2025-11-17

HV Controller (Remove and Replace)

Correction code 16301602 FRT 1.08 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 wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-11-17: Added step to apply dielectric grease to the X484 connector. Added step to tuck the pyrotechnic disconnect harness underneath the ancillary bay harness.
  • 2025-09-30: Updated Correction Code to 16301602.

Torque Specifications

Table 1. Torque Specifications:HV Controller (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (X2) secure the HV controller to ancillary bay
2 Nm (1.5 lbs-ft)
  • Electrical Protective Gloves
  • Insulated Ratchet/torque wrench
  • External Torx E6
 Reuse

Remove

  1. Perform the HVC controller backup. See Controller - High Voltage (Backup and Restore).
  2. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  3. Disconnect the ancillary bay harness from the high voltage controller connectors.
  4. Remove the bolts that attach the high voltage controller to the hinge tray, and then remove the controller from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Insulated Ratchet/torque wrench
    • External Torx E6

Install

  1. Install the high voltage controller into the ancillary bay, and then install the bolts that attach the high voltage controller to the hinge tray.
    4.5 Nm (3.3 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Electrical protective gloves must be worn.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Insulated Ratchet/torque wrench
    • External Torx E6
  2. Apply dielectric grease to the X484 connector cavity.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use a syringe if possible and do not bend the connector pins.
    Figure 1. X484 Connector
  3. Connect the ancillary bay harness to the high voltage controller connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wipe off any excess grease after inserting the X484 connector.
  4. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  5. Tuck the pyrotechnic disconnect wiring under the main ancillary bay harness.
  6. Perform the HVC controller Restore. See Controller - High Voltage (Backup and Restore).
  7. Move the LH and RH front seats to original position.
  8. Raise all windows and close all doors.