2026-11-05

HV Battery (RWD) (Remove and Install)

Correction code 16010101 3.12 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. 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.

  • 2026-11-05: Removed the removal and installation steps for the stabilizer bar, the 2nd row 40 seat, the HV battery front manifold tube, and the ancillary bay.
  • 2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
  • 2025-05-28: Modified step for attaching pyrotechnic battery disconnect when shipping the HV battery.
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.

Remove

  1. Open all four doors.
  2. Lower all four windows.
  3. Enable Service Mode. See Service Mode.
  4. Remove the LH and RH rocker carriers. See Rocker Carrier - LH (Remove and Replace).
  5. Remove butyl patches covering LH rocker access holes.
  6. Install lift pad adapters onto LH lift.
  7. Repeat step 5 and 6 for the RH side.
  8. Unlock the gateway. See Gateway (Unlock).
  9. On the touchscreen, tap Thermal > Coolant System > Coolant Fill/Drain, then click Run and allow the routine to complete.
    Note
    Thermal Fill Drain routine has a 5 hour time limit. If the run time exceeds 5 hours, the routine must be performed again.
  10. Move both front seats forward.
    Note
    Adjust seat back if needed to avoid contacting headliner
  11. Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  12. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  13. Remove the 2nd row 60 seat assembly from the vehicle. See Seat Assembly - 2nd Row - LH (5-Seat) (Remove and Install).
  14. Disengage the tab and disconnect the 2nd row 40 seat connector.
  15. Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt
    Note
    Located below rear of LH front seat, Expand the hole if necessary
  16. Remove LH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  17. Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt
    Note
    Located below rear of RH front seat, Expand the hole if necessary
  18. Remove RH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  19. Position air bag beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts
  20. Remove LH rear inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  21. Remove RH rear inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
  22. Remove the LH and RH lower A-pillar trims. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  23. Move the front seats backward.
  24. Remove the LH and RH footwell hush panels. See Hush Panel - Footwell - Driver (Remove and Replace) and Hush Panel - Footwell - Front Passenger (Remove and Replace).
  25. Remove the LH and RH center console front side panels. See Side Panel - Front - Center Console - LH (Remove and Replace) and Side Panel - Front - Center Console - RH (Remove and Replace).
  26. Fold the LH front cabin carpet rearward.
    Note
    Maneuver carpet below brake pedal and accelerator pedal. Different regions may stick the carpet and foam together and tear them apart
  27. Remove foam plugs to access LH front inner HV battery bolts.
    Note
    1x foam plug
  28. Remove both LH front inner HV battery bolts.
    Note
    2x bolts, EP20, 136 Nm
  29. Fold the RH front cabin carpet rearward.
    Note
    Maneuver carpet below brake pedal and accelerator pedal. Different regions may stick the carpet and foam together and tear them apart
  30. Remove foam plugs to access RH front inner HV battery bolts.
    Note
    1x foam plug
  31. Remove both RH front inner HV battery bolts.
    Note
    2x bolts, EP20, 136 Nm
  32. Disconnect the LV power. See LV Power (Disconnect and Connect) (Modify).
  33. Release the clip that attach the LH body harness to the rear body and move it aside.
  34. Partially remove the LH B-pillar lower trim.
    Note
    1x push clip
  35. Partially pull out the LH rear body harness.
  36. Perform the HV disablement procedure. See Vehicle HV Disablement Procedure.
  37. Remove the bolt that secures the busbar cover access door.
    Note
    1x bolt, 10mm, 9 Nm
  38. Remove the bolts that secure the charge port busbar kit to the HV header.
    Note
    2x bolts, 10mm, 9 Nm
  39. Lift the busbar kit connector to remove it from the HV header.
    Note
    Use inflatable air bag to suspend busbar away from HV header during removal and installation. Hold busbar firmly as there is tension on. Avoid damaging the harness bracket.
  40. Disconnect the AC charge port inlet harness from the HV header.
    Note
    1x connector. Release red locking tab and rotate lever arm to release.
  41. Disconnect the HVC logic connector and install logic cap.
    Note
    1x connector, 1x cap, Release locking tab then push the handle downward to release connector
  42. Release the positive 12V output cover from the PCS cable.
    Note
    1x cover
  43. Remove and discard the nut that secures the PCS cable to the 12V passthrough output.
    Note
    1x nut, 13mm, 9 Nm, Discard nut after removal
  44. Remove nut securing DCDC ground busbar to HV battery
    Note
    1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
  45. Gently lift the DCDC ground busbar upwards
  46. Remove the front skid plate from HV battery. See Skid Plate - HV Battery - Front (Remove and Replace).
  47. Inspect and put on 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
  48. Disconnect AC compressor HV harness connector.
    Note
    Disengage the red locking tab by pulling it away from the connector, depress yellow tab and pull the connector backward then depress the green tab to release.
  49. Remove leather over gloves and HV insulating gloves.
  50. Position coolant drain container underneath LH front of HV battery.
  51. Disconnect the HV battery return hose at LH side of vehicle and plug hoses.
    Note
    1x spring clip. Loss of coolant greater than 1L requires coolant vacuum fill.
  52. Release chiller to battery hose from body.
  53. Disconnect HV battery front manifold hose from chiller to battery hose.
    Note
    Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill.
  54. Position coolant drain container underneath RH front of HV battery.
  55. Disconnect powertrain return hose from powertrain return tube and plug hoses
    Note
    1x spring clip
  56. Disconnect powertrain supply hose from powertrain supply tube and plug hoses.
    Note
    1x spring clip, Coolant loss greater than 1 L will require vacuum fill
  57. Remove coolant drain container from underneath vehicle.
  58. Remove rear skid plate from HV battery. See Skid Plate - Rear (Remove and Replace).
  59. Put on HV insulating gloves and leather over gloves.
  60. Remove nut securing RDU HV cable bracket to HV battery.
    Note
    1x nut, 10mm, 10 Nm
  61. Disconnect RDU HV cable from HV battery.
    Note
    1x connector, Release locking tab and rotate the release lever up to disengage the connector. Do not force the release lever up. Ensure the alignment tabs on the RDU header are not damaged.
  62. Remove HV insulating gloves.
  63. Position coolant drain container under LH rear of vehicle.
  64. Disconnect the LH coolant hose from rear of HV battery.
    Note
    1x spring clip, 2x plugs. Plug both the coolant hose and passthrough.
  65. Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
    Note
    1x spring clip, 2x plugs, Coolant loss greater than 1 L will require vacuum fill
  66. Position coolant drain underneath RH rear of HV battery
  67. Disconnect coolant outlet hose to rear return hose and plug hoses
    Note
    1x spring clip, 2x plugs, Use shop towel to clean any residue coolant inside RH rocker panel if necessary, Coolant loss greater than 1 L will require vacuum fill
  68. Position support stand to support the front portion of the rear subframe.
  69. Remove both LH and RH shear plate for the rear subframe. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  70. Hand tighten the bolt securing LH side of subframe to body.
    Note
    1x bolt, 21mm, 125 Nm
  71. Hand tighten bolt securing RH side of subframe to body.
    Note
    1x bolt, 21mm, 125 Nm
  72. Remove support stand from under vehicle.
  73. Place HV battery table into position and lower vehicle to support HV battery.
    Note
    Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
  74. Remove central bolts securing HV battery center ski cover.
    Note
    4x bolts, EP14, 34 Nm
  75. Remove bolts securing LH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  76. Remove bolts securing RH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  77. Remove LH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  78. Remove RH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  79. Raise the vehicle free of HV battery.
  80. Remove battery from under vehicle.
    Note
    Recommend assistance
  81. Remove penthouse engagement seal from HV battery pack.
    Note
    Discard anytime HV battery is removed from vehicle
  82. If the HV battery is being shipped, attach the old pyrotechnic battery disconnect to the brackets on the ancillary bay cover of the old HV battery using cable ties. If the ancillary bay cover is not equipped with brackets, attach the old pyrotechnic battery disconnect to the RH rear corner of the old HV battery using cable ties.
    Note
    Put a piece of paper under the pyrotechnic battery disconnect. Use masking tape if necessary to prevent movement.
    Figure 1. Pyrotechnic battery disconnect attached to brackets on the ancillary bay cover
    Figure 2. Pyrotechnic battery disconnect attached to RH rear corner of HV battery

Install

  1. Install penthouse engagement seal onto HV battery pack
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped
  2. Put on HV insulating gloves and leather over gloves
  3. Install HV battery alignment rods
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
  4. Position HV battery under vehicle
    Note
    Recommend assistance
  5. Lower vehicle onto HV battery and align holes
  6. Loosely install RH bolts securing HV battery to vehicle hand tight
    Note
    8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
  7. Loosely install LH bolts securing HV battery to vehicle hand tight
    Note
    8x bolts, 13mm, 35 Nm, 8x bolts, 13mm, 35 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
  8. Remove HV battery alignment rods
    Note
    2x rods, To body at front of vehicle, 2x rods, To battery near penthouse
  9. Set up ladder (Ladder - 1088037-00-A).
  10. Install LH rear inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  11. Install LH middle inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  12. Install RH rear inner battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  13. Install RH inner HV battery bolt hand tight
    Note
    1x bolt, 16mm, 66 Nm, Torque at later step
  14. Install both LH front inner HV battery bolts hand tight
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  15. Install both RH front inner HV battery bolts hand tight
    Note
    2x bolts, EP20, 136 Nm, Torque at later step
  16. Remove the ladder.
  17. Set bolts securing RH front support bracket to vehicle with cordless impact
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  18. Set bolts securing LH front support bracket to vehicle with cordless impact
    Note
    4x bolts, 16mm, 110 Nm, Torque at later step
  19. Set central bolts securing HV battery center ski cover with cordless impact
    Note
    4x bolts, EP14, 34 Nm, Ensure smooth thread engagement and bolts are not cross threaded into casting, Flush down bolts, Do not over tighten bolts, Fully torque at later step
  20. Lower vehicle onto pack completely
  21. Torque RH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  22. Torque LH bolts securing HV battery to vehicle
    Note
    8x bolts, 13mm, 35 Nm
  23. Torque bolts securing RH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  24. Torque bolts securing LH front support bracket to vehicle
    Note
    4x bolts, 16mm, 110 Nm
  25. Torque central bolts securing HV battery through center ski cover
    Note
    4x bolts, EP14, 34 Nm
  26. With assistance, raise vehicle and lower onto locks, then remove battery table from under vehicle.
  27. Position support stand to support front section of rear subframe
  28. Remove bolts securing LH and RH side of rear subframe to body.
    Tip
    Use of the following tool(s) is recommended:
    • 21 mm socket
    • Cordless Ratchet/Impact Driver
  29. Install the LH and RH rear shear plate. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  30. Remove support stand from under vehicle
  31. Install clips securing coolant hoses to LH shear plate
    Note
    2x fir tree clips
  32. Position coolant drain underneath RH rear of HV battery
  33. Install clip securing coolant hoses to RH shear plate
    Note
    1x fir tree clip
  34. Remove hose plugs and connect coolant outlet hose to rear return hose
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  35. Position coolant drain container under LH rear of vehicle
  36. Remove plugs and connect RDU inverter inlet hose to rear of HV battery
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  37. Connect LH coolant hose to rear of HV battery
    Note
    Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
  38. Remove coolant drain container from underneath vehicle.
  39. Put on HV insulating gloves and leather over gloves.
  40. Connect RDU HV cable to HV battery.
    Note
    1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector. Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
  41. Install nut securing RDU HV cable bracket to HV battery
    Note
    1x nut, 10mm, 10 Nm
  42. Remove HV insulating gloves.
  43. Install the rear skid plate. See Skid Plate - Rear (Remove and Replace).
  44. Position coolant drain container underneath LH front of HV battery
  45. Connect HV battery front manifold coolant hose
    Note
    1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  46. Secure chiller to battery hose onto body.
  47. Connect HV battery coolant return hose.
    Note
    Perform push-pull test to verify hoses are fully engaged. If the coolant loss is greater then 1L, vacuum fill will be required. See Cooling System - Vacuum Refill (Test/Adjust).
  48. Connect HV battery coolant return hose
    Note
    1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  49. Position coolant drain container underneath RH front of HV battery
  50. Connect powertrain return hose
    Note
    1x spring clip, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  51. Connect powertrain supply hose
    Note
    1x spring clip, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill
  52. Remove coolant drain container from underneath vehicle.
  53. Put on HV insulating gloves and leather over gloves.
  54. Connect AC compressor HV harness connector to the HV ancillary harness.
    Note
    1x locking connector, 3 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector, Engage locking tab
  55. Remove HV insulating gloves.
  56. Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  57. Move the rack arms away from the vehicle.
  58. Install butyl patches onto LH and RH rocker access holes.
    Note
    2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
  59. Install the LH and RH rocker carrier. See Rocker Carrier - LH (Remove and Replace).
  60. Install DCDC ground busbar to HV battery
    Note
    Gently press down
  61. Install nut securing DCDC ground busbar to HV battery
    Note
    1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
  62. Install positive 12V output from PCS cable and torque nut securing it
    Note
    1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque
  63. Install positive 12V output cover to PCS cable
    Note
    1x cover
  64. Remove logic cap and connect HVC logic connector
    Note
    1x connector, 1x logic cap, Align connector then pull the handle to locking position get connector fully seated
  65. Put on HV insulating gloves and leather over gloves.
  66. Clean HV connector contact surface of residual Penetrox.
    Note
    Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
  67. Clean busbar HV connector contact surface of residual Penetrox.
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  68. Apply Penetrox onto HV connector joints
    Note
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  69. Remove Inflatable Air Bag from under HV header
  70. Position busbar kit connector and lower onto HV header
    Note
    4x guide tabs, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
  71. Install bolts securing charge port busbar kit to HV header
    Note
    2x bolts, 10mm, 9 Nm, Mark after torque
  72. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note
    2x HV joints. The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step.
  73. Install fastener securing busbar cover access door
    Note
    1x bolt, 10mm, 9 Nm
  74. Connect 3PH chargeport inlet harness to HV header
    Note
    1x connector, Rotate lever arm and secure locking tab
  75. Remove HV insulating gloves.
  76. Position LH rear body harness under LH lower C pillar trim
  77. Install LH body harness onto rear body
    Note
    1x clip
  78. Partially install LH B-pillar lower trim
    Note
    1x push clip
  79. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  80. Connect the LV power. See LV Power (Disconnect and Connect) (Modify)
  81. Unlock the gateway. See Gateway (Unlock).
  82. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  83. Tap Thermal > Coolant System > Coolant Purge Start > Run, and allow the routine to complete.
    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.
  84. Torque both RH forward HV battery bolts
    Note
    2x bolts, EP20, 136 Nm
  85. Install RH front cabin carpet support access plug
    Note
    1x plug
  86. Fold RH front main cabin carpet back to original position
  87. Torque both LH front inner HV battery bolts
    Note
    2x bolts, EP20, 136 Nm
  88. Install LH front cabin carpet support access plugs
    Note
    1x plug
  89. Fold LH front main cabin carpet back to original position
  90. Install the LH and RH center console front side panels. See Side Panel - Front - Center Console - LH (Remove and Replace) and Side Panel - Front - Center Console - RH (Remove and Replace).
  91. Install the LH and RH footwell hush panels. See Hush Panel - Footwell - Driver (Remove and Replace) and Hush Panel - Footwell - Front Passenger (Remove and Replace).
  92. Install the LH and RH lower A-pillar trims. See Trim - A-Pillar - Lower - LH (Remove and Replace).
  93. Move the front seats forward.
  94. Torque LH rear inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
  95. Torque RH rear inner battery bolt
    Note
    1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
  96. Remove air bag from between rear cabin carpet and body
  97. Torque LH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  98. Fold LH side of rear main carpet to its original position
  99. Torque RH middle inner HV battery bolt
    Note
    1x bolt, 16mm, 66 Nm
  100. Fold RH side of rear main carpet to its original position
  101. Connect the 2nd row 40 seat connector.
    Note
    1x connector, Engage the tab.
  102. Install the 2nd row 60 seat assembly from the vehicle. See Seat Assembly - 2nd Row - LH (5-Seat) (Remove and Install).
  103. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  104. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  105. Move LH and RH front seats to original positions.
  106. Inspect coolant level and top off as necessary.
    Note
    Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair
  107. Install coolant bottle cap.
  108. Exit Service Mode. See Service Mode.
  109. Install the HEPA filter assembly. See HEPA And Carbon Filters (Remove and Replace).
  110. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  111. Raise all the windows and close all the doors.