2025-10-10

HV Battery (AWD) (Remove and Replace)

Correction code 16010202 5.16 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

  • 2025-10-10: Removed redundant steps from removal section.
  • 2024-10-31: Updated HV battery discharge steps.
  • 2024-07-08: Added note to refer to retrofit procedure(s) to install HV header connectors on new HV battery if vehicle has had retrofit performed.
  • 2023-11-06: Updated UI steps.
  • 2023-08-03: Added notes, cautions, and warnings for releasing and installing charge port busbar connector.
  • 2023-05-24: Resequenced vacuum refill.
  • 2023-05-23: Reorganized Removal first steps.
  • 2023-05-22: Added conspicuous discharge warning table.
  • 2023-03-16: Updated Discharge section and added steps to configure the HV battery.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.

  • 1637160-00-A - H-Frame Hoist, Sling Attachment

Discharge

WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be shipped must have a State of Charge (SoC) of less than 30% or 50%, depending on the region. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%.

WARNING: After discharge, wait 20 minutes and verify that the SoC is less than 30% or 50%, depending on the region and method of shipment. Proceed with discharging if the SoC does not meet the required level.

Make sure to collect all HV battery shipping data using the HV Battery Communication Tool, preferably before removing the HV battery from the vehicle.

WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
Informational PurposesAn informational icon, calling your attention
Note
If possible, perform the discharge procedure and collect HV battery shipping data before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians..
Informational PurposesAn informational icon, calling your attention
Note
The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians..
  1. Enable Service Mode Plus. See Service Mode Plus.
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to step 6 of this sub-procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, use the HV Battery Communication Tool to collect HV battery shipping data, and then move the vehicle to the service bay.

Remove

  1. Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See Firmware Update.
  2. Remove the HV battery from the vehicle. See HV Battery (AWD) (Remove and Install).
  3. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain) (On Table).
  4. Perform a platter enclosure coolant drain. See Platter Enclosure Coolant (Drain) (On Table).
  5. Release the clip that attaches the power conversion system coolant return hose to the HV battery.
  6. Release the clip, and then disconnect the power conversion system coolant return hose from the HV battery.
    Figure 1. Long Range hose shown, Plaid hose similar
  7. Attach the HV battery H-frame to the gantry and raise the H-frame into position.
  8. Use shackles (x4) (1637160-00-A) to attach the P2 battery sling adapter to the H-frame.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the shackles are tight, secure, and the sling will not bind or twist when lifting the HV battery.
  9. With the help of an assistant, remove the top from the HV battery shipping crate.
  10. With the help of an assistant, position the gantry over the HV battery shipping crate.
  11. Lower the H-frame to the new HV battery.
  12. Install the P2 sling adapter onto the new HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Insert the lifting pin into the lifting hole of the HV battery.
    3. Install the collar over the end of the lifting pin, and then release the button.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.
    4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
    5. Repeat substeps 12.a through 12.d for the other 5 lifting pins.
  13. Lift the new HV battery out of the shipping crate.
  14. With the help of an assistant, move the gantry away from the HV battery shipping crate and over a battery table.
  15. Lower the new HV battery onto the battery table.
  16. Remove the P2 battery sling adapter from the new HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
      Informational PurposesAn informational icon, calling your attention
      Note
      The collar will fall free, but is tethered to the lifting pin.
    3. Repeat substeps 16.a through 16.b for the other 5 lifting pins.
  17. With the help of an assistant, remove the new HV battery and battery table out from under the gantry.

Install

  1. With the help of an assistant, position the old HV battery and battery table under the gantry.
  2. Install the P2 sling adapter onto the old HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Insert the lifting pin into the lifting hole of the HV battery.
    3. Install the collar over the end of the lifting pin, and then release the button.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.
    4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
    5. Repeat substeps 2.a through 2.d for the other 5 lifting pins.
  3. Raise the old HV battery off of the battery table.
  4. Move the HV battery table out from under the gantry.
  5. With the help of an assistant, position the gantry over the HV battery shipping crate.
  6. With the help of an assistant, align the old HV battery to the shipping crate, then lower the battery into the crate.
  7. Remove the P2 battery sling adapter from the old HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
      Informational PurposesAn informational icon, calling your attention
      Note
      The collar will fall free, but is tethered to the lifting pin.
    3. Repeat substeps 7.a through 7.b for the other 5 lifting pins.
  8. Raise the gantry and H-frame from the shipping crate.
  9. With the help of an assistant, install the top onto the HV battery shipping crate, and return the battery to MRB.
  10. Remove the P2 battery sling adapter from the H-frame.
  11. Return the gantry to storage, and then remove the HV battery H-frame from the gantry.
  12. Connect the power conversion system coolant return hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.
    Figure 2. Long Range hose shown, Plaid hose similar
  13. Fasten the clip that attaches the power conversion system coolant return hose to the HV battery.
  14. Install the HV battery into the vehicle. See HV Battery (AWD) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    If the vehicle has had Rev-F to Rev-H HV battery retrofit procedure performed, refer to the following procedure(s) to install the correct HV header connector on the new HV battery.
  15. Install the front skid plate. See Skidplate - Front (Remove and Replace).
  16. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  17. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  18. Install the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  19. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  20. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
  21. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
  22. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
  23. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the busbar is seated flush onto pack port to prevent arcing.
  24. Put on the HV insulating gloves and leather over gloves.
  25. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  26. Repeat step 25 for the other charge port busbar connector lead and DC input HV header bolt head.
  27. Remove the HV insulating gloves and leather over gloves.
  28. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
  29. If a 3-phase connector or dummy was disconnected, verify that the black release lever of the 3-phase connector or dummy is in the open position, install the connector square to the HV battery 3-phase HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
    Figure 3. Dummy shown, 3-phase connector similar
  30. Install the LH inner reinforcement to the body, and then install the bolts (x10) that attach the reinforcement to the body.
    27 Nm (19.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bottom two bolts require improvising an 8 mm ratchet box-end wrench to turn the T40 socket.
  31. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  32. Connect LV power. See LV Power (Disconnect and Connect).
  33. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  34. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  35. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  36. Enable Service Mode Plus. See Service Mode Plus.
  37. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  38. Under High-Voltage-Battery, touch High Voltage Battery Replacement.
  39. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
  40. Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
  41. Disable Service Mode Plus. See Service Mode Plus.
  42. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  43. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  44. Install the trunk side trim bracket. See:
  45. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  46. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  47. Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
    2.5 Nm (1.8 lbs-ft)
  48. Install the 2nd row rear floor panel. See:
  49. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  50. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  51. Install the 2nd row mid floor panel. See:
  52. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  53. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  54. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  55. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  56. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.