Correction code TBD FRT 1.62 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

1. Open all four doors

   

2. Lower all four windows

   

3. Move LH front seat forward
   Note

   Adjust seat back if needed to avoid contacting headliner

   

4. Move RH front seat forward
   Note

   Adjust seatback if needed to avoid contacting headliner

   

5. Move 60 seat to easy entry position
   Note

   Press shoulder switch then push seat forward

   

   

6. Partially remove lower portion of LH rear door seal

   

7. Remove LH 7s lower C-pillar trim
   Note

   8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips

   

   

8. Move 60 seat to original position
   Note

   Press shoulder switch then pull seat backward

   

9. Fold 2nd row 60 seatback down
   Note

   Via seat switch or manual tether, Protect seat back upholstery if necessary

   

   

10. Disconnect 2nd row 60 seat connector
    Note

    1x connector,

    

    

11. Move 60 seat forward using towel bar
    Note

    With one hand on towel bar pull up and slide the seat forward with your other hand

    

    

12. Remove 60 seat rear outboard track fastener
    Note

    1x patch bolt, 11mm, 37 Nm, Discard after removal

    

13. Remove 60 seat rear inboard track fasteners
    Note

    2x patch bolts, 11mm, 37 Nm, Discard after removal

    

14. Move 60 seat fully rearward using towel bar
    Note

    pull up bar, slide seat forward

    

15. Remove 60 seat outboard track cover
    Note

    1x clip, Slide covers forward to release from 60 seat tracks

    

    

    

16. Remove center track cover from 2nd row seats
    Note

    2x clips, Slide covers forward to release from 2nd row seat tracks

    

    

    

17. Release cabin carpet from 60 seat
    Note

    Pull cabin carpet towards front of vehicle

    

    

18. Remove 60 seat front inboard track fasteners
    Note

    1x bolts, 11mm, 37 Nm, Discard after removal

    

19. Remove 2nd row 60 seat frame front outboard track fasteners
    Note

    1x bolts, 11mm, 37 Nm, Discard after removal

    

20. Remove 2nd row 60 seat assembly from vehicle
    Note

    Recommend assistance, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

    

    

21. Move RH front seat forward
    Note

    Adjust seatback if needed to avoid contacting headliner

    

22. Move 60 seat to easy entry position
    Note

    Press shoulder switch then push seat forward

    

    

23. Partially remove RH rear door seal
    Note

    Pillar and sill trim have tabs seated underneath seal

    

24. Remove RH C-pillar lower trim
    Note

    5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ by vehicle build location, and the number of clips may also varyt, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall

    

    

25. Move 40 seat to original position
    Note

    Press shoulder switch then pull seat backward

    

26. Fold 2nd row 40 seatback down
    Note

    Via seat switch or manual tether, Protect seat back upholstery if necessary

    

    

27. Remove 40 seat outboard track cover
    Note

    1x clip, Slide cover forward to release from 40 seat track

    

28. Remove bolts securing 40 seat podium to vehicle
    Note

    2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

    

29. Move 40 seat forward using towel bar
    Note

    With one hand on towel bar pull up and slide the seat forward with your other hand

    

30. Remove bolts securing 40 seat inner and outer tracks to vehicle
    Note

    2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

    

31. Move 40 seat fully rearward using towel bar
    Note

    pull bar, slide seat forward

    

32. Disconnect 2nd row 40 seat connector
    Note

    1x connector, Newer models may have red locking tab

    

    

33. Remove 40 seat from vehicle
    Note

    Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

    

    

34. Remove 3rd row seat cushion
    Note

    2x clips, 1x connector, 2x circular hooks, Press tabs backward then pull front edge up, Press rear seat cushion and lift the front seat cushion

    

    

    

    

    

35. Remove 3rd row LH seat cushion bolster
    Note

    1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster towards front of vehicle to remove

    

36. Remove 3rd row RH seat cushion bolster
    Note

    1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster towards front of vehicle to remove

    

    

    

37. Release LH side of 3rd row rear carpet
    Note

    2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

    

    

    

    

38. Release RH side of 3rd row rear carpet
    Note

    2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

    

    

    

    

39. Remove 3rd row rear cabin carpet

    

    

40. Open hood

    

    

41. Power off vehicle from center display
    Note

    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

    

    

42. Remove rear apron
    Note

    16x trim clips, 3x datums, 2x clips

    

    

    

    

43. Remove HEPA filter assembly
    Note

    2x bolts, 10mm, 10 Nm, Pivot rear edge up past brake reservoir then lift up to clear frunk assembly

    

    

    

    

44. Disconnect LV battery and first responder loop
    Note

    2x connectors, Ensure that one minute has passed after window movement before performing the power-off, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

    

    

    

    

    

45. Verify operation of multimeter
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

    

46. Remove 3rd row NVH insulator
    Note

    1x connector, Disconnect connector then remove insulator

    

    

    

    

47. Install HVC logic cap
    Note

    1x logic cap

    

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

    

49. 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

    

50. Put on HV insulating gloves and leather over gloves
    Note

    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

    

51. Release positive LV output cover from PCS cable
    Note

    1x cover

    

    

52. Remove PCS cable from LV passthrough output
    Note

    1x nut, 13mm, 9 Nm, Discard nut after removal

    

53. Remove bolts securing ancillary bay probe lid cover
    Note

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

    

54. Remove ancillary bay probe lid cover

    

    

55. Verify no high voltage
    Note

    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

    

    

    

    

56. Wipe ancillary bay cover with IPA to clean surface
    Note

    Allow to 1 minute dry time

    

57. Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
    Note

    Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time

    

    

58. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

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

    

59. Remove bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

60. Remove bolts securing ancillary bay cover to HV battery
    Note

    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

    

    

61. Remove HVC logic cap
    Note

    1x logic cap

    

62. Remove ancillary bay cover from HV battery

    

    

63. Install HVC logic cap
    Note

    1x logic cap

    

64. Inspect ancillary bay for any missing insulators
    Note

    Install service insulator kit before continuing to next step

    

    

    

    

    

65. Remove bolts securing pyro disconnect to ancillary bay
    Note

    1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal

    

    

66. Remove pyro disconnect from ancillary bay
    Note

    1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay

    

    

67. Install pyro disconnect dummy

    

68. Lift HV Controller up
    Note

    Hold HVC assembly and tray in upward positition with rubber bungee

    

69. 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

    

70. Disconnect PCS logic connector from PCS
    Note

    1x connector

    

71. Disconnect PCS LV connector from PCS
    Note

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

    

72. Remove nut securing DCDC ground busbar to HV battery
    Note

    1x nut, 13mm, 9 Nm, Discard nut after removal

    

73. Gently lift the DCDC ground busbar upwards

    

74. Remove bolts securing DCDC pass through to ancillary bay
    Note

    2x bolts, E10 5-Lobe, 10 Nm

    

75. Remove DCDC pass through from ancillary bay
    Note

    Attention: To avoid metal damage to the cable insulation layer

    

    

76. Disconnect ancillary bay harness connectors from positive pack contactor
    Note

    2x connectors

    

77. Remove HV PCS to DC Bus harness clip from positive pack contactor
    Note

    1x clip

    

78. Remove HV joint insulators from positive HV switch
    Note

    2x insulators

    

79. Remove bolt securing positive pack contactor to positive busbar
    Note

    1x patch bolt, 13mm, 9 Nm, Discard after removal

    

80. Remove nut securing positive pack contactor to module 4 rear terminal
    Note

    1x patch nut, 13mm, 9 Nm, Discard after removal

    

81. Remove nuts securing positive pack contactor to ancillary bay
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

    

82. Remove positive pack contactor from ancillary bay
    Note

    2x guide pins

    

    

    

83. Position positive pack contactor to ancillary bay for installation
    Note

    2x guide pins

    

    

    

84. Install nuts securing positive pack contactor to ancillary bay
    Note

    3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary

    

85. Install bolt securing positive pack contactor to positive busbar
    Note

    1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque

    

86. Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
    Note

    1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

    

87. Measure resistance from HV joint between HV battery positive contactor and center of HV battery positive terminal
    Note

    1x HV joint, 110μΩ or less

    

    

88. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
    Note

    1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

    

    

89. Install HV joint insulators onto positive pack contactor
    Note

    2x insulators

    

90. Install ancillary bay harness clip to positive pack contactor
    Note

    1x clip

    

91. Connect ancillary bay harness connectors to positive pack contactor
    Note

    2x connectors

    

92. Position DCDC pass through to ancillary bay for installation
    Note

    Attention: To avoid metal damage to the cable insulation layer

    

    

93. Install bolts securing DCDC pass through to ancillary bay
    Note

    2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque

    

94. Install DCDC ground busbar to HV battery
    Note

    Gently press down

    

95. Install nut securing DCDC ground busbar to HV battery
    Note

    1x nut, 13mm, 9 Nm, Install new nut

    

96. Connect PCS LV connector to PCS
    Note

    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

    

97. Connect PCS logic connector to PCS
    Note

    1x connector

    

98. Connect PCS to DC bus HV connector
    Note

    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

    

99. Lower HV Controller back into place
    Note

    Remove bungee and slowly lower controller

    

100. Disconnect ancillary bay harness connectors from negative pack contactor
     Note

     2x connectors

     

101. Remove HV joint insulators from negative pack contactor
     Note

     2x insulators

     

102. Remove bolt securing negative pack contactor to DC link busbar joint
     Note

     1x patch bolt, 13mm, 9 Nm, Discard after removal

     

103. Remove nut securing negative pack contactor to HV battery tall silicon terminal
     Note

     1x patch nut, 13mm, 9 Nm, Discard after removal

     

104. Remove nuts securing negative pack contactor to ancillary bay
     Note

     3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

     

105. Remove negative pack contactor from ancillary bay
     Note

     2x guide pins

     

     

     

106. Position negative pack contactor to ancillary bay for installation
     Note

     2x guide pins

     

     

     

107. Install nuts securing negative pack contactor to ancillary bay
     Note

     3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs

     

108. Install nut securing negative pack contactor to HV battery tall terminal
     Note

     1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

     

109. Install bolt securing negative pack contactor to DC link busbar joint
     Note

     1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque

     

110. Perform Hioki impedance test at HV joint of negative pack contactor to negative DC link busbar
     Note

     1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

     

     

111. Perform Hioki impedance test at negative pack contactor to module 1 rear terminal
     Note

     1x HV joint, 110μΩ or less

     

     

112. Install HV joint insulators to negative pack contactor
     Note

     2x insulators

     

113. Connect ancillary bay harness connectors to negative pack contactor
     Note

     2x connectors

     

114. Remove pyro disconnect dummy

     

115. Clean mating surface of pyro
     Note

     Allow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, Busbar, And the pyrotechnic battery disconnect

     

     

     

116. Set multimeter to "LoZ" (low impedance) mode

     

117. Measure voltage between busbar and shunt
     Note

     Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points

     

     

118. Position pyro disconnect to ancillary bay for installation
     Note

     1x connector, While still measuring the voltage, Have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, And then press the pyrotechnic battery disconnect down onto the busbars, The pyro disconnect can only be installed one way

     

     

     

     

119. Install bolts securing pyro disconnect to ancillary bay
     Note

     2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen

     

120. Measure resistance from module 2 busbar to pyro disconnect
     Note

     1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

     

     

121. Measure resistance from pyro disconnect to shunt
     Note

     1x HV joint, 45μΩ or less, Perform zero adjust to Hioki meter prior to testing

     

     

122. Remove service insulator kit

     

     

     

     

123. Remove HVC logic cap
     Note

     1x logic cap

     

124. Inspect ancillary bay walls for damage
     Note

     Any dent or depression in the sealing surface that causes it to not be flat will result in a leak, Any paint that comes off the ancillary bay wall, Whether or not it sticks to the seal, Will require enclosure leak test when reassembled, It can still be reused

     

125. Inspect ancillary bay cover seal to confirm it has no visual damage
     Note

     Image up close for clarity, Delaminated and torn seals cannot be reused

     

     

     

     

     

126. Wipe ancillary bay cover with IPA to clean surface
     Note

     Allow to 1 minute dry time

     

127. Position ancillary bay cover to HV battery for installation
     Note

     Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered.

     

     

128. Remove leather over gloves and HV insulating gloves

     

129. Install bolts securing ancillary bay cover to HV battery
     Note

     18x bolts, EP10 5-Lobe, 8 Nm, Fasteners are captive, Follow torque sequence per image

     

     

130. Install bolts securing ancillary bay cover to HVC
     Note

     3x bolts, E10, 5 Nm + 30 degrees

     

131. Install positive LV output from PCS cable and torque nut securing it
     Note

     1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque

     

132. Install positive LV output cover to PCS cable
     Note

     1x cover

     

133. Remove HVC logic cap
     Note

     1x logic cap

     

134. Install 3rd row NVH insulator
     Note

     1x connector, Install insulator then connect connector

     

     

     

     

135. Position 3rd row rear cabin carpet

     

     

136. Secure RH side of 3rd row rear carpet
     Note

     2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

     

     

     

     

137. Secure LH side of 3rd row rear carpet
     Note

     2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

     

     

     

     

138. Install 3rd row LH seat cushion bolster
     Note

     1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster into seat frame complete

     

     

139. Install 3rd row RH seat cushion bolster
     Note

     1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster into seat frame complete

     

     

     

140. Install 3rd row seat cushion and connect harness
     Note

     1x connector, Secure 3rd row seat cushion into RH and LH latches

     

     

141. Connect first responder loop and LV battery
     Note

     2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

     

     

     

     

     

142. Install HEPA filter assembly
     Note

     2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct, Do not pinch washer hose inbetween HEPA filter assembly and body

     

     

     

     

     

     

143. Install rear apron
     Note

     16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron

     

     

     

144. Close hood

     

     

145. Install 40 seat into vehicle
     Note

     Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium

     

     

146. Connect 2nd row 40 seat connector
     Note

     1x connector,

     

     

147. Install bolts securing 40 seat podium to vehicle hand tight
     Note

     2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step

     

148. Move 40 seat forward using towel bar
     Note

     pull up bar, slide seat forward

     

149. Install bolts securing 40 seat inner and outer tracks to vehicle
     Note

     2x patch bolts, 11mm, 37 Nm, Install new bolts

     

150. Move 40 seat to original position
     Note

     Press shoulder switch then pull seat backward

     

151. Install cabin carpet to 40 seat

     

152. Torque bolts securing 40 seat podium to vehicle
     Note

     2x patch bolts, 11mm, 37 Nm

     

153. Install center track cover to 2nd row seats
     Note

     2x clip, Slide cover straight on to clip to 2nd row seat tracks

     

     

     

154. Install 40 seat outboard track cover
     Note

     1x clip

     

155. Position 40 seat into easy entry mode
     Note

     Press shoulder switch and push 40 seat forward

     

     

156. Install RH rear sill trim
     Note

     4x tabs, 3x clips, 5x location pins, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips

     

     

157. Reseat RH rear door seal
     Note

     Seat pillar and sill trim tabs underneath seal

     

158. Move 40 seat to original position
     Note

     Press shoulder switch then pull seat backward

     

159. Move RH front seat to original position

     

160. Install 2nd row 60 seat assembly
     Note

     Recommend assistance

     

     

     

161. Connect 2nd row 60 seat connector
     Note

     1x connector,

     

     

162. Install fasteners securing 60 seat frame to body
     Note

     5x patch bolts, 11mm, 37 Nm, Install new patch bolts, bottom seat bolts located in rear

     

     

     

     

163. Secure cabin carpet to 60 seat
     Note

     Strap velcro on

     

     

164. Return 2nd row 60 seatback to vertical position
     Note

     Via trunk seat switch, Remove seatback protection if necessary

     

     

165. Install 60 seat outboard track cover
     Note

     1x clip

     

     

     

166. Position 60 seat into easy entry mode
     Note

     Press shoulder switch and push 60 seat forward to position into easy entry mode

     

     

167. Install LH 7s lower C-pillar trim
     Note

     8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips

     

     

168. Reseat LH rear door seal
     Note

     Seat pillar and sill trim tabs underneath seal

     

169. Move 60 seat to original position

     

170. Move RH front seat to original position

     

171. Move LH front seat to original position

     

172. Raise all four windows
     Note

     Via LH front door switch

     

173. Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)
174. Unlock the vehicle gateway. See Gateway (Unlock).
175. Run ODIN routine PROC_VCLEFT_X_2R-SEAT-RECLINE-CALIBRATIONvia Service Mode:Low Voltage ➜ Second Row Seats ➜ Calibratevia Toolbox:(link)
176. Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
177. Close all four doors
     Note

     If LV is powered up then unlatch rear doors before closing