High Voltage Battery (1-Phase) (RHD) (Model Y L) (Remove and Replace)

Open all four doors

Lower all four windows

Partially remove LH front primary door seal from body

Remove LH IP end cap

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5x clips, 2x guide tabs

Remove LH lower A pillar trim from body

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7x clips,4x guide tabs, 1x push clip, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet

Move LH front seat backward

Release LH front cabin carpet cover

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2x magnets, 2x datums

Release OBD port from LH cabin carpet cover

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

Disconnect E-CALL speaker connector

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1x connector

Remove LH hush panel assembly

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6x clips, 1x connector

Remove console LH front side panel from center console

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14x clips, 1x location pin, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, If panel is peeled off it could be damaged

Fold LH front cabin carpet rearward

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Maneuver carpet below brake pedal and accelerator pedal, Different regions may stick the carpet and foam together and tear them apart

Remove foam plugs to access LH front inner HV battery bolts

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1x foam plug

Move LH front seat forward

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Adjust seat back if needed to avoid contacting headliner

Move LH 2nd row seat backward

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Adjust seat back if needed to avoid contacting other parts

Remove front bolts securing LH 2nd row seat

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2x patch bolts, TP45, 33.5 Nm, Discard patch bolts after removal

Move LH 2nd row seat forward

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Adjust seat back if needed

Remove rear bolts securing LH 2nd row seat

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2x patch bolts, TP45, 33.5 Nm, Discard patch bolts after removal

Adjust LH 2nd row seat position for removal

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Center seat on tracks to minimize risk of damage to trim during removal

Partially release RH front primary door seal

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For remove RH IP end cap, RH lower A pillar trim, RH front B pillar trim

Remove RH IP end cap

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5x clips, 2x guide tabs

Remove RH lower A pillar trim

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7x clips, 4x guide tabs, 1x push clip, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet

Move RH front seat backward

Release front RH cabin carpet cover from driver footwell hush panel

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2x magnets, 2x datums

Remove driver footwell hush panel

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1x connector, 7x tabs, 2x location pins

ODIN 루틴 실행

Fold RH front cabin carpet rearward

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

Remove foam plug to access RH front inner HV battery bolts

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1x foam plug

Move RH front seat forward

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Adjust seatback if needed to avoid contacting headliner

Move RH 2nd row seat backward

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Adjust seat back if needed to avoid contacting other parts

Remove front bolts securing RH 2nd row seat

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2x patch bolts, TP45, 33.5 Nm, Discard after removal

Move RH 2nd row seat forward

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Adjust seat back if needed

Remove rear bolts securing RH 2nd row seat

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2x patch bolts, TP45, 33.5 Nm, Discard after removal

Adjust position of RH 2nd row seat for easy removal

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For the convenience remove from vehicle

ODIN 루틴 실행

Access thermal system routines via UI

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Select Service mode > Thermal

Perform "Start Thermal Fill/Drain (Coolant Only)" through Service UI

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Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again

Open hood

Power off vehicle from center display

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

Remove rear apron

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

Remove HEPA filter assembly

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

Disconnect LV battery and first responder loop

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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

Remove air intake duct

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2x clips, 1x align pin, 1x bolt, 10mm, 4 Nm, Gently pry pin out from thermal beam then remove duct from bulkhead studs

Disconnect LH 2nd row seat connector

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1x connector, 1x clip, Partily lift seat assembly, Release red locking tab and then press white tab to disconnect connector

Remove LH 2nd row seat from vehicle

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Recommend assistance, Caution not to damage any trim, Protect the seat upholstery when the seat is outside of the vehicle

Disconnect RH 2nd row seat connector

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1x connector, 1x clip, Partily lift seat assembly, Release red locking tab and then press white tab to disconnect connector

Remove RH 2nd row seat from vehicle

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Recommend assistance, Caution not to damage any trim, Protect the seat upholstery when the seat is outside of the vehicle

Remove 3rd row seat cushion

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2x clips, 1x connector, 2x circular hooks, Press tabs backward then pull front edge up, Press rear seat cushion and lift the front seat cushion

Release clip securing 3rd row LH seat frame harness to seat cushion bolster

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1x clip

Remove 3rd row LH seat cushion bolster

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1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster towards front of vehicle to remove

Release clip securing 3rd row RH seat frame harness to seat cushion bolster

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1x clip

Remove 3rd row RH seat cushion bolster

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1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster towards front of vehicle to remove

Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt

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Located below rear of LH front seat, Expand the hole if necessary

Remove LH middle inner HV battery bolt

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1x bolt, 16mm, 66 Nm

Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt

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Located below rear of RH front seat, Expand the hole if necessary

Remove RH middle inner HV battery bolt

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1x bolt, 16mm, 66 Nm

Partially release LH rear primary door seal from body

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For remove LH rear B pillar trim, LH lower C pillar trim

Remove LH lower C pillar trim from body

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7x clips, 1x guide tab, Pull the trim upward to release all clips

Partially release RH rear primary door seal from body

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For remove RH rear B pillar trim, RH lower C pillar trim

Remove RH lower C pillar trim from body

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7x clips, 1x guide tab, Pull the trim upward to release all clips

Remove rear cabin carpet harness clips

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2x retaining clips

Fold rear cabin carpet access to rear inner HV battery bolts

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2x datums, Pull out the carpet from the side trunk trim on both sides, When remove, please make sure to thread the harness of the second row seats through the carpet

Remove clip securing 2nd row LH seat harness to ancillary bay

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1x clip

Remove clip securing 2nd row RH seat harness to ancillary bay

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1x clip

Remove both LH front inner HV battery bolts

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2x bolts, EP20, 136 Nm

Remove both RH front inner HV battery bolts

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2x bolts, EP20, 136 Nm

Remove rear inner HV battery bolts

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2x bolts, 16mm, 66 Nm

Remove rear outer HV battery bolts

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2x bolts, 15mm, 45 Nm

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

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2x clips

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

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2x clips

Remove LH rocker cover from rocker carrier

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12x clips, 11x tabs, 1x location pin, Work a plastic trim tool between door panel and rocker cover to release tabs

Remove bolts securing LH rocker carrier to body

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2x bolts, 10mm, 9 Nm

Remove LH rocker carrier from body

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12x clips, 1x location pin

Remove clips securing RH rocker cover and rocker carrier to RH front wheel liner

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2x clips

Remove clips securing RH rocker cover and rocker carrier to RH rear wheel liner

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2x clips

Remove RH rocker cover from rocker carrier

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12x clips, 11x tabs, 1x location pin, Work a plastic trim tool between door panel and rocker cover to release tabs

Remove bolts securing RH rocker carrier to body

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2x bolts, 10mm, 9 Nm

Remove RH rocker carrier from body

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12x clips, 1x location pin

Remove butyl patches covering LH rocker access holes

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

Remove butyl patches covering RH rocker access holes

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

Install lift pad adapters onto lift

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4x lift pad adapters

Raise and support vehicle

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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

Verify operation of multimeter

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

Raise vehicle fully and lower lift onto locks

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Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

Remove LH and RH push clips securing mid aero shield to wheel house liner

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2x clips

Remove mid aero shield

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11x bolts, 2x tabs, 10mm, 5 Nm

Release LH side hose clip from rear battery skid plate

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1x fir tree clip

Release RH side hose clips from rear battery skid plate

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2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

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2x bolts, EP10, 13 Nm

Remove upper bolts securing HV battery rear skid plate enclosure

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4x bolts, 13mm, 64 Nm

Remove HV battery rear skid plate enclosure

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

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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

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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.

Install amp clamp to RDU HV harness

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Verify meter is zeroed out before performing measurement, Measure single cableIf current > 0.5A do not proceed with disconnecting HV connector, In this case, Start vehicle electrical isolation again to make sure that all was properly shut downIf the current is within the range of -0.5 A to 0.5 A, Continue to the next step, Disconnect and check voltage at HV plug on the battery side If the measurement is still outside the range of -0.5 A to 0.5 A, Do not disconnect any HV harness, Escalate for assistance

Remove nut securing RDU HV cable bracket to HV battery

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1x nut, 10mm, 10 Nm

Disconnect RDU HV cable from HV battery

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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

Verify no high voltage at RDU HV header

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Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, 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

Lower vehicle partially and set onto locks

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Raise lift off locks, Then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Release LH body harness from rear body and move aside

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1x clip

Remove fastener securing busbar cover access door

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1x bolt, 10mm, 9 Nm

Remove bolts securing charge port busbar kit to HV header

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2x bolts, 10mm, 9 Nm

Lift busbar kit connector to remove from HV header

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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 AC chargeport inlet harness from HV header

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1x connector, Release red locking tab and rotate lever arm to release

Remove leather over gloves and HV insulating gloves

Disconnect HVC logic connector and install logic cap

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

Release positive LV output cover from PCS2 lite cable

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1x cover

Remove PCS2 lite cable from LV passthrough output

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

Remove nut securing DCDC ground busbar to HV battery

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

Gently lift DCDC ground busbar upward

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Don't bend excessively

Raise vehicle fully and lower lift onto locks

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

Remove bolts securing front aero shield

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7x bolts, 10mm, 5 Nm

Remove front aero shield

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2x nuts, 15mm, 5 Nm

Remove bolt securing LH front wheel liner to skid plate

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1x bolt, 10mm, 5 Nm

Remove clip securing LH wheel liner to body

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1x push clip

Remove bolt securing RH front wheel liner to skid plate

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1x bolt, 10mm, 5 Nm

Remove clip securing RH wheel liner to body

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1x push clip

Secure LH front wheel liner aside

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1x bungee strap, Secure to subframe

Secure RH front wheel liner aside

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1x bungee strap, Secure to subframe

Remove front skid plate

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

Put on HV insulating gloves and leather over gloves

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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.

Disconnect AC compressor HV harness connector from HV Ancillary harness

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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

Release FDU HV harness from FDU

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1x bolt,10mm, 10 Nm

Release FDU HV harness connector

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1x connector. Release red 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 FDU header are not damaged

Release FDU HV harness from casting and move aside

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1x casting datum

Remove leather over gloves and HV insulating gloves

Remove FDU ground strap bolt from HV battery

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1x bolt, 10mm, 10 Nm

Position coolant drain container underneath LH front of HV battery

Disconnect HV battery return hose

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1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill

Release chiller to battery hose from body

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1x clip

Disconnect HV battery front manifold hose from chiller to battery hose

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1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container underneath RH front of HV battery

Disconnect FDU inverter inlet hose to rear powertrain return hose and plug hoses

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

Disconnect PT supply hose

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1x spring clip, Plug coolant connections as needed, Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container under LH rear of vehicle

Disconnect RDU inverter inlet hose from PCS outlet hose coupling

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1x spring clip, 2x plugs, Connection is located at the LH rear of the HV Battery, Install plugs once disconnected, 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 container underneath RH rear of HV battery

Disconnect coolant outlet hose to rear return hose and plug hoses

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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

Position support stand to support front portion of rear subframe

Release clip securing coolant hoses to RH shear plate

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1x fir tree clip

Release clips securing coolant hoses to LH shear plate

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2x fir tree clips

Remove smaller fasteners for LH shear plate

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2x bolts, 13mm, 64 Nm

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

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1x bolt, 21mm, 125 Nm

Hand tighten bolt securing LH side of subframe to body

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1x bolt, 21mm, 125 Nm

Remove smaller fasteners for RH shear plate

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2x bolts, 13mm, 64 Nm

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

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1x bolt, 21mm, 125 Nm, Discard after removal

Hand tighten bolt securing RH side of subframe to body

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1x bolt, 21mm, 125 Nm

Remove support stand from under vehicle

Place HV battery table into position and lower vehicle to support HV battery

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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

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4x bolts, EP14, 35 Nm

Remove bolts securing LH front support bracket to vehicle

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4x bolts, 16mm, 110 Nm

Remove bolts securing RH front support bracket to vehicle

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4x bolts, 16mm, 110 Nm

Remove LH bolts securing HV battery to vehicle

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9x bolts, 13mm, 35 Nm

Remove RH bolts securing HV battery to vehicle

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9x bolts, 13mm, 35 Nm

Raise vehicle free of HV battery

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Recommend assistance

Remove battery from under vehicle

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Recommend assistance

Remove ancillary bay engagement seal from HV battery pack

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Discard anytime HV battery is removed from vehicle

Install new ancillary bay engagement seal onto HV battery pack

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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

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

Position HV battery under vehicle

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Recommend assistance

Lower vehicle onto HV battery and align holes

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Recommend assistance, Use alignment rods, When installing HV battery, Ensure that the coolant hoses and HV cable at the back of the HV battery are not stuck, Caution not to damage coolant hoses and 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

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9x bolts, 13mm, 35 Nm, Ensure smooth thread engagement, Do not over tighten bolts, Fully torque at later step

Loosely install LH bolts securing HV battery to vehicle hand tight

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9x bolts, 13mm, 35 Nm, Ensure smooth thread engagement, Do not over tighten bolts, Fully torque at later step

Remove HV battery alignment rods

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

Install rear inner HV battery bolts hand tight

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2x bolts, 16mm, 66 Nm, Torque at later step

Install rear outer HV battery bolts hand tight

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2x bolts, 15mm, 45 Nm, Torque at later step

Install middle inner HV battery bolts hand tight

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2x bolts, 16mm, 66 Nm, Torque at later step

Install both LH front inner HV battery bolts hand tight

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

Install both RH front inner HV battery bolts hand tight

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

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

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

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

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

Set central bolts securing HV battery center ski cover with cordless impact

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4x bolts, EP14, 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

Lower vehicle onto pack completely

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Recommend assistance

Torque RH bolts securing HV battery to vehicle

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9x bolts, 13mm, 35 Nm

Torque LH bolts securing HV battery to vehicle

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9x bolts, 13mm, 35 Nm

Torque bolts securing RH front support bracket to vehicle

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4x bolts, 16mm, 110 Nm

Torque bolts securing LH front support bracket to vehicle

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4x bolts, 16mm, 110 Nm

Torque central bolts securing HV battery through center ski cover

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4x bolts, EP14, 35 Nm

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

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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

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1x bolt, 21mm, 125 Nm, Discard after removal

Install bolts securing LH shear plate to HV battery hand tight

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

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

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

Torque bolt securing subframe and LH shear plate to body

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

Torque bolts securing LH shear plates to vehicle

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2x bolts, 13mm, 64 Nm

Remove bolt securing RH side of rear subframe to body

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1x bolt, 21mm, 125 Nm, Discard after removal

Install bolts securing RH shear plate to HV battery hand tight

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

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

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

Torque bolt securing subframe and RH rear shear plate to body

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1x bolt, 21mm, 125 Nm

Torque bolts securing RH shear plates to vehicle

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2x bolts, 13mm, 64 Nm

Remove support stand from under vehicle

Put on HV insulating gloves and leather over gloves

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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.

Connect RDU HV cable to HV battery

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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

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1x nut, 10mm, 10 Nm

Connect A/C compressor HV harness connector to HV Ancillary harness

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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

lnstall FDU HV harness to casting

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Install HV connector lever lock to FDU HV cable connector

Install FDU HV harness connector to FDU

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1x connector, Align connector to FDU then remove HV connector lever lock before fully latching 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 FDU HV harness to FDU

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1x bolt, 10mm, 10 Nm

Remove leather over gloves and HV insulating gloves

Position coolant drain container underneath RH rear of HV battery

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

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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

Install clip securing coolant hoses to RH shear plate

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1x fir tree clip

Position coolant drain container under LH rear of vehicle

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

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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.

Install clips securing coolant hoses to LH shear plate

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2x fir tree clips

Remove coolant drain container from underneath vehicle

Position HV battery rear skid plate enclosure

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Recommend assistance if needed

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

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4x bolts, 13mm, 64 Nm

Install lower bolts securing HV battery rear skid plate enclosure

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2x bolts, EP10, 13 Nm

Torque bolts securing HV battery rear skid plate enclosure to vehicle

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4x bolts, 13mm, 64 Nm

Install RH side hose clips to rear battery skid plate

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2x fir tree clips

Install LH side hose clip to rear battery skid plate

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1x fir tree clip

lnstall mid aero shield

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2x tabs, 11x bolts, 10mm, 5 Nm, Position rear datums first, Apply Loctite 222 onto rear aero shield bolts

Install LH and RH push clips securing mid aero shield to wheel house liner

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2x clips

Position coolant drain container underneath LH front of HV battery

Connect HV battery front manifold hose onto chiller to battery hose

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1x spring clip, Remove plugs as needed, Perform push-pull test, Loss of coolant greater than 1L requires coolant vacuum fill

Secure chiller to battery hose onto body

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1x clip

Connect HV battery return hose

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1x spring clip, Remove plugs as needed, Perform push-pull test, Loss of coolant greater than 1L requires coolant vacuum fill

Position coolant drain container underneath RH front of HV battery

Connect FDU inverter inlet hose to rear powertrain return hose

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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 PT supply hose

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1x spring clip, Remove plugs as needed, Perform push-pull test, Loss of coolant greater than 1L requires coolant vacuum fill

Remove coolant drain container from underneath vehicle

Install FDU ground strap and bolt to HV battery

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1x bolt, 10mm, 10 Nm

Install front skid plate

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

Release LH front wheel liner

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1x bungee strap, Remove bungee strap as needed

Install bolt securing LH front wheel liner to skid plate

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1x bolt, 10mm, 5 Nm

Install clip securing LH wheel liner to body

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1x push clip

Release RH front wheel liner

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1x bungee strap, Remove bungee strap as needed

Install bolt securing RH front wheel liner to skid plate

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1x bolt, 10mm, 5 Nm

Install clip securing RH wheel liner to body

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1x push clip

Position front aero shield onto vehicle

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2x datums, 2x nuts, 15mm, 5 Nm, Hand-tighten the nuts to temporarily hold the panel in place

Install front aero shield onto vehicle

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7x bolts, 10mm, 5 Nm, Apply Loctite 222 onto front aero shield bolts and install fasteners to front aero shield

Torque front aero shield nuts

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2x nuts, 15mm, 5 Nm

Lower vehicle fully

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Raise lift off locks, Then hold lock release lever to keep locks free while vehicle is lowered

Move rack arms away from vehicle

Remove coolant bottle cap

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(*Use this step for Model Y vehicles with heat pump)

Place empty coolant container into front storage area

Fill container with coolant

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Do not draw in air during fill process, For RWD, The entire system requires coolant is 15L, for AWD, The entire system requires coolant is 18L

Place filled coolant container into front storage area

Install coolant reservoir adaptor cap onto coolant bottle assembly

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(*Use step for Model Y & NV36 coolant procedures)1x adaptor cap, Adaptor found in Vacuum Refill kit, turn clockwise to tighten cap onto coolant bottle

Setup vacuum refill tool

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Verify all valves on refill tool are in the closed position, See image for clarity

Connect vacuum refill hose to refill cap on coolant bottle

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Perform push-pull-push test to verify hose is fully engaged

Position overflow hose into empty container

Place refill hose inside filled coolant container

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Make sure hose end is fully submerged into coolant

Connect shop air supply to coolant refill tool

Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

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Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system

Slowly open refill valve to allow coolant to be drawn into system

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Make sure hose end of refill hose is fully submerged during entire process

Once gauge reads zero, close refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Disconnect vacuum refill hose from refill cap on coolant bottle

Remove refill tool cap from coolant bottle assembly

Remove coolant refill tool from vehicle

Remove both coolant containers from inside underhood area

Install butyl patches onto LH rocker access holes

참고

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

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12x clips, 1x location pin

Install bolts securing LH rocker carrier to body

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2x bolts, 10mm, 9 Nm

Install LH rocker cover onto rocker carrier

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12x 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

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2x clips

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

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2x clips

Install butyl patches onto RH rocker access holes

참고

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 RH rocker carrier onto body

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12x clips, 1x location pin

Install bolts securing RH rocker carrier to body

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2x bolts, 10mm, 9 Nm

Install RH rocker cover onto rocker carrier

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12x 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 RH rocker cover and rocker carrier to RH front wheel liner

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2x clips

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

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2x clips

Install DCDC ground busbar to HV battery

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Gently press down

Install nut securing DCDC ground busbar to HV battery

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

Install positive LV output from PCS2 lite cable and torque nut securing it

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

Install positive LV output cover to PCS2 lite cable

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1x cover

Remove logic cap and connect HVC logic connector

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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

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

Clean busbar HV connector contact surface of residual penetrox

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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

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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

참고

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

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

Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

참고

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

Install fastener securing busbar cover access door

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1x bolt, 10mm, 9 Nm

Connect 1PH chargeport inlet harness to HV header

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1x connector, Rotate lever arm and secure locking tab

Remove HV insulating gloves

Install LH body harness onto rear body

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1x clip

Torque rear inner HV battery bolt

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2x bolts, 16mm, 66 Nm

Torque rear outer HV battery bolts

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2x bolts, 15mm, 45 Nm

Install clip securing 2nd row LH seat harness to ancillary bay

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1x clip

Install clip securing 2nd row RH seat harness to ancillary bay

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1x clip

Fold rear cabin carpet assembly to original position

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2x datums, When installing, First thread the seat wire harness through the carpet, And then insert the carpet under the trunk side trim on both sides

Install rear cabin carpet harness clips

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2x retaining clips

Install LH lower C pillar trim onto body

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7x clips, 1x guide tab, Align guide tabs, Then press down to securing all clips

Partially install LH rear primary door seal

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Verify seal is seated properly on all trim panels

Install RH lower C pillar trim to body

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7x clips, 1x guide tab, Align guide tab, Then press down to securing all clips

Partially install RH rear primary door seal

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Verify seal is seated properly on all trim panels

Torque LH middle inner HV battery bolt

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1x bolt, 16mm, 66 Nm

Fold LH side of rear main carpet to its original position

Torque RH middle inner HV battery bolt

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1x bolt, 16mm, 66 Nm

Fold RH side of rear main carpet to its original position

Install 3rd row RH seat cushion bolster

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1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster into seat frame complete

Install clip securing 3rd row RH seat frame harness to seat cushion bolster

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1x clip

Install 3rd row LH seat cushion bolster

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1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster into seat frame complete

Install clip securing 3rd row LH seat frame harness to seat cushion bolster

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1x clip

Connect 3rd row seat harness connector and secure seats cushion complete

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2x clips, 1x connector, 2x circular hooks, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test

Install LH 2nd row seat to vehicle

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Recommend assistance

Connect LH 2nd row seat connector

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1x connector, 1x clip, Partily lift seat assembly, Engage red locking tab

Install RH 2nd row seat to vehicle

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Recommend assistance, Caution not to damage any trim

Connect RH 2nd row seat connector

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1x connector, 1x clip, Partily lift seat assembly, Engage red locking tab

Connect first responder loop and LV battery

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2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

Move LH 2nd row seat backward

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Adjust seat back if needed to avoid contacting other parts

Install LH 2nd row seat front bolts

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2x patch bolts, TP45, 33.5 Nm, Install new patch bolts

Move LH 2nd row seat forward

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Adjust seat back if needed

Install LH 2nd row seat rear bolts

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2x patch bolts, TP45, 33.5 Nm, Install new patch bolts

Move LH 2nd row seat to original position

Move RH 2nd row seat backward

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Adjust seat back if needed to avoid contacting other parts

Install RH 2nd row seat front bolts

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2x patch bolts, TP45, 33.5 Nm, Install new patch bolts

Move RH 2nd row seat forward

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Adjust seat back if needed

Install RH 2nd row seat rear bolts

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2x patch bolts, TP45, 33.5 Nm, Install new patch bolts

Move RH 2nd row seat to original position

Move LH front seat backward

ODIN 루틴 실행

Torque both LH front inner HV battery bolts

참고

2x bolts, EP20, 136 Nm

Install LH front cabin carpet support access plugs

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1x plug

Fold LH front main cabin carpet back to original position

Install console LH front side panel to center console

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14x clips, 1x location pin, Ensure all clips and pin seat properly

Connect E-CALL speaker connector

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1x connector

Install OBD port

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2x tabs, Ensure black tabs in lock position

Install LH hush panel

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6x clips, 1x connector

Secure LH front cabin carpet cover

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2x magnets, 2x datums, Align air vents with grills

Install LH lower A pillar trim

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7x clips, 4x guide tabs, 1x push clip, Align guide tabs with body and harness bracket then push downwards to secure

Install LH IP end cap

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5x clips, 2x guide tabs

Partially install LH front primary door seal

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Verify seal is seated properly on all trim panels

Move RH front seat backward

Torque both RH forward HV battery bolts

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2x bolts, EP20, 136 Nm

Install RH front cabin carpet support access plug

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1x plug

Fold RH front main cabin carpet back to original position

Install console RH front side panel to center console

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15x clips, 1x location pin, Ensure all clips and pin seat properly

Install driver footwell hush panel

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1x connector, 7x tabs, 2x location pins, Align air vent with grill

Secure front RH cabin carpet cover to driver footwell hush panel

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2x magnets, 2x datums

Install RH lower A pillar trim

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7x clips, 4x guide tabs, 1x push clip, Align front guide tabs then align slot with harness bracket and then push rear clip to secure, Make sure all clips and tabs fully seated

Install RH IP end cap

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5x clips, 2x guide tabs, Pull the seal over end cap

Install RH front primary door seal

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Verify seal is seated properly on all trim panels

Coolant air purge run time

참고

Run time: 00:10:00, Subtract overlap time spent on other operations while waiting for coolant purge run

Inspect coolant level and top off as necessary

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Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair

Install coolant bottle cap

Install air intake duct

참고

2x clips, 1x align pin, 1x bolt, 10mm, 4 Nm, Position clips onto bulkhead studs then duct secure onto thermal bar

Install HEPA filter assembly

참고

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