Correction code 16300072 5.46 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 proper PPE is worn when performing the below procedure.

1. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
2. Secure PCS Flush adapter to PCS inlet hose coupling
   Note

   Remove plugs as required, Verify fully seated, Perform push-pull-push test

   

   

   

3. Secure coolant cart flush hose to regulator and PCS Flush adapter
   Note

   Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi)

   

   

   

4. Secure PCS Drain adapter to the end of the PCS outlet hose
   Note

   Verify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test

   

   

   

5. Secure coolant cart drain hose to PCS drain adapter and coolant drain container

   

   

   

6. Open valve on PCS Drain adapter

   

7. Connect shop air to regulator
   Note

   Make sure regulator valve is closed prior to connecting shop air

   

8. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
   Note

   Allow coolant to drain

   

9. Close valve on pressure regulator once no more coolant is draining

   

10. Close valve on PCS Drain adapter

    

11. Remove cart drain hose from PCS Drain adapter

    

12. Remove PCS Drain adapter from end of PCS outlet hose
    Note

    1x spring clip

    

    

    

13. Remove cart flush hose from PCS Flush adapter

    

14. Remove PCS Flush adapter from PCS inlet coupling
    Note

    1x spring clip

    

    

    

15. Remove clip securing PCS outlet hose to HV battery
    Note

    1x clip

    

16. Release PCS outlet hose from HV battery
    Note

    1x spring clip

    

17. Remove all items from pockets and ensure not wearing metal items
18. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

    

19. Put on HV insulating gloves and leather over gloves

    

20. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
21. Remove fasteners securing front access cover to HV battery assembly and remove doubler
    Note

    17x bolts, 7mm, 4 Nm, 2x nuts, 10mm, 4 Nm, 2x datums, Discard patch fasteners, Remove all fasteners and separate doubler from front cover

    

    

22. Disconnect coolant hoses from PCS and install plugs
    Note

    2x hoses, Use the special tool to release the 2x clips on each hose, Support front access cover with non-conductive material as needed, Use a shop towel to catch any minimal excess coolant

    

    

    

    

    

23. Remove front access cover from HV battery

    

24. Remove front access cover foam gasket
    Note

    1x gasket, Remove seal, Discard seal after removal

    

    

25. Disconnect PCS to DC bus HV connector
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

26. Disconnect PCS logic connector from PCS
    Note

    1x connector

    

27. Disconnect PCS LV DC power harness connector
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

28. Disconnect AC filter HV harness connector from PCS
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

29. Release AC Filter harness clips
    Note

    3x clips

    

30. Remove bolts securing PCS to mounting tray
    Note

    6x bolts, 8mm, 6 Nm, Only remove the 8mm fasteners, Do not remove the T30 fasteners, Depending on battery revision, mica tape may be covering the rear bolts, Peel tape aside as required

    

    

31. Lift PCS up and out of front ancillary bay area and remove from vehicle
    Note

    Shift PCS left to clear lip of battery enclosure then straight up to remove

    

32. Remove PCS mounting tray from front ancillary bay area
    Note

    6x bolts, 10mm, 8 Nm, Take note of ground bolt, Ground fastener may vary depending on battery pack revision

    

    

33. Release HV connector 6 pin carrier connection
    Note

    1x locking connector, Disengage locking tab and release connector

    

34. Release HV connector 6 pin carrier connection from clipping point
    Note

    1x clip, Release from clipping location

    

    

35. Remove mica shielding over FDU carrier
    Note

    1x Mica shielding

    

36. Remove mica shielding over the fuses
    Note

    1x Mica shielding

    

37. Remove mica tape shielding over inductor coil
    Note

    1x Mica Shielding, Remove the shielding, Use combination of HV tools and trim tools to aid in unwrapping the shield, Note as the shielding tears there will be leftover debris

    

    

38. Clean away all excess debris caused by the mica shielding
    Note

    Use ESD vacuum and carefully remove all leftover debris

    

    

39. Release HV connector FDU carrier connection
    Note

    1x locking connector, Disengage locking tab and release connector

    

40. Release HV connector 6 pin carrier connection from clipping point
    Note

    1x clip, Release from clipping location

    

    

41. Remove FDU HV header
    Note

    2x bolts, EP10, 10 Nm, Gently separate FDU HV header

    

    

    

    

42. Release bolts securing HV connector 0 degree carrier and remove
    Note

    2x bolts, 13mm, 5 Nm +60 degrees, Discard fasteners after removal

    

    

43. Release HV connector 6 pin carrier cable from fuse
    Note

    1x nut, 8mm, 4.5 Nm, Do not drop fastener, Move cable aside

    

44. Release HV connector 6 pin carrier cable from inductor coil
    Note

    1x nut, 7mm, 2.5 Nm, Do not drop fastener, Move cable aside

    

45. Release HV connector 6P header
    Note

    2x bolts, EP10, 10 Nm, Gently separate HV header

    

    

46. Remove HVB Heat Pump HV Harness
    Note

    Release tape securing harness to front tray, Remove harness from battery pack

    

    

    

47. Position HVB Heat Pump HV Harness
    Note

    Position harness into pack, Return to original position, Apply new Kapton tape as required

    

    

    

48. Secure HV connector 6P header
    Note

    2x bolts, EP10, 10 Nm, Align connector casing to header, Verify the fitment as this header will secure at a slight angle, Take time to line them up and then begin threads

    

    

    

49. Secure HV connector 6 pin carrier cable onto inductor coil
    Note

    1x nut, 7mm, 2.5 Nm, Do not drop fastener

    

50. Secure HV connector 6 pin carrier cable onto fuse
    Note

    1x nut, 8mm, 4.5 Nm, Do not drop fastener

    

51. Cleaning mating surfaces of the HV connector 0 degree carrier
    Note

    Allow 1 min for IPA to dry

    

    

52. Install bolts securing FDU HV connector 0 degree carrier
    Note

    2x bolts, 13mm, 5nm +60 degrees, Install new fasteners

    

53. Install FDU HV header
    Note

    2x bolts, EP10, 10 Nm

    

    

    

54. Perform Hioki impedance test at the HV joints of the FDU HV connector 0 degree carrier
    Note

    2x HV joint, Verify meter has been properly zero adjusted prior to usage, The acceptable resistance is below d 0.045 mΩ (45 μΩ), If the resistance is greater than 0.045 mΩ (45 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

    

    

    

55. Secure HV connector FDU carrier connection
    Note

    1x connector, Fully engage locking tab

    

56. Secure HV connector 6 pin carrier connection onto clipping point
    Note

    1x clip

    

    

57. Secure HV connector 6 pin carrier connection
    Note

    1x connector, Fully engage locking tab

    

58. Install front ancillary insulator in area of previous mica shields - Placeholder
    Note

    1x insulator, Install a new insulator where the old mica tape use to be, Maneuver insulator and secure into place, Do not pinch any wiring

    

    

    

59. Install PCS mounting tray to front ancillary bay area
    Note

    6x bolts, 10mm, 8 Nm, Be mindful not to pinch any wires underneath the tray

    

60. Install PCS to front ancillary bay area
    Note

    Shift PCS under lip of battery enclosure

    

61. Install fasteners securing PCS to mounting tray
    Note

    6x bolts, 8mm, 6 Nm, Depending on battery revision, mica tape may be equipped over the rear bolts, Re-secure tape as required

    

    

62. Secure AC Filter harness clips
    Note

    3x clips

    

63. Connect AC filter HV harness connector to PCS
    Note

    1x connector, Push down to secure locking tab

    

64. Connect PCS LV DC power harness connector
    Note

    1x connector, Push down to secure locking tab

    

65. Connect PCS logic connector to PCS
    Note

    1x connector

    

66. Connect PCS to DC bus HV connector
    Note

    1x connector, Push down to secure locking tab

    

67. Install front access cover foam gasket
    Note

    1x gasket, Install new gasket, Position gasket over the raised thread and stud collars, Verify there is no excess debris on the cover or pack casing that would prevent proper sealing,

    

    

68. Position front cover for installation and secure hoses to PCS
    Note

    2x hoses, 2x clips on each hose, Recommend assistance, Secure hoses while holding cover, Remove plugs

    

    

    

    

    

69. Install front access cover to HV battery

    

70. Position front cover doubler and install fasteners securing front access cover to HV battery assembly
    Note

    17x patch bolts, 7mm, 4 Nm, 2x nuts, 10mm, 4 Nm, 2x datums, Install new patch fasteners, Position doubler over front access cover and thread in bolts, Some tension may be present, Verify bolts are all threaded and torque down fasteners in an even pattern

    

    

71. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
72. Secure coolant leak test adapter to PCS inlet coupling
    Note

    This adapter is connected to regulated air line adapter, Make sure the locking tab is fully seated, Perform push-pull-push test

    

    

73. Secure closed ended coolant leak test adapter to PCS outlet coupling
    Note

    Perform push-pull-push test

    

    

74. Secure pressure test fixture hose to leak test adapter

    

    

75. Secure compressed air line to pressure test fixture
    Note

    Make sure valves are closed on pressure regulator

    

    

76. Open the regulator valve then slowly adjust regulator to 50 psi
    Note

    Use caution due to high pressure, Make sure to wear safety glasses and personal protection equipment

    

    

77. Open the 2nd valve slowly
    Note

    Slowly allow air to enter system

    

78. Allow 1 minutes and 50 seconds for the pressure to stabilize
    Note

    Allow 1 minutes and 50 seconds (110 seconds) for pressure to stabilize
79. Close the regulator valve

    

80. Record start pressure value

    

81. Allow 4 minutes to test
82. Record end pressure value
    Note

    If pressure did not drop more than 0.35 psi, continue to next step, If pressure dropped more than 0.35 psi, then inspect for leaks and retest

    

83. Release compressed air line from pressure test fixture

    

84. Open the regulator valve slowly
    Note

    Slowly allow air to leave the system

    

85. Release pressure test fixture hose from coolant leak test adapter

    

    

86. Remove coolant leak test adapter from PCS inlet coupling

    

    

87. Remove closed ended coolant leak test adapter from PCS outlet coupling

    

    

88. Secure PCS outlet hose to HV battery
    Note

    1x spring clip, Perform push-pull-push test

    

89. Install clip securing PCS outlet hose to HV battery
    Note

    1x clip

    

90. Install the HV battery. See HV Battery (AWD) (Remove and Install).