Code de correction 16102012 3.96 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 Protection individuelle to make sure wearing proper PPE when performing the below procedure.

1. Open all doors and lower all windows.
2. Place the vehicle on the 2-post lift.
   Conseil : Ensure the vehicle is not charging.
3. Place vehicle in service mode through UI
   Remarque

   Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box

   

   

   

4. Turn Off the AC and Blower motor
   Remarque

   Check temperature icon at the bottom of the screen, If it greyed, AC is already off, If it bright, press and hold it for 2 seconds or press it once and press the switch icon in pop-up menu

   

5. Turn on the drive rail
   Remarque

   Sit in the driver’s seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle

   

   

6. Access Thermal System routines using the UI
   Remarque

   Select Service mode > Thermal

   

   

7. Connect to vehicle using Toolbox 3.0
   Remarque

   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

   

   

   

8. Select ‘Actions/Autodiag’ and search for ‘Plus’

   

9. Select "PROC_ICE_X_ENTER-SERVICE-MODEEnter Service ModeCommon/tasks/PROC_ICE_X_ENTER-SERVICE-MODEInfotainment-PLUS ", click "Run", and allow routine to complete
   Remarque

   Select "x" at the top right of the window to close once complete

   

   

   

10. Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle

    

    

11. Select "Start Thermal Fill Drain (Coolant only)" using the UI
    Remarque

    Reference pictures for navigation, Wait for the coolant section to say "Ready for Fill/Drain" and turn green also for "Inactive" to turn green and say "Success"

    

    

    

12. Move LH front seat forward

    

13. Move RH front seat forward

    

14. Open hood
    Remarque

    Press "Open" button on the touchscreen to release the latch, Lift the lid manually

    

    

15. Power off vehicle from center display
    Remarque

    Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box

    

    

16. Remove rear apron
    Remarque

    12x clips, Only store rear apron visible face upwards

    

    

    

17. Remove cabin intake upper duct assembly
    Remarque

    4x clips, Heat pump vehicles have 3x clips

    

    

18. Remove closeout panel from frunk assembly
    Remarque

    4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab closeout panel from bottom then pull it upward to release clips, Disconnect the switch

    

    

19. Remove bolts securing frunk assembly
    Remarque

    7x bolts, 10mm, 5 Nm, Lift up RBN covers to access upper fasteners, Newer vehicles may not be equipped with covers

    

20. Remove frunk assembly from vehicle
    Remarque

    12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles

    

    

    

21. Release positive terminal cover
    Remarque

    2x clips

    

22. Verify operation of multimeter
    Remarque

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 12v battery

    

23. Install positive terminal cover
    Remarque

    2x clips

    

24. Disconnect 12V negative terminal
    Remarque

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

    

25. Disconnect first responder loop
    Remarque

    1x connector, Release locking tab

    

26. Remove 2nd row seat cushion and disconnect harness
    Remarque

    2x tabs, 2x connectors, Press tab toward LH side of vehicle on each side to release front edge of seat cushion

    

    

    

    

27. Remove all items from pockets and ensure not wearing metal items

    

    

28. Inspect HV insulating gloves
    Remarque

    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

    

29. Put on HV insulating gloves and leather over gloves
    Remarque

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

30. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Remarque

    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

    

31. Remove ancillary bay probe lid cover from ancillary bay cover

    

32. Verify no high voltage
    Remarque

    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

    

    

    

    

33. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Remarque

    Confirm no damage is present, Seal can be re-used

    

34. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Remarque

    2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners

    

35. Remove HV insulating gloves

    

36. Raise vehicle fully and lower lift onto locks
    Remarque

    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

    

    

37. Remove outer fasteners securing front aero shield
    Remarque

    9x bolts, 10mm, 5 Nm

    

38. Remove remaining nuts and remove front aero shield from vehicle
    Remarque

    2x nuts, 15mm, 5 Nm

    

    

39. Remove the clips securing the front LH and RH wheel liners to the front skid plate
    Remarque

    2x push clips

    

40. Remove bolts securing front skid plate
    Remarque

    4x bolts, EP10, 13 Nm

    

41. Remove skid plate from HV battery

    

42. Inspect Front Skid Plate Bracket for the damage
    Remarque

    If HV battery passed all the previous checks and there is no visible damage to the HV battery structure apart of Front Skid Plate Bracket, continue with further steps

    

    

    

    

43. Position coolant drain container below HV battery hose

    

44. Remove RH manifold tube from LH manifold tube
    Remarque

    1x spring clip, 2x plugs,Prepare plugs from Coolant Hose Plug Kit, red and 18mm black,Move the retaining spring clip up into the grooves in the quick release coolant hose connector, Separate connectors and plug both ends

    

    

    

    

45. Position coolant drain container underneath RH manifold tube inner connection to HV battery

    

46. Remove RH manifold tube
    Remarque

    1x spring clip, 2x plugs. Prepare plugs from Coolant Hose Plug Kit, Dark Green and 12mm black,Move the retaining spring clip up into the grooves in the quick release coolant hose connector, Separate connectors and plug both ends

    

    

    

47. Remove RH manifold tube
    Remarque

    Move RH manifold tube and secure it with cable tie

    

48. Remove coolant drain container from underneath vehicle

    

49. Remove bolt securing FDU HV harness to FDU
    Remarque

    1x bolt, 10mm, 10 Nm

    

50. Remove all items from pockets and ensure not wearing metal items

    

    

51. Inspect HV insulating gloves
    Remarque

    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

    

52. Put on HV insulating gloves and leather over gloves
    Remarque

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

53. Disconnect the FDU HV harness connector
    Remarque

    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

    

    

    

54. Remove the FDU HV harness connector from the FDU and move aside
    Remarque

    1x connector

    

55. Disconnect both AC compressor and PTC heater HV harness connectors on HV battery
    Remarque

    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

    

    

    

    

56. Remove ancillary harness bracket from front of HV battery
    Remarque

    2x barrel clips

    

57. Wrap connectors
    Remarque

    Wrap connectors to prevent from debris or metal chips

    

58. Remove HV insulating gloves

    

59. Remove center ski cover from HV battery
    Remarque

    6x bolts, EP14, 34 Nm. Gently lower front of center ski cover to the floor

    

    

60. Use a spring loaded center punch to mark locations for drilling
    Remarque

    Use a center punch to create a small dimple in the center of each spot weld

    

    

61. Use spot weld cutters to remove the Front Skid Plate Bracket
    Remarque

    Use 3/8" size spot weld cutter,Use chiseling technique at high speed to allow the chips to fly out as the cut exits the aluminum, or clean the cutter manually after short drilling, Drill to a depth of no more than the thickness of the Skid Plate Bracket approximately 2.5mm,

    

    

    

62. Separate Skid Plate Bracket from HV battery
    Remarque

    When cutter is deep enough, use 38 mm Scraper or plastic wheel weight removal chisel and light hammer blows to try to separate the skid plate from the battery, If it didn't get off easy, try to drill a little deeper

    

    

63. Apply masking tape
    Remarque

    Mark mating surface with masking tape

    

64. Clean mating area
    Remarque

    Use 120 grit sand paper to remove paint on the mating surfaces

    

65. Create a stencil of holes for new skid plate bracket
    Remarque

    Stick the masking tape on old Skid Plate Bracket along the top edge,Use thin ballpoint pen to mark the holes and Skid Plate Bracket location on a masking tape peace

    

    

66. Mark the location of the new holes
    Remarque

    Remove a stencil from the old bracket and apply to the new one strictly in the same location,Use center punch to create a small dimple in the center of each circle

    

67. Drill holes in the new Skid Plate Bracket.
    Remarque

    Secure the new Skid Plate Bracket in a vise with a 5/16" Spot Weld Cutter. Use chiseling technique at high speed to allow the chips to fly out as the cut exits the hole, or clean the cutter manually after short drilling.

    Conseil : Nous recommandons l’utilisation des outils suivants :

    • Bench Vise
    • Size Spot Weld Cutter
    • Cordless Drill
    • Safety Glasses

    

    

    

68. Remove masking tape
    Remarque

    Remove masking tape from the HV battery and Skid Plate Bracket

    

69. Clean mating area
    Remarque

    Use 120 grit sand paper to clean future mating surfaces

    

70. Fit the pieces together
    Remarque

    Try the Skid Plate Bracket on a HV battery and check that the flat surfaces fit snugly together

    

    

    

71. Clean mating areas with Isopropyl alcohol

    

72. Allow 1 minute dry time

    

73. Apply adhesive

    

    

74. Install the Skid Plate Bracket on a HV battery
    Remarque

    Install Skid Plate Bracket on a HV battery. Use the long bolt from the ski plate, screw it in by hand in the first hole,Apply slight pressure to the bracket using 2 wedges, slightly zip tie the wedge as shown on pictures

    

    

75. Set up temperature measurement tool
    Remarque

    Set up the Digital multimeter with thermocouple attached to it, Be careful with the polarity of the plug, Press LPF button to change from °F to C°, Turn switch to Temp position,Check if the temperature readings are real,Attach thermocouple to the skid plate

    

    

76. Use a heat gun to reduce curing time of adhesive
    Avertissement

    When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery. Attach the Bosch digitally adjustable temperature heat gun to the Transmission Jack with the zip ties, Install it facing the skid plate bracket 10 cm from it curing▪ 7 days at 23 ± 2 °C▪ 2 hours at 65 ± 2 °C

    

77. Allow adhesive to cure
    Avertissement

    When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery. Plug the heat gun to the power source, Turn it on and set up 100°C and air flow on average speed, Keep in mind, that temperature readings on a heat gun is not real but predicted,Monitor temperature on multimeter every 5 minutes for the first 30 minutes, every 10 minutes after establishment,If after 30 minutes temperature is less than 65°C or rising above adjust it on heat gun. Allow adhesive to cure for 2x hours

    

78. Allow adhesive to cure
    Remarque

    Allow adhesive to cure 2 hours

    

79. Remove wedges
    Remarque

    Cut the zip tie and remove wedges, Remove bolt from the center ski cover first hole

    

    

80. Touch Up bare metal spots
    Remarque

    Touch Up bare metal spots

    

81. Install center ski cover onto HV battery
    Remarque

    6x bolts, EP14, 34 Nm

    

82. Remove all items from pockets and ensure not wearing metal items

    

    

83. Inspect HV insulating gloves
    Remarque

    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

    

84. Put on HV insulating gloves and leather over gloves
    Remarque

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

85. Remove masking tape from connectors

    

    

86. Install ancillary harness bracket to front of HV battery
    Remarque

    2x barrel clips

    

87. Connect both AC compressor and PTC heater HV harness connectors on HV battery
    Remarque

    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

    

    

88. Install FDU HV harness connector to FDU
    Remarque

    1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU then remove HV connector lever lock before fully latching 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

    

    

    

89. Remove HV insulating gloves

    

90. Install bolt securing FDU HV harness to FDU
    Remarque

    1x bolt, 10mm, 10 Nm

    

91. Set free RH manifold tube
    Remarque

    Cut cable tie and set free RH manifold tube

    

92. Position coolant drain container underneath RH manifold tube inner connection to HV battery

    

93. Install RH manifold tube to front of HV battery
    Remarque

    1x spring clip, 2x plugs, Remove plugs from HV battery and manifold tube,Join quick release coolant hose connectors, Push the retaining spring clip to the place, Perform push-pull-push test to make sure hose is fully seated

    

94. Position coolant drain container below HV battery hose

    

95. Install RH manifold tube to LH manifold tube
    Remarque

    1x spring clip, 2x plugs, Remove plugs from HV battery and manifold tube,Join quick release coolant hose connectors, Push the retaining spring clip to the place, Perform push-pull-push test to make sure hose is fully seated

    

    

96. Remove coolant drain container from underneath vehicle

    

97. Install front skid plate onto HV battery
    Remarque

    2x tabs, Slide tabs onto front of HV battery

    

    

98. Install the bolts securing the front skid plate to the HV battery
    Remarque

    4x bolts, E10, 13 Nm

    

99. Install the clips securing the front LH and RH wheel liners to the front skid plate
    Remarque

    2x push clips

    

100. Position front aero shield to vehicle and install nuts
     Remarque

     2x nuts, 15mm, 5 Nm

     

     

101. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
     Remarque

     9x bolts, 10mm, 5 Nm

     

     

102. Lower vehicle fully
     Remarque

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

     

     

     

103. Remove coolant bottle cap

     

104. Inspect coolant level and top off as necessary
     Remarque

     Ensure that fluid level is at Max line

     

105. Connect first responder loop and 12V negative terminal
     Remarque

     1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer

     

     

106. Connect 2nd row seat cushion harness and install 2nd row seat cushion
     Remarque

     2x connectors, 2x clips, 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

     

     

     

     

107. Move RH front seat to original position

     

108. Move LH front seat to original position

     

109. Turn on the drive rail
     Remarque

     Sit in the driver’s seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle

     

     

110. Access Thermal System routines using the UI
     Remarque

     Select Service mode > Thermal

     

     

111. Select "Stop Thermal Fill Drain" using the UI

     

     

     

112. Select "Start Coolant Air Purge" using the UI
     Remarque

     Wait till coolant pumps stop to run (audible noise), The Success sign will appear shortly, but pumps will run for 10 minutes, If you start next procedure during this time, it will fail, Make sure vehicle is not in "Drive", Plan is still running despite the stop message, 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" 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

     

     

     

113. Inspect coolant level and top off as necessary
     Remarque

     Ensure that the fluid level is at the Max line

     

114. Install coolant bottle cap

     

115. Install frunk assembly to vehicle
     Remarque

     12x clips, Make sure frunk assembly is fully seated onto clips, Number of clips may vary on older vehicles

     

     

116. Install bolts securing frunk assembly
     Remarque

     7x bolts, 10mm, 5 Nm, Lower RBN covers after installing upper fasteners, Newer vehicles may not be equipped with covers

     

117. Install frunk close out panel
     Remarque

     4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align 3x tabs then push downward to secure clips

     

118. Install cabin intake upper duct assembly
     Remarque

     4x clips, Heat pump vehicles have 3x clips

     

     

119. Install rear apron
     Remarque

     12x clips

     

     

120. Close hood

     

121. Raise all windows

     

122. Exit Service Mode +
     Remarque

     Use UI screen to exit SM+

     

     

123. Close all four doors
     Remarque

     Unlatch rear doors before closing

     

124. Remove lift arms from below vehicle
     Remarque

     Lower rack arms fully and remove them from under vehicle