Correction code 1630012122 FRT 1.38 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. 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, 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. 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

    

    

    

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

    

12. 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

    

13. Put on HV insulating gloves and leather over gloves

    

14. Verify operation of multimeter
    Note

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

    

15. Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

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

    

16. Remove ancillary bay probe lid cover from ancillary bay cover

    

    

17. 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

    

    

    

    

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

    Allow to 1 minute dry time

    

19. 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

    

    

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

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

    

21. Remove leather over gloves and HV insulating gloves

    

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

    3x push clips

    

23. 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

    

    

    

24. Disconnect 2nd row 40 seat connector
    Note

    1x connector, Disengage the tab

    

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

    Recommend assistance

    

26. 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

    

    

    

27. Disconnect 2nd row 60 seat connector
    Note

    1x connector, Disengage locking tab

    

28. 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

    

    

    

29. Disconnect HVC logic connector and install logic cap
    Note

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

    

    

30. Release positive LV output cover from PCS cable
    Note

    1x cover

    

    

31. Remove PCS cable from LV passthrough output
    Note

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

    

32. Remove bolts securing ancillary bay cover to HVC
    Note

    3x bolts, E10, 5 Nm + 30 degrees

    

33. 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

    

    

34. Remove HVC logic cap
    Note

    1x logic cap

    

35. 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

    

36. Put on HV insulating gloves and leather over gloves

    

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. Lift HV Controller up
    Note

    Hold HVC assembly and tray in upward positition with rubber bungee

    

44. 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

    

45. Disconnect PCS logic connector from PCS
    Note

    1x connector

    

46. 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

    

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

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

    

48. Gently lift the DCDC ground busbar upwards

    

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

    2x bolts, E10 5-Lobe, 10 Nm

    

50. Remove DCDC pass through from ancillary bay
    Note

    Attention: To avoid metal damage to the cable insulation layer

    

    

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

    2x connectors

    

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

    1x clip

    

53. Remove HV joint insulators from positive HV switch
    Note

    2x insulators

    

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

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

    

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

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

    

56. 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

    

57. Remove positive pack contactor from ancillary bay
    Note

    2x guide pins

    

    

    

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

    2x guide pins

    

    

    

59. 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

    

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

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

    

61. 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

    

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

    1x HV joint, 110μΩ or less

    

    

63. 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.

    

    

64. Install HV joint insulators onto positive pack contactor
    Note

    2x insulators

    

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

    1x clip

    

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

    2x connectors

    

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

    Attention: To avoid metal damage to the cable insulation layer

    

    

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

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

    

69. Install DCDC ground busbar to HV battery
    Note

    Gently press down

    

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

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

    

71. 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

    

72. Connect PCS logic connector to PCS
    Note

    1x connector

    

73. 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

    

74. Lower HV Controller back into place
    Note

    Remove bungee and slowly lower controller

    

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

    2x connectors

    

76. Remove HV joint insulators from negative pack contactor
    Note

    2x insulators

    

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

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

    

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

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

    

79. 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

    

80. Remove negative pack contactor from ancillary bay
    Note

    2x guide pins

    

    

    

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

    2x guide pins

    

    

    

82. 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

    

83. 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

    

84. 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

    

85. 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.

    

    

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

    1x HV joint, 110μΩ or less

    

    

87. Install HV joint insulators to negative pack contactor
    Note

    2x insulators

    

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

    2x connectors

    

89. Remove pyro disconnect dummy

    

90. 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

    

    

    

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

    

92. 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

    

    

93. 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

    

    

    

    

94. Install bolts securing pyro disconnect to ancillary bay
    Note

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

    

95. 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

    

    

96. Measure resistance from pyro disconnect to shunt
    Note

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

    

    

97. Remove service insulator kit

    

    

    

    

98. Remove HVC logic cap
    Note

    1x logic cap

    

99. 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

    

100. 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

     

     

     

     

     

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

     Allow to 1 minute dry time

     

102. 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.

     

     

103. Remove leather over gloves and HV insulating gloves

     

104. Install HVC logic cap
     Note

     1x logic cap

     

105. 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

     

     

106. Install bolts securing ancillary bay cover to HVC
     Note

     3x bolts, E10, 5 Nm + 30 degrees

     

107. 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

     

108. Install positive LV output cover to PCS cable
     Note

     1x cover

     

109. 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

     

     

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

     Recommend assistance

     

111. 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

     

     

     

     

     

112. Connect 2nd row 40 seat connector
     Note

     1x connector, Engage the tab

     

113. 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

     

     

     

114. 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

     

     

     

     

     

115. Connect 2nd row 60 seat connector
     Note

     1x connector, Engage the tab

     

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

     3x push clips

     

117. 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

     

     

118. 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

     

     

     

     

     

119. 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

     

     

     

     

     

     

120. 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

     

     

     

121. Close hood

     

     

122. Move RH front seat to original position

     

123. Move LH front seat to original position

     

124. Raise all four window

     

125. Close all four doors
     Note

     Unlatch doors before closing if necessary