2025-03-12

High Voltage Battery Return (Remove and Install)

Correction code 1830020402 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.

  • 1080568-00-A Fluid Catcher
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • 1065131-00-A Battery Coolant Drain Kit

Torque Specifications

Table 1. Torque Specifications:High Voltage Battery Return (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the LH front wheel arch liner to the skid plate
5 Nm (3.7 lbs-ft)
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
  • 10 mm deep socket
Reuse

Remove

  1. Open LH front door, and Lower LH front window.
  2. Unlock the gateway. See Gateway (Unlock).
  3. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  4. Disconnect the LV battery. See LV Power (Disconnect and Connect).
  5. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  6. Remove the push clip and bolt that attach the LH front wheel arch liner to the skid plate.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    • 10 mm deep socket
  7. Use a bungee strap to pull back the LH front wheel arch liner and secure it to the subframe.
  8. Position a coolant drain container underneath the LH front of the HV battery.
  9. Disconnect the HV battery return hose and plug the hose as soon as possible to avoid coolant loss.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug the HV battery return tube as quickly as possible to minimize coolant loss.
  10. Release the clips (x2) that attach the HV battery return hose to the vehicle.
  11. Remove the coolant drain collector from under the vehicle.
  12. Lower the vehicle to a comfortable working height.
  13. Position a fluid catcher underneath the front of vehicle.
  14. Remove the LV battery. See LV Battery (Remove and Install).
  15. Release the clips (x2) that attach the HV battery return hose to the LV battery bracket.
  16. Remove the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  17. Disconnect PT supply hose from supermanifold.
  18. Disconnect HV battery return hose from Supermanifold.
  19. Remove the HV battery return hose from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill.

Install

  1. Position the new HV battery return hose into the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the HV battery return hose from the RH side of vehicle and feed it towards LH side of vehicle and down into wheel arch liner area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not bend or force the hose during installation, Slowly rotate the hose as required.
  2. Fasten the clips (x2) that attach the HV battery return hose to the LV battery bracket.
  3. Remove the plug from the supermanifold, immediately connect the HV battery return hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  4. Remove the plug from the supermanifold, immediately connect the chiller to battery hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  5. Install the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  6. Install the LV battery. See LV Battery (Remove and Install).
  7. Remove the fluid catcher from underneath the front of the vehicle.
  8. Raise the vehicle fully and then lower the lift until the safety locks are safely engaged.
  9. Position a coolant drain container underneath the LH front of the HV battery.
  10. Remove the plug from the HV battery return tube, immediately connect the HV battery return hose to the HV battery return tube, and then fasten the clip.
  11. Fasten the clip that attach the HV battery return hose to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  12. Remove the coolant drain collector from under the vehicle.
  13. Remove the bungee strap from the LH front wheel arch liner.
  14. Install the push clip and bolt that attach the LH front wheel arch liner to the skid plate.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
    • 10 mm deep socket
  15. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  16. Perform the cooling system (partial refill and bleed) procedure. See Cooling System (Partial Refill And Bleed) (Modify).
  17. Connect the LV battery. See LV Power (Disconnect and Connect).
  18. Unlock the gateway. See Gateway (Unlock).
  19. Select Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  20. Select Coolant Purge Start > Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  21. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  22. Install the HEPA filter assembly. See Service Kit - Hepa And Carbon Filters (Remove and Replace).
  23. Install the rear aero shield panel. See Underhood Apron - Rear (Remove and Replace).
  24. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Stands.