| Tesla

Open all four doors and lower all four windows.

Open the liftgate.

Enter Service Mode. See Service Mode.

Remove the LH and RH rocker carriers. See Rocker Carrier - LH (Remove and Replace).

Remove butyl patches covering LH rocker access holes

Note

2x butyl patches, Clean excess butyl from area, Discard after removal

Install lift pad adapters onto LH lift

Note

2x lift pad adapters

Remove butyl patches covering RH rocker access holes

Note

2x butyl patches, Clean excess butyl from area, Discard after removal

Install lift pad adapters onto RH lift

Note

2x lift pad adapters

Unlock the vehicle gateway. See Gateway (Unlock).

Run ODIN routine PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:

Thermal ➜ Actions ➜ Start Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain

via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain

Move RH front seat forward

Note

Adjust seat back if needed to avoid contacting headliner

Move LH front seat forward

Note

Adjust seat back if needed to avoid contacting headliner

Remove the 2nd row LH and center seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).

Remove the 2nd row RH seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).

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

Remove LH middle inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm

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

Remove RH middle inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm

Position air bag beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts

Remove LH rear inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm, Located below LH rear main carpet

Remove RH rear inner HV battery bolt

Note

1x bolt, 16mm, 66 Nm, Located below RH rear main carpet

Remove the LH lower A-pillar trim. See A Pillar Lower Trim - LH (Remove and Replace).

Remove the LH side center console panel. See Console Side Panel LH (Remove and Replace).

Release OBD port from LH cabin carpet cover

Note

2x tabs, Press black tabs to unlock then push upwards out of footwell cover

Disconnect E-CALL speaker connector

Note

1x connector

Fold LH front cabin carpet rearward

Note

Different regions may stick the carpet and foam together and tear them apart

Remove foam plug to access LH front inner HV battery bolts

Note

1x foam plug

Remove both LH front inner HV battery bolts

Note

2x bolts, EP20, 136 Nm

Remove the RH lower A-pillar trim. See A Pillar Lower Trim - LH (Remove and Replace).

Remove the RH side center console panel. See Console Side Panel RH (Remove and Replace).

Fold 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

Remove foam plug to access RH front inner HV battery bolts

Note

1x foam plug

Remove both RH front inner HV battery bolts

Note

2x bolts, EP20, 136 Nm

Disconnect the LV power. See LV Power (Disconnect and Connect).

Verify operation of multimeter

Note

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

Release LH body harness from rear body and move aside

Note

1x clip

Partially remove LH B-pillar lower trim

Note

1x push clip

Partially pull out LH rear body harness

Remove all items from pockets and ensure not wearing metal items

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

Put on HV insulating gloves and leather over gloves

Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

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

Remove ancillary bay probe lid cover from ancillary bay cover

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

Wipe ancillary bay cover with IPA to clean surface

Note

Allow to 1 minute dry time

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

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

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

Remove fastener securing busbar cover access door

Note

1x bolt, 10mm, 9 Nm

Remove bolts securing charge port busbar kit to HV header

Note

2x bolts, 10mm, 9 Nm

Remove HV insulating gloves

Lift busbar kit connector to remove from 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

Disconnect HVC logic connector and install logic cap

Note

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Release positive 12V output cover from PCS cable

Note

1x cover

Remove PCS cable from 12V passthrough output

Note

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

Remove nut securing DCDC ground busbar to HV battery

Note

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

Gently lift the DCDC ground busbar upwards

Close LH front door latch

Close LH rear door latch manually

Close RH front door latch

Close RH rear door latch manually

Close all four doors

Raise and support vehicle

Note

Recommended assistance, Before lifting, Ensure that the vehicle is not connected to a charging device, The positioning pin must be inserted into the car body holes

Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).

Release LH front wheel liner from skid plate

Note

1x bolt, 10mm, 5 Nm

Remove clip securing LH wheel liner to body

Note

1x push clip

Release RH front wheel liner from skid plate

Note

1x bolt, 10mm, 5 Nm

Remove clip securing RH wheel liner to body

Note

1x push clip

Use bungee strap to pull back LH front wheel liner

Note

Secure to subframe

Use bungee strap to pull back RH front wheel liner

Note

Secure to subframe

Remove front skid plate

Note

4x bolts, EP10, 13 Nm, 2x tabs, Move foward to remove

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

Put on HV insulating gloves and leather over gloves

Disconnect AC compressor HV harness connector from HV Ancillary harness

Note

1x locking connector, 3 stage locking connectors, 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

Remove HV insulating gloves

Position coolant drain container underneath LH front of HV battery

Disconnect HV battery return hose at LH side of vehicle and plug hoses

Note

1x spring clip, If the battery is returned to Reman, Please remove the special tool plugs

Release Chiller to Battery hose from Dash Crossmember

Note

1x clip

Disconnect HV battery manifold hoses and plug hoses

Note

1x spring clip, Loss of coolant greater than 1L requires coolant vacuum fill, If the battery is returned to Reman, Please remove the special tool plugs

Position coolant drain container underneath RH front of HV battery

Disconnect powertrain return hose from powertrain return tube and plug hoses

Note

1x spring clip

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, If the battery is returned to Reman, Please remove the special tool plugs

Position coolant drain container underneath front of HV battery

Remove manifold tube from front of HV battery and plug HV battery

Note

4x spring clips, If the battery is returned to Reman, Please remove the special tool plugs

Remove coolant drain container from underneath vehicle

Remove the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear - 23.6MM X 3.5MM (Remove and Replace).

Release clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Release LH side hose clip from rear battery skid plate

Note

1x fir tree clip

Release RH side hose clips from rear battery skid plate

Note

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm

Remove upper bolts securing HV battery rear skid plate enclosure

Note

4x bolts, 13mm, 64 Nm

Remove HV battery rear skid plate enclosure

Put on HV insulating gloves and leather over gloves

Remove nut securing RDU HV cable bracket to HV battery

Note

1x nut, 10mm, 10 Nm

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

Remove HV insulating gloves

Position coolant drain container under LH rear of vehicle

Disconnect LH coolant hose from rear of HV battery

Note

1x spring clip, 2x plugs, Plug both the coolant hose and passthrough, If the battery is returned to Reman, please remove the special tool plug

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, If the battery is returned to Reman, Please remove the special tool plug

Position coolant drain underneath RH rear of HV battery

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, If the battery is returned to Reman, Please remove the special tool plugs

Remove coolant drain container from underneath vehicle

Release clip securing coolant hoses to RH shear plate

Note

1x fir tree clip

Position support stand to support front portion of rear subframe

Remove smaller fasteners for LH shear plate

Note

2x bolts, 13mm, 64 Nm

Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 125 Nm

Hand tighten bolt securing LH side of subframe to body

Note

1x bolt, 21mm, 125 Nm

Remove smaller fasteners for RH shear plate

Note

2x bolts, 13mm, 64 Nm

Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note

1x bolt, 21mm, 125 Nm

Hand tighten bolt securing RH side of subframe to body

Note

1x bolt, 21mm, 125 Nm

Remove support stand from under vehicle

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

Remove central bolts securing HV battery center ski cover

Note

4x bolts, EP14, 34 Nm

Remove bolts securing LH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove bolts securing RH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Remove LH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Remove RH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Raise vehicle free of HV battery

Note

Recommend assistance

Remove battery from under vehicle

Note

Recommend assistance

Remove penthouse engagement seal from HV battery pack

Note

Discard anytime HV battery is removed from vehicle

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

Install HV battery alignment rods

Note

2x rods, To body at front of vehicle, 2x rods, To battery near penthouse

Position HV battery under vehicle

Note

Recommend assistance

Lower vehicle onto HV battery and align holes

Note

Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)

Loosely install RH bolts securing HV battery to vehicle hand tight

Note

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

Loosely install LH bolts securing HV battery to vehicle hand tight

Note

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

Remove HV battery alignment rods

Note

2x rods, To body at front of vehicle, 2x rods, To battery near penthouse

Install LH rear inner HV battery bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step

Install LH middle inner HV battery bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step

Install RH rear inner battery bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step

Install RH inner HV battery bolt hand tight

Note

1x bolt, 16mm, 66 Nm, Torque at later step

Install both LH front inner HV battery bolts hand tight

Note

2x bolts, EP20, 136 Nm, Torque at later step

Install both RH front inner HV battery bolts hand tight

Note

2x bolts, EP20, 136 Nm, Torque at later step

Set bolts securing RH front support bracket to vehicle with cordless impact

Note

4x bolts, 16mm, 110 Nm, Torque at later step

Set bolts securing LH front support bracket to vehicle with cordless impact

Note

4x bolts, 16mm, 110 Nm, Torque at later step

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

Lower vehicle onto pack completely

Note

Recommend assistance

Torque RH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Torque LH bolts securing HV battery to vehicle

Note

8x bolts, 13mm, 35 Nm

Torque bolts securing RH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Torque bolts securing LH front support bracket to vehicle

Note

4x bolts, 16mm, 110 Nm

Torque central bolts securing HV battery through center ski cover

Note

4x bolts, EP14, 34 Nm

Raise vehicle and lower onto locks, then remove battery table from under vehicle

Note

Recommend assistance, Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side

Position support stand to support front section of rear subframe

Remove bolt securing LH side of rear subframe to body

Note

1x bolt, 21mm, 125 Nm

Install bolts securing LH shear plate to HV battery hand tight

Note

2x bolts, 13mm, 64 Nm, Torque at later step

Install bolt and shear plate to LH side of rear subframe hand tight

Note

1x bolt, 21mm, 125 Nm, Torque at later step

Torque bolt securing subframe and LH shear plate to body

Note

1x front bolt, 21mm, 125 Nm, Mark bolt after torque

Torque bolts securing LH shear plates to vehicle

Note

2x bolts, 13mm, 64 Nm

Remove bolt securing RH side of rear subframe to body

Note

1x bolt, 21mm, 125 Nm

Install bolts securing RH shear plate to HV battery hand tight

Note

2x bolts, 13mm, 65 Nm, Torque at later step

Install bolt and shear plate to RH side of rear subframe hand tight

Note

1x bolt, 21mm, 125 Nm, Torque at later step

Torque bolt securing subframe and RH rear shear plate to body

Note

1x bolt, 21mm, 125 Nm

Torque bolts securing RH shear plates to vehicle

Note

2x bolts, 13mm, 64 Nm

Remove support stand from under vehicle

Install clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Position coolant drain underneath RH rear of HV battery

Install clip securing coolant hoses to RH shear plate

Note

1x fir tree clip

Remove hose plugs and connect coolant outlet hose to rear return hose

Note

1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary.Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container under LH rear of vehicle

Remove plugs and connect RDU inverter inlet hose to rear of HV battery

Note

1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Loss of coolant greater than 1L requires coolant vacuum fill.

Connect LH coolant hose to rear of HV battery

Note

1x spring clip, 2x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

Remove coolant drain container from underneath vehicle

Put on HV insulating gloves and leather over gloves

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

Install nut securing RDU HV cable bracket to HV battery

Note

1x nut, 10mm, 10 Nm

Remove HV insulating gloves

Position HV battery rear skid plate enclosure

Note

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note

4x bolts, 13mm, 64 Nm

Install lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm

Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note

4x bolts, 13mm, 64 Nm

Install RH side hose clips to rear battery skid plate

Note

2x fir tree clips

Install LH side hose clip to rear battery skid plate

Note

1x fir tree clip

Install the rear stabilizer bar. See Rear Stabilizer Bar and Links - Stabar - Rear - 23.6MM X 3.5MM (Remove and Replace).

Position coolant drain container underneath front of HV battery

Install manifold tube of front of HV battery

Note

4x spring clips, Remove plugs, Perform push-pull test to verify hoses are fully engaged. Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container underneath LH front of HV battery

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

Install Chiller to Battery hose to Dash Crossmember

Note

1x clip

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

Position coolant drain container underneath RH front of HV battery

Connect bypass 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

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

Remove coolant drain container from underneath vehicle

Put on HV insulating gloves and leather over gloves

Connect AC compressor HV harness connector to 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

Remove HV insulating gloves

Install front skid plate

Note

4x bolts, EP10, 13 Nm, 2x tabs, Position and move backward to installation

Release LH front wheel liner from bungee strap

Note

Remove strap from vehicle

Install LH front wheel liner from skid plate

Note

1x bolt, 10mm, 5 Nm

Install clip securing LH wheel liner to body

Note

1x push clip

Release RH front wheel liner from bungee strap

Note

Remove strap from vehicle

Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).

Move rack arms away from vehicle

Install butyl patches onto LH rocker access holes

Note

2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch, Cut to the required size, Roughly 2" x 2 1/2"

Install LH rocker carrier onto body

Note

10x clips, 1x location pin

Install bolts securing LH rocker carrier to body

Note

2x bolts, 10mm, 9 Nm

Install LH rocker cover onto rocker carrier

Note

11x clips, 11x tabs, 1x location pin, Tabs go into cavities on rocker carrier and cannot be accessed from outer side of cover, Ensure that all tabs are installed properly

Install clips securing LH rocker cover and rocker carrier to LH front wheel liner

Note

2x clips

Install clips securing LH rocker cover and rocker carrier to LH rear wheel liner

Note

2x clips

Install butyl patches onto RH rocker access holes

Note

2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch, Cut to the required size, Roughly 2" x 2 1/2"

Install the RH rocker carrier. See Rocker Carrier - LH (Remove and Replace).

Install DCDC ground busbar to HV battery

Note

Gently press down

Install nut securing DCDC ground busbar to HV battery

Note

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

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

Install positive 12V output cover to PCS cable

Note

1x cover

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

Put on HV insulating gloves and leather over gloves

Clean HV connector contact surface of residual Penetrox

Note

Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector

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

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

Remove Inflatable Air Bag from under HV header

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

Install bolts securing charge port busbar kit to HV header

Note

2x bolts, 10mm, 9 Nm, Mark after torque

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