04/06/2024 18:04:05

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.

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.

Remove

Remove bolts securing LH rocker panel lower cover to body

Note
4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
Remove clips securing the LH rocker panel lower cover to wheel liners

Note
4x push clips
Remove LH rocker panel lower cover

Note
10x clips
Remove bolts securing RH rocker panel lower cover to body

Note
4x bolts, 10mm, 5 Nm, Release 4x covers to access bolts, The number of fasteners on newer vehicles may vary
Remove push clips (x4) securing the RH rocker panel lower cover to wheel liners
Remove RH rocker panel lower cover

Note
10x clips
Open all doors and lower all windows.
Open hood

Note
Press "Open" button on touchscreen to release latch, Lift lid manually
Remove rear apron

Note
12x clips, Only store rear apron visible face upwards
Remove cabin intake upper duct assembly

Note
3x clips, Some configurations may come with 4x clips
Move LH front seat backward
Remove LH IP end cap

Note
3x clips
Remove LH mid A-pillar assembly

Note
1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
Remove clip for LH lower A-pillar trim

Note
1x push clip
Remove LH lower A-pillar trim

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
Remove screw and clips securing LH footwell cover

Note
2x push clips, 1x screw, T20, 2.5 Nm
Remove connectors from LH footwell cover and remove from vehicle

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector that will have to be disconnected
Remove LH front floor mat
Remove LH console side panel carpet

Note
12x clips, Use trim tool starting at rear edge to release upper clips, then pull bottom to release remaining clips
Remove clips securing LH front main carpet to vehicle

Note
3x clips, Number of clips on new vehicles may vary
Fold the LH front main cabin carpet aside for access

Note
Dead pedal and foam block are part of carpet, Release seat harness from clip to allow the carpet to fold back more
Remove LH front footwell HV battery bolts

Note
2x bolts, EP20, 136 Nm
Move RH front seat backward
Remove RH IP end cap

Note
3x clips
Remove RH mid A-pillar assembly

Note
1x clip, 1x tab, Release upper clip then pull mid A-pillar upward to remove from vehicle
Remove clip from RH lower A-pillar trim

Note
1x push clip
Remove RH lower A-pillar trim

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
Release RH footwell assembly from IP

Note
4x push clips
Remove RH footwell assembly

Note
2x connectors
Remove RH front floor mat
Remove RH console side panel carpet

Note
12x clips, Use trim tool starting at rear edge to release upper clips, Pull bottom to release remaining clips
Remove clips securing RH front main cabin carpet to footwell area

Note
3x push clips, Number of clips may vary on older vehicles
Fold RH front main cabin carpet aside for access

Note
2x clips, Lift center piece and pull carpet back, Release seat harness from clips to allow carpet to fold back more
Remove RH front footwell HV battery bolts

Note
2x bolts, EP20, 136 Nm
Move RH front seat forward
Move LH front seat forward
Remove 2nd row floor mat from vehicle
Remove 2nd row seat cushion and disconnect harness

Note
2x 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
Fold the 40 seat in down position

Note
Protect the seat cushion
Remove RH side bolster

Note
1x clip, 1 tab, Pull outward then slightly upward to remove
Remove and discard bolster plastic bracket from RH side

Note
2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
Fold the 40 seat into vertical position
Remove the RH rear door sill trim panel

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
Fold the 60 seat in down position

Note
Protect the seat cushion
Remove LH side bolster

Note
1x clip, 1 tab, Pull outward then slightly upward to remove
Remove and discard bolster plastic bracket from LH side

Note
2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
Fold the 60 seat into vertical position

Note
Remove seat protection
Remove the LH rear door sill trim panel

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
Remove clips securing rear main cabin carpet to vehicle

Note
2x push clips
Remove LH rear HV battery interior bolt

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access
Remove RH rear HV battery interior bolt

Note
1x bolt, 16mm, 66 Nm, Lift up carpet for access
Place wheel chocks to keep vehicle from moving
Connect to vehicle using Toolbox 3.0

Note
Vehicle 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
Enter EPB Service Mode through toolbox 3

Note
Select ‘Actions’ tab and search for 'EPB Enter Service Mode', Select 'PROC_EPB_X_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
Enter EPB Service Mode through toolbox 3

Note
Select ‘Actions’ tab and search for 'EPB Enter Service Mode', Select 'PROC_EPB_X_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
Enter EPB Service Mode through toolbox 3

Note
Select ‘Actions’ tab and search for 'EPB Enter Service Mode', Select 'PROC_EPB_X_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
Remove laptop from vehicle

Note
Do not close Toolbox 3.0, we will need to resume later
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect 12V negative terminal

Note
1x nut, 10mm, 6 Nm, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
Disconnect first responder loop

Note
1x connector, Release locking tab
Remove all items from pockets and ensure not wearing metal items
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
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
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 damage is present, Seal can be re-used
Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Remove HV cap from ancillary bay

Note
1x cap
Remove edge support bracket

Note
2x bolts, 10mm, 10 Nm, 1x clip
Remove fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Remove bolts securing charge port busbar to HV header

Note
2x bolts, 10mm, 9 Nm
Lift charge port busbar connector to remove from HV header

Note
4x guide tabs, Slightly wiggle aluminum connector housing back and forth to ease removal
Remove bolts securing LH inner ancillary bay rail to the ancillary bay cover

Note
2x bolts, T40, 24 Nm
Remove bolts securing RH inner ancillary bay rail to the ancillary bay cover

Note
2x bolts, T40, 24 Nm
Remove 12V cap from ancillary bay

Note
1x cap
Disconnect HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
Remove bolt securing DCDC ground busbar to body

Note
1x bolt, 12mm, 20 Nm
Remove DCDC ground busbar
Remove 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 nyloc nut, 13mm, 9 Nm, Discard nut after removal
Close all four doors

Note
Make sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down
Push vehicle onto lift

Note
Recommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
Raise and support vehicle

Note
Remove body plugs and install M3 lift pad adapters to indicated locations
Raise vehicle fully and lower lift onto locks

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
Remove outer fasteners securing front aero shield

Note
9x bolts, 10mm, 5 Nm
Remove remaining nuts and remove front aero shield from vehicle

Note
2x nuts, 15mm, 5 Nm
Remove the clips securing the front LH and RH wheel liners to the front skid plate

Note
2x push clips
Remove bolts securing front skid plate

Note
4x bolts, EP10, 13 Nm
Remove skid plate from HV battery
Remove bolt securing FDU HV harness to the FDU

Note
1x bolt, 10mm, 10 Nm
Disconnect the FDU HV harness connector

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
Remove the FDU HV harness connector from the FDU and move aside

Note
1x connector
Remove bolt securing FDU ground strap to HV battery

Note
1x bolt, 10mm, 10 Nm
Release FDU ground strap harness clip from FDU

Note
1x clip
Disconnect both AC compressor HV harness connectors on HV battery

Note
2x 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
Remove push clip securing LH front wheel liner to LH rocker panel

Note
1x push clip
Remove push clip securing RH front wheel liner to RH rocker panel

Note
1x push clip
Use bungee strap to pull back LH front wheel liner

Note
Secure to subframe
Use bungee strap to pull back RH front wheel liner

Note
Secure to subframe
Position coolant drain container underneath RH front of HV battery
Disconnect PT return tube from FDU inverter inlet hose

Note
2x clips, 2x plugs, Lower hose located on RH front of HV battery, Plug both hose ends
Disconnect PT supply tube and plug both hose ends

Note
2x clips, 2x plugs, Upper hose located on RH front of HV battery
Position coolant drain container underneath LH front of HV battery
Disconnect HV battery return tube from HV battery hose

Note
2x 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
Position coolant drain container below HV battery front manifold hose
Release HV battery front manifold hose from body

Note
1x clip
Disconnect HV battery front manifold hose and plug both hose ends

Note
1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill
Remove coolant drain container from underneath vehicle
Remove mid aero shield

Note
13x bolts, 10mm, 5 Nm
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate enclosure

Note
2x fir tree clips
Release clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Remove lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Older VINs may be equipped with additional fastener count
Remove upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
Remove upper bolts securing HV battery rear skid plate enclosure

Note
4x bolts, 13mm, 35 Nm
Remove HV battery rear skid plate enclosure
Position coolant drain container underneath LH rear of HV battery
Disconnect RDU inverter inlet tube from LH rear of HV battery

Note
1x spring clip, 2x plugs, Plug HV battery and hose, Coolant loss greater than 1 L will require vacuum fill
Position coolant drain container underneath RH rear of vehicle
Disconnect RDU outlet hose from PT return tube and plug both hose ends

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
Remove coolant drain container from underneath vehicle
Remove nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary
Disconnect RDU HV cable from HV battery

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
Support front portion of rear subframe
Remove smaller fasteners securing LH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove smaller fasteners for RH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard at later step
Hand tighten bolt securing RH side of subframe to body

Note
1x bolt, 21mm, 130 Nm
Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Hand tighten bolt securing LH side of subframe to body

Note
1x bolt, 21mm, 130 Nm
Remove support stand from under vehicle
Place HV battery table into position and lower vehicle to support HV battery

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
Remove central bolts securing HV battery center ski cover

Note
4x bolts, EP14, 34 Nm
Remove bolts securing RH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Remove bolts securing LH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Remove LH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Remove RH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Raise vehicle free of HV battery

Note
Recommend assistance
Remove ancillary bay perimeter seal from HV battery pack

Note
Discard anytime HV battery is removed from vehicle
Remove PT return tube from RH side of HV battery

Note
5x clips, Lower hose location, Remove plugs from both ends of hose and allow coolant to fully drain if discarding

Install

Install PT return tube to RH side of HV battery

Note
5x clips, Lower hose location
Install ancillary bay perimeter seal onto HV battery pack

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
Install HV battery alignment rods

Note
2x rods, To body at front of vehicle, 2x rods, To battery near ancillary bay
Lower vehicle onto HV battery and align holes

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)
Set RH bolts securing HV battery to vehicle with cordless impact

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
Set LH bolts securing HV battery to vehicle with cordless impact

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
Remove HV battery front alignment rods

Note
2x rods
Set bolts securing RH front support bracket to vehicle with cordless impact

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
Set bolts securing LH front support bracket to vehicle with cordless impact

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
Set central bolts securing HV battery center ski cover with cordless impact

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
Open LH rear door
Remove HV battery alignment rod from LH rear HV battery interior bolt location

Note
1x rod
Set LH rear HV battery interior bolt with cordless impact

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
Close LH rear door
Open LH front door
Set LH front footwell HV battery bolts with cordless impact

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
Close LH front door
Close RH rear door

Note
Do not latch
Open RH rear door
Remove HV battery alignment rod from RH rear HV battery interior bolt location

Note
1x rod
Set RH rear HV battery interior bolt with cordless impact

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
Close RH rear door

Note
Do not latch
Open RH front door
Set LH front footwell HV battery bolts with cordless impact

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
Close RH front door

Note
Do not latch
Lower vehicle onto pack completely

Note
Recommend assistance
Torque RH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque LH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque bolts securing RH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque bolts securing LH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque central bolts securing HV battery center ski cover

Note
4x bolts, EP14, 34 Nm
Raise vehicle and lower onto locks, then remove battery table from under vehicle

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
Support front portion of rear subframe
Remove bolt securing LH side of rear subframe to body

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Install bolt and shear plate to LH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing LH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm
Remove bolt securing RH side of rear subframe to body

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Install RH front bolt and shear plate to rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm
Torque bolts securing shear plates to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque bolt securing subframe and LH shear plate to body

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque
Torque bolt securing subframe and RH shear plate to body

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque
Remove support stand from under vehicle
Connect RDU HV cable to HV battery

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
Install nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary
Position coolant drain container underneath RH rear of vehicle
Remove hose plug from RDU outlet hose and connect to PT return hose

Note
1x 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

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
Remove coolant drain container from underneath vehicle
Position HV battery rear skid plate enclosure onto HV battery for installation

Note
Recommend assistance if needed
Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing HV battery rear skid plate enclosure hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts
Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm
Install clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Install RH side hose clips to HV battery rear skid plate enclosure

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
13x bolts, 10mm, 5 Nm
Position coolant drain container underneath LH front of HV battery
Remove plugs then connect HV battery return tube

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.
Position coolant drain container below HV battery front manifold hose
Remove plugs then connect HV battery front manifold hose

Note
1x 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.
Secure HV battery front manifold hose to body

Note
1x barrel clip
Position coolant drain container underneath RH front of HV battery
Remove plugs then connect PT supply tube

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
Remove plug and connect PT return tube

Note
2x 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

Note
Remove strap from vehicle
Release LH front wheel liner from bungee strap

Note
Remove strap from vehicle
Install push clip securing LH front wheel liner to LH front rocker panel

Note
1x push clip
Install clip securing RH front wheel liner to RH rocker panel

Note
1x push clip
Connect both AC compressor HV harness connectors on HV battery

Note
2x 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

Note
1x clip
Install FDU ground strap and bolt to HV battery

Note
1x bolt, 10mm, 10 Nm
Install FDU HV harness connector to FDU

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
Secure FDU HV harness connection to FDU

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
Install bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Install front skid plate onto HV battery

Note
2x tabs, Slide tabs onto front of HV battery
Install the bolts securing the front skid plate to the HV battery

Note
4x bolts, E10, 13 Nm
Install the clips securing the front LH and RH wheel liners to the front skid plate

Note
2x push clips
Position front aero shield to vehicle and install nuts

Note
2x nuts, 15mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
9x bolts, 10mm, 5 Nm
Lower vehicle fully and move rack arms away from vehicle

Note
Remove M3 lift adapters from body and install body plugs
Push vehicle away from lift

Note
Recommend 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

Note
1x 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

Note
1x cover
Install DCDC ground busbar
Install bolt securing DCDC ground busbar to body

Note
1x bolt, 12mm, 20 Nm
Install nut securing DCDC ground busbar to HV battery

Note
1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
Remove logic cap and connect HVC logic connector

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
Install 12V cap to ancillary bay

Note
1x cap
Install bolts securing RH inner ancillary bay rail to the ancillary bay cover

Note
2x bolts, T40, 24 Nm
Install bolts securing LH inner ancillary bay rail to the ancillary bay cover

Note
2x bolts, T40, 24 Nm
Clean busbar HV connector contact surface of residual Penetrox

Note
Allow 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

Note
Allow 1 minute dry time after wiping away Penetrox, New busbar comes with penetrox applied to HV connector
Apply Penetrox onto HV connector joints

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
Position charge port busbar connector to HV header

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
Install bolts securing charge port busbar HV header

Note
2x bolts, 10mm, 9 Nm
Install edge support bracket

Note
2x bolts, 10mm, 10 Nm, 1x clip
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
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

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
Remove HV insulating gloves
Install fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Install HV cap to ancillary bay

Note
1x cap
Torque LH rear HV battery interior bolt

Note
1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access if necessary
Torque RH rear HV battery interior bolt

Note
1x bolt, 16mm, 66 Nm, Lift up RH rear main carpet for access if necessary
Install clips and secure Velcro holding rear main cabin carpet to vehicle

Note
2x push clips
Install the LH rear door sill trim panel

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
Install RH rear door sill trim panel

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
Connect 2nd row seat cushion harness and install 2nd row seat cushion

Note
2x 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
Install 2nd row floor mat into vehicle
Remove coolant bottle cap
Install refill tool cap onto coolant bottle assembly
Setup vacuum refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose onto refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully engaged
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Position overflow hose into empty container
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open refill valve to allow coolant to be drawn into system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once gauge reads zero, close refill valve
Disconnect shop air supply from coolant refill tool
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect first responder loop

Note
1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer
Connect 12V negative terminal

Note
1x nut, 10mm, 6 Nm
Move LH front seat backward
Press and hold park button to release EPB service mode

Note
Remove wheel chocks if necessary
Torque LH front footwell HV battery bolts

Note
2x bolts, EP20, 136 Nm
Fold the LH front main cabin carpet back to original position

Note
Move front edge down and slide back section up to ease positioning, Install seat harness into clip
Install clips securing LH front main cabin carpet to vehicle

Note
3x push clips, Number of clips on newer vehicles may vary
Install LH console side panel carpet

Note
1 tab, 12x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
Install LH front floor mat
Install LH lower A-pillar trim

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
Install clip for LH lower A-pillar trim

Note
1x push clip
Install LH mid A-pillar assembly

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
Install LH IP end cap

Note
3x clips
Install connectors to LH footwell cover and position for installation, securing front tabs to driver air bag assembly

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector, APAC specific vehicles have an additional OBDII connector
Install screw and clips securing LH footwell cover

Note
1x screw, T20, 2.5 Nm, 2x push clips
Connect to vehicle using Toolbox 3.0

Note
Vehicle 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
Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete

Note
Select ‘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-PURGE ’, click ‘Run’, and allow routine to complete

Note
Make 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

Note
Select ‘Actions’ tab and search for 'Thermal System Performance Test', Select TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE, select 'Complete inflate' click 'RUN'. Select ‘X’ at top right of window to close once complete.
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Install coolant bottle cap
Install cabin intake upper duct assembly

Note
3x clips, Some configurations may come with 4x clips
Install rear apron

Note
12x clips
Close hood
Move RH front seat backward
Torque RH front footwell HV battery bolts

Note
2x bolts, EP20, 136 Nm
Unfold RH front main cabin carpet back to original position

Note
Move 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

Note
3x push clips, Number of clips may vary on older vehicles
Install RH console side panel carpet

Note
1 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

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
Install clip for RH lower A-pillar trim

Note
1x push clip
Install RH mid A-pillar assembly

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
Install RH IP end cap

Note
3x clips
Position RH footwell assembly

Note
2x connectors
Install RH footwell assembly onto IP

Note
4x push clips
Move RH front seat to original position
Move LH front seat to original position
Raise all windows
Close all four doors

Note
Unlatch rear doors before closing
Install RH rocker panel lower cover into position

Note
10x clips
Install clips securing the RH rocker panel lower cover to wheel liners

Note
4x push clips
Install bolts securing RH rocker panel lower cover to body

Note
4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary
Install LH rocker panel lower cover into position

Note
10x clips
Install clips securing the LH rocker panel lower cover to wheel liners

Note
4x push clips
Install bolts securing LH rocker panel lower cover to body

Note
4x bolts, 10mm, 5 Nm, Secure 4x covers, The number of fasteners on newer vehicles may vary