2025-03-12

Penthouse Cover (Remove and Replace)

Correction code 1630012202 FRT 0.84 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 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 safety information.

Torque Specifications

Table 1. Torque Specifications:Penthouse Cover (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut secure PCS cable to 12V passthrough output
9 Nm (6.6 lbs-ft)
  • Electrical Protective Gloves
  • Cordless Ratchet/Impact Driver
  • 12 mm deep socket
 Replace
Bolts (X3) securing ancillary bay cover to HVC
5 Nm (3.7 lbs-ft) + 30 degrees
  • DRIVER KIT, 1/4" HEX, M12
  • External Torx E10
 Reuse
Bolts (X18) securing ancillary bay cover to HV battery
8 Nm (5.9 lbs-ft)
  • External Torx E10
  • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
 Reuse The fasteners are captive and will stay attached to the ancillary bay cove

Remove

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.
  1. Open all the doors and lower all the windows.
  2. Remove the HEPA filter assembly. See Hepa Filter (Remove and Replace).
  3. Disconnect the LV power. See LV Power (Disconnect and Connect).
  4. Remove the 2nd row lower seat cushion. See 2nd Row Seat Cushion (Remove and Replace).
  5. Verify operation of multimeter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals.
  6. Perform Vehicle HV Disablement Procedure. See .
  7. Remove HV insulating gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If flashing is present on the vehicle single-piece rear casting, put on cut-resistant gloves.
  8. Remove the 2nd row seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).
  9. Remove the 2nd row seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).
  10. Disconnect HVC logic connector and install logic cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then pivot handle downward to release connector.
  11. Install the logic connector cap onto the high voltage controller connector to prevent mistaken reconnection and protect the connector.
  12. Release positive 12V output cover from PCS cable.
  13. Remove PCS cable from 12V pass through output.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Cordless Ratchet/Impact Driver
    • 12 mm deep socket
  14. Remove the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • DRIVER KIT, 1/4" HEX, M12
    • External Torx E10
  15. Remove the bolts (x18) that attach the ancillary bay cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  16. Put on HV insulating gloves, leather outer gloves, and safety glasses before continuing this procedure.
  17. Remove the ancillary bay cover from the vehicle.
  18. Visually inspect the condition of the ancillary bay cover gasket and the HV battery mating surface for cracks, cuts, gouges, abrasions, or any damage that could affect the seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the damage to the gasket is severe, replace the ancillary bay cover. If there is minor damage (including paint) that might affect the seal, perform an ancillary bay air leak test when instructed to do so.

Install

  1. Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
  2. Position the ancillary bay cover to the HV battery.
  3. Remove the HV insulating gloves.
  4. Install the bolts (x18) that attach the ancillary bay cover to the HV battery.
    8 Nm (5.9 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  5. Install the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
    5 Nm (3.7 lbs-ft) + 30 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • DRIVER KIT, 1/4" HEX, M12
    • External Torx E10
  6. Install PCS cable to 12V pass through output.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Cordless Ratchet/Impact Driver
    • 12 mm deep socket
  7. Install positive 12V output cover to PCS cable.
  8. Remove the logic connector cap from the high voltage controller connector.
  9. Install the 2nd row seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).
  10. Install the 2nd row seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).
  11. Install the 2nd row lower seat cushion. See 2nd Row Seat Cushion (Remove and Replace).
  12. Connect the LV power. See LV Power (Disconnect and Connect).
  13. Install the HEPA filter assembly. See Hepa Filter (Remove and Replace).
  14. Move the front seats to original positions.
  15. Remove vehicle from lift.
  16. Raise all four windows.
  17. Close all four doors.