
-
Raise all windows
-
Close all four doors
NoteUnlatch rear doors before closing
-
Install RH rocker panel lower cover into position
Note10x clips
-
Install clips securing the RH rocker panel lower cover to wheel liners
Note4x push clips
-
Install bolts securing RH rocker panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary
-
Install LH rocker panel lower cover into position
Note10x clips
-
Install clips securing the LH rocker panel lower cover to wheel liners
Note4x push clips
-
Install bolts securing LH rocker panel lower cover to body
Note4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary