Correction code 16304402 FRT 1.08 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. Open hood

   

   

6. Power off vehicle from center display
   Note

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

   

   

7. Remove rear apron
   Note

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

   

   

   

   

8. Remove HEPA filter assembly
   Note

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

   

   

   

   

9. 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

   

   

   

   

   

10. Verify operation of multimeter
    Note

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

    

11. Remove 2nd row seat cushion
    Note

    1x connector, Lift front edge of seat cushion upward to release foam from frame, Adjust the backrest to the appropriate position as needed

    

    

    

12. Remove clips securing rear main cabin carpet to vehicle
    Note

    3x push clips

    

13. Remove fasteners securing 2nd row 40 seat frame to body
    Note

    4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Discard after removal

    

    

    

14. Disconnect 2nd row 40 seat connector
    Note

    1x connector, Disengage the tab

    

15. Remove 2nd row 40 seat assembly from vehicle
    Note

    Recommend assistance

    

16. Remove fasteners securing 2nd row 60 seat frame to body
    Note

    5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Discard after removal

    

    

    

17. Disconnect 2nd row 60 seat connector
    Note

    1x connector, Disengage locking tab

    

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

    Set 60 seat assembly onto rear load floor, Then remove the seat assembly from the rear side of the vehicle, Use fender cover to avoid damaging trims, Recommend assistance

    

    

    

19. Partially release LH rear primary door seal from body

    

    

20. Remove LH lower C pillar trim
    Note

    7x clips, 2x guide tabs, Pull the trim upward to release all clips

    

    

    

21. Partially remove lower portion of LH C-pillar trim

    

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

    

23. 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

    

24. 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.

    

25. Remove bolts securing ancillary bay probe lid cover
    Note

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

    

26. Remove ancillary bay probe lid cover

    

    

27. 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

    

    

    

    

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

    Allow to 1 minute dry time

    

29. 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

    

    

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

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

    

31. Disconnect HVC logic connector and install logic cap
    Note

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

    

    

32. Release positive LV output cover from PCS cable
    Note

    1x cover

    

    

33. Remove PCS cable from LV passthrough output
    Note

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

    

34. Remove bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

35. 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

    

    

36. Remove HVC logic cap
    Note

    1x logic cap

    

37. Remove ancillary bay cover from HV battery

    

    

38. Install HVC logic cap
    Note

    1x logic cap

    

39. Inspect ancillary bay for any missing insulators
    Note

    Install service insulator kit before continuing to next step

    

    

    

    

    

40. Remove bolts securing pyro disconnect to ancillary bay
    Note

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

    

    

41. Remove pyro disconnect from ancillary bay
    Note

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

    

    

42. Install pyro disconnect dummy

    

43. Remove fuse access insulator
    Note

    3x clips, Lift straight up off of the fuses

    

44. Release 700VDC 63A compressor fuse
    Note

    2x patch nuts, 8mm, 2.5 Nm, Discard after removal

    

45. Remove 700VDC 63A compressor fuse from AWD bus and dist assembly
    Note

    1x fuse

    

46. Position 700VDC 63A compressor fuse to AWD bus and dist assembly
    Note

    1x fuse

    

47. Install 700VDC 63A compressor fuse
    Note

    2x patch nuts, 8mm, 2.5 Nm, Install new patch nuts, Mark after torque

    

48. Perform Hioki resistance test at 63A fuse out joint
    Note

    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

49. Perform Hioki resistance test at 63A fuse in joint
    Note

    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing

    

    

50. Install fuses access insulator
    Note

    3x clips

    

51. Remove pyro disconnect dummy

    

52. 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

    

    

    

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

    

54. 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

    

    

55. 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

    

    

    

    

56. Install bolts securing pyro disconnect to ancillary bay
    Note

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

    

57. 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

    

    

58. Measure resistance from pyro disconnect to shunt
    Note

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

    

    

59. Remove service insulator kit

    

    

    

    

60. Remove HVC logic cap
    Note

    1x logic cap

    

61. 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

    

62. 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

    

    

    

    

    

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

    Allow to 1 minute dry time

    

64. 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.

    

    

65. Remove leather over gloves and HV insulating gloves

    

66. Install HVC logic cap
    Note

    1x logic cap

    

67. 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

    

    

68. Install bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

69. 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

    

70. Install positive LV output cover to PCS cable
    Note

    1x cover

    

71. 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

    

    

72. Position LH rear body harness under LH lower C pillar trim

    

73. Install LH body harness onto rear body
    Note

    1x clip

    

74. Partially install LH B-pillar lower trim
    Note

    1x push clip

    

75. Partially install lower portion of LH C-pillar trim

    

76. Install LH lower C pillar trim
    Note

    7x clips, 2x guide tabs, Align guide tabs, Then press down to securing all clips

    

    

    

77. Partially install LH rear primary door seal
    Note

    Verify seal is seated properly on all trim panels

    

    

78. Position 2nd row 40 seat assembly into vehicle
    Note

    Recommend assistance

    

79. Install 2nd row 40 seat frame to vehicle
    Note

    4x bolts, 11mm, 37 Nm, Install new bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front

    

    

    

    

    

80. Connect 2nd row 40 seat connector
    Note

    1x connector, Engage the tab

    

81. Position 2nd row 60 seat assembly
    Note

    Set 60 seat assembly onto rear load floor through the rear side of the vehicle, Then install the seat assembly onto body, Use fender cover to avoid damaging trims, Recommend assistance

    

    

    

82. Install 2nd row 60 seat frame to body
    Note

    5x bolts, 11mm, 37 Nm, Install new bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front

    

    

    

    

    

83. Connect 2nd row 60 seat connector
    Note

    1x connector, Engage the tab

    

84. Install clips securing rear main cabin carpet to vehicle
    Note

    3x push clips

    

85. Install 2nd row seat cushion
    Note

    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test, And ensure the buckles get stuck under the 2nd row cushion

    

    

86. 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

    

    

    

    

    

87. 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 in between HEPA filter assembly and body

    

    

    

    

    

    

88. 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

    

    

    

89. Close hood
90. Move RH front seat to original position
91. Move LH front seat to original position
92. Raise all four window
93. Close all four doors
    Note

    Unlatch doors before closing if necessary