HV Battery (AWD) (Structural Pack) (Remove and Install)
Correction code 16010211 4.56 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-06-13: Updated lift pad adapter PNs.
- 2023-11-21: Added new lift pad instructions.
- 2023-11-07: Added references to wade seal procedures.
- 2023-08-23: Updated EPB Service Mode reference.
Only
technicians who have been trained in High Voltage Awareness and
have completed all required certification courses (if applicable) are permitted to
perform this procedure. Proper personal protective equipment
(PPE) and insulating HV gloves with a minimum rating
of class 0 (1000V) must be worn at all times a high voltage
cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness
Care Points
for additional safety
information.
Remove
- Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove butyl patches covering LH
rocker access holes
Note2x butyl patches, Clean excess butyl from area
-
Install lift pad adapters.
- For EMEA only, install Adapter, Lift Pad, Model Y (1614078-00-A)
- For other regions, install Universal Lift Pad Adapters (1936724-00-A)
WarningDO NOT use any other lift pad adapters.NoteOutside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.NoteIn EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.Instructions for Universal Lift Pad Adapters:
- Depending on the lift type, install the correct thread adapter onto the lift adapter.
- Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
- Install the lift adapters onto the
lift arms so that the black lift pad is toward the vehicle.WarningMake sure the adapter is install in the correct orientation.
- Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
- Lift the lift arms to fully seat the lift pads into the vehicle.
- Make sure all 4 adapters are fully seated into the vehicle.
- Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove butyl patches covering RH
rocker access holes
Note2x butyl patches, Clean excess butyl from area
-
Install lift pad adapters.
- For EMEA only, install Adapter, Lift Pad, Model Y (1614078-00-A)
- For other regions, install Universal Lift Pad Adapters (1936724-00-A)
WarningDO NOT use any other lift pad adapters.NoteOutside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.NoteIn EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.Instructions for Universal Lift Pad Adapters:
- Depending on the lift type, install the correct thread adapter onto the lift adapter.
- Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
- Install the lift adapters onto the
lift arms so that the black lift pad is toward the vehicle.WarningMake sure the adapter is install in the correct orientation.
- Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
- Lift the lift arms to fully seat the lift pads into the vehicle.
- Make sure all 4 adapters are fully seated into the vehicle.
- Open all four doors
- Lower all four windows
- Chock LH rear wheel
- Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
- Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
-
Using Toolbox 3:
-
Remove laptop from vehicle
NoteDo not close Toolbox 3.0, we will need to resume later
- Remove the LH middle A-pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
- Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
-
Release LH front door seal from
body
-
Remove clip securing LH front cabin
carpet to body
Note1x clip
-
Pull LH front cabin carpet away from
A-pillar to access LH front seat connector
- Move LH front seat forward
- Repeat steps 14 through 19 for the RH side of the vehicle.
-
Release seat belt retractor from RH
and LH front seats
NoteInsert special removal tool into the bottom of the retractor to release
-
Remove LH front seat rear
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Discard after removal
- Move LH front seat backward
-
Remove screw and clips securing LH
footwell cover
Note2x push clips, 1x screw, T20, 2.5 Nm
-
Remove connectors from LH footwell
cover and remove from vehicle
Note3x tabs, 1x Ethernet connector, 1x puddle light connector
- Remove LH front floormat
-
Remove LH front seat front
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Discard after removal
-
Adjust position of LH front seat for
easy removal
NoteMove seat to middle of track at most upright position
-
Remove RH front seat rear
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Discard after removal
- Move RH front seat backward
- Remove the passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
- Remove RH front floormat
-
Remove RH front seat front
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Discard after removal
-
Adjust position of RH front seat for
easy removal
NoteMove seat to middle of track at most upright position
- Open hood
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
- Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
-
Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
-
Disconnect LH front seat harness from
VC left
Note1x electrical connector, Release the lock by squeezing the release tab, Then fully disengage the lock by moving it away from the VC left, Do not force the connector, If the connector does not easily release from the VC the lock is still engaged
-
Remove LH front seat harness from LH
footwell support bracket
Note2x retaining clips
-
Position LH front seat up and tilt
backwards
NoteCarefully lean LH front seat backwards
- Remove the LH center console side panel. See Side Panel - Center Console - LH (Remove and Replace).
-
Release clips securing LH cabin carpet
to cabin support
Note2x push clips, 1x vertical clip, Insert clip pry tool outboard of clip and rotate to the right to release one side of clip, Move clip pry tool inboard of clip and rotate to left to fully release carpet clip from cabin support
-
Release clips securing LH front cabin
carpet underneath front seat
Note4x clips
-
Remove LH front cabin carpet from
vehicle
Note1x harness clip, Release seat harness clip and harness, Release all edges, Take note of short edge under center console
-
Release clips securing LH front seat
harness and route out from under seat riser
Note3x clips, Lean seat back as required, Route harness out and release clips
-
Remove LH front seat from
vehicle
NoteRecommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
-
Disconnect RH front seat harness from
VC right
Note1x electrical connector, Release the lock by squeezing the release tab, Then fully disengage the lock by moving it away from the VC right, Do not force the connector, If the connector does not easily release from the VC the lock is still engaged
-
Remove RH front seat harness from RH
footwell support bracket
Note2x retaining clips
-
Position RH front seat up and tilt
backwards
NoteCarefully lean RH front seat backwards
- Remove the RH center console side panel. See Side Panel - Center Console - LH (Remove and Replace).
-
Release clips securing RH cabin carpet
to cabin support
Note2x clips
-
Release clips securing RH front cabin
carpet underneath front seat
Note4x clips
-
Remove RH front cabin carpet from
vehicle
Note1x harness clip, Release seat harness clip and harness, Release all edges, Take note of short edge under center console
-
Release clips securing RH front seat
harness and route out from under seat
Note3x clips, Lean seat back as required, Route harness out and release clips
-
Remove RH front seat from
vehicle
NoteRecommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
- Remove the center console. See Center Console (2.0) (Structural Pack) (Remove and Replace).
- Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Remove the LH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Structural Pack) (Remove and Replace).
- Repeate steps 60and 61 for the RH side of the vehicle.
- Remove rear floormat
-
Remove clips securing rear main cabin
carpet to vehicle
Note3x push clips
-
Remove rear main cabin carpet from
vehicle
NotePull up at the rear of rear main carpet and slide back, Remove from LH rear door
-
Remove clip securing center console
harness to body
Note1x clip
-
Remove LH and RH lower IP carrier
brackets
Note4x bolts, 10mm, 25 Nm
-
Remove LH and RH floor ducts
Note2x clips
-
Loosen rear inner HV battery bolts
with ratchet and remove with battery powered drill
Note4x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 35 to 38
-
Remove wheel chocks and push vehicle
onto lift
NoteRecommend assistance, Note this vehicle can only be safely pushed for a very short distance and at very slow speed, Replace wheel chocks once vehicle in correct position
-
Raise and support vehicle
NoteVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
-
Raise vehicle fully and lower lift
onto locks
NoteSet 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
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
-
Release RH front wheel liner from HV
battery and lower wheel well area
Note3x clips, 1x bolt, 10mm, 5 Nm
-
Release LH front wheel liner from HV
battery and lower wheel well area
Note3x clips, 1x bolt, 10mm, 5 Nm
-
Remove mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
-
Remove all items from pockets and
ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Install amp clamp to RDU HV
harness
NoteVerify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If 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 down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
-
Release RDU HV harness from HV
battery
Note1x 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
NoteMake 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
- Remove HV insulating gloves
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Disconnect logic connector at LH seat
frame
Note1x connector
-
Remove clip securing logic connector
harness to LH seat frame
Note1x clip, Pinch tabs on clip to avoid damage
-
Remove bolt securing busbar cover
access door
Note1x bolt, 10mm, 9 Nm
-
Remove bolts securing charge port
busbar kit to HV header
Note2x bolts, 10mm, 9 Nm
-
Disengage LH body harness from rear
body and move aside
Note1x clip
-
Lift busbar kit connector to remove
from HV header
NoteUse inflatable air bag to suspend busbar away from HV header during removal and installation
-
Disconnect HVC logic connector and
install logic cap
Note1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
-
Disconnect power connector to HV
battery
Note1x connector, Pull locking tab upward then release connection
-
Close all four doors
NoteUnlatch rear doors at later step
-
Raise vehicle fully and lower lift
onto locks
NoteSet 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 coolant drain container
underneath LH front of HV battery
-
Disconnect PT supply hose at LH front
side of vehicle
Note1x spring clip, Plug hose connections as needed
-
Position coolant drain container
underneath LH RDU area
NotePosition neck to catch all coolant loss
-
Disconnect RDU inverter inlet hose
from fluid coupling
Note1x spring clip, 2x plugs, Plug ends as needed
-
Remove clip securing RDU inverter
inlet hose to RDU HV cable
Note1x clip
-
Position coolant drain container
underneath center front of HV battery pack
NoteUnderneath front left manifold battery supply tube
-
Disconnect front left manifold battery
supply tube
Note1x spring clip, 1x clip, Plug hose connections as needed
-
Disconnect HV battery RH front inlet
hose
Note1x spring clip, Plug hose connections as needed
-
Remove clip securing HV battery RH
front inlet hose to skid plate
Note1x clip
-
Disconnect PT return hose at RH front
side of vehicle
Note1x spring clip, Plug hose connections as needed
-
Remove clip securing PT return hose to
RH front side of HV battery pack
Note1x clip
- Remove coolant drain container from underneath vehicle
-
Remove bolt securing FDU HV harness to
FDU
Note1x bolt, 10mm, 6 Nm
-
Disconnect FDU HV harness
connector
Note1x 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 FDU header are not damaged
-
Remove FDU HV harness connector from
FDU and move aside
Note1x connector
-
Release PT coolant hose from LH side
of front HV battery bash plate
Note1x clip
-
Release compressor HV harness
connection from HV battery
Note1x locking connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up
-
Release clips securing compressor HV
harness to rear of HV battery
Note4x clips
- Position coolant drain container underneath LH rear of HV battery
-
Remove RDU inverter inlet hose
Note1x spring clip, 1x clip, Rotate between subframe and battery out of vehicle
-
Release RDU oil cooler outlet
pipe
Note2x spring clips, 5x clips, Plug hose connections as needed
-
Remove RDU oil cooler outlet
pipe
NoteRotate down over RDU and rearward around subframe
- Remove coolant drain container from underneath vehicle
-
Remove bolt securing RDU HV cable
bracket to RDU
Note1x bolt, 10mm, 6 Nm
-
Disconnect RDU HV cable from RDU
Note1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up
-
Remove RDU HV cable
NoteRotate cable underneath logic cable harness between subframe and HV battery
-
Remove smaller fasteners for LH and RH
shear plates
Note4x bolts, 13mm, 47 Nm, Bolt position 8-9 and 14-15NoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Loosen large bolt securing LH shear
plate and subframe to body and rotate shear plate clear of HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Loosen large bolt securing RH shear
plate and subframe to body and rotate shear plate clear of HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Place battery table into position and
lower vehicle to support battery
NoteRecommend assistance, Line up table so bolts at front bash plate are accessible and rear HV cables are accessible, Adjust final battery table position using adjustable caster jacks on table
-
Loosen front bolts securing HV battery
through skid plate cover with ratchet and remove with battery powered drill
Note6x bolts, 16mm, 90 Nm, Bolt location 23 to 28
-
Loosen bolts securing skid plate to
vehicle with ratchet and remove with battery powered drill
Note6x bolts, 13mm, 62 Nm, Bolt location 29-34
-
Loosen bolts securing rear HV battery
to vehicle with ratchet and remove with battery powered drill
Note4x bolts, 13mm, 62 Nm, Bolt position 10-13NoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Loosen LH bolts securing HV battery to
vehicle with ratchet and remove with battery powered drill
Note7x bolts, 15mm, 56 Nm, Bolt position 16-22
-
Loosen RH bolts securing HV battery to
vehicle with ratchet and remove with battery powered drill
Note7x bolts, 15mm, 56 Nm, Bolt position 1-7
-
Raise vehicle to free from HV
battery
NoteRecommend assistance
-
Remove battery from under
vehicle
NoteRecommend assistance
-
Inspect and clean body side of HV
battery wade seal interface.
NoteClean with water and dry surface completely
Install
-
Inspect and clean wade seal on battery prior to installation.
If the wade seal is damaged, rework or replace the seal.
- If the damage is less than 25 mm, rework the wade seal. See Wade Seal - HV Battery (Structural Pack) (Rework).
- If the damage is more than 25 mm, replace the wade seal. See Wade Seal - HV Battery (Structural Pack) (Remove and Replace).
- If there is no damage, clean the seal with water and dry the surface completely.
-
Install HV battery alignment rods onto
body
Note2x rods, Use smaller rods only, Thread onto RH front most and LH rear most side holes
-
Position HV battery pack under
vehicle
NoteRecommend assistance
-
Lower vehicle onto HV battery pack and
align battery holes with rods
NoteRecommend assistance, Use smaller rods only, Be sure coolant hoses and harnesses do not get pinched
-
Remove HV battery alignment rods from
body
Note2x rods, Remove rods once the HV battery is aligned
-
Thread in by hand all bolts securing HV
battery to vehicle - (Except for shear plates)
Note34x bolts, Includes top bolts, Do not thread shear plate bolts (3-9, 14-15), Ensure smooth thread engagement and bolts are not cross threaded into casting
-
Lower vehicle onto pack completely
NoteRecommend assistance
-
Seat all bolts securing HV battery to
vehicle with battery powered drill - (Except for shear plates)
Note34x bolts, Includes top bolts, Do not seat shear plate bolts (3-9, 14-15), 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
-
Fully torque LH bolts securing HV
battery to vehicle
Note7x bolts, 15mm, 56 Nm, Bolt position 1-7
-
Fully torque RH bolts securing HV
battery to vehicle
Note7x bolts, 15mm, 56 Nm, Bolt position 16-22
-
Fully torque front bolts securing HV
battery through bash plate openings
Note6x bolts, 16mm, 90 Nm, Bolt location 23 to 28
-
Fully torque front bolts securing bash
plate to vehicle
Note6x bolts, 13mm, 62 Nm, Bolt location 29-34
-
Fully torque rear bolts securing HV
battery to vehicle
Note4x bolts, 13mm, 62 Nm, Bolt position 10-13NoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Loosen RH rear subframe bolt and align
RH rear shear plate with HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Install bolts securing RH shear plate to
HV battery hand tight
Note2x bolts, 13mm, Bolt position 8-9, Torque at later stepNoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Torque bolt securing subframe and RH
rear shear plate to body
Note1x bolt, 21mm, 130 Nm
-
Torque small fasteners securing RH rear
shear plate to body
Note2x bolts, 13mm, 62 Nm, Bolt position 8-9NoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Loosen LH rear subframe bolt and align
LH rear shear plate with HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Install bolts securing LH rear shear
plate to body hand tight
Note2x bolts, 13mm, 62 Nm, Bolt position 14-15, Torque at later stepNoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Torque bolt securing subframe and LH
rear shear plate to body
Note1x bolt, 21mm, 130 Nm
-
Torque small fasteners securing LH rear
shear plate to body
Note2x bolts, 13mm, 62 Nm, Bolt position 14-15NoteSome vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
-
Open LH rear door
NoteUse caution while working around this area not to damage any components
-
Fully torque LH rear inner bolts
securing HV battery to vehicle
Note2x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 35-36
-
Close LH rear door
NoteDo not latch
-
Open RH rear door
NoteUse caution while working around this area not to damage any components
-
Fully torque RH rear inner bolts
securing HV battery to vehicle
Note2x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 37-38
-
Visually inspect wade seal to ensure no gaps are present
- Close RH rear door
-
Raise vehicle and lower onto locks, then
remove battery table from under vehicle
NoteRecommend 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
-
Install RDU oil cooler outlet pipe
NoteRotate up over RDU and rearward around subframe to oil cooler
-
Secure RDU oil cooler outlet pipe
Note2x spring clips, 5x clips, Remove plugs as needed
-
Position RDU HV cable up to RDU
NoteRotate cable underneath logic cable harness between subframe and HV battery
-
Connect RDU HV cable onto RDU
Note1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
-
Install bolt securing RDU HV cable
bracket to RDU
Note1x bolt, 10mm, 6 Nm
-
Install RDU inverter inlet hose
Note1x spring clip, 1x clip, Rotate between subframe and battery into RDU and PCS outlet, Remove plugs as needed
-
Install clip securing RDU inverter inlet
hose to RDU HV cable
Note1x clip
-
Secure RDU HV harness onto HV
battery
Note1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
-
Install clips securing compressor HV
harness to rear of HV battery
Note4x clips
-
Secure HV compressor connection to HV
battery
Note1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked
-
Apply Loctite 222 onto mid aero shield
bolts and install mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
-
Position coolant drain container
underneath LH front of HV battery
-
Connect PT supply hose at LH front side
of vehicle
Note1x spring clip, Remove plugs as needed
-
Secure PT coolant hose onto LH side of
front HV battery bash plate
Note1x clip
-
Position FDU HV harness connector up to
FDU
Note1x connector
-
Install FDU HV harness connector onto
FDU
Note1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
-
Connect FDU HV harness connector and
lock release lever
Note1x connector, Apply slight pressure to the connector as the lever is rotated into position, Move the lever to the closed position slowly and ensure the lever teeth and manifold teeth are properly meshed, There should be a very small gap between the manifold and the connector when fully seated
-
Install bolt securing FDU HV harness to
FDU
Note1x bolt, 10mm, 6 Nm
- Position coolant drain container underneath RH front of HV battery
-
Connect PT return hose at RH front side
of vehicle
Note1x spring clip, Remove plugs as needed
-
Install clip securing PT return hose to
RH front side of HV battery pack
Note1x clip
-
Connect HV battery RH front inlet
hose
Note1x spring clip, Remove plugs as needed
-
Install clip securing HV battery RH
front inlet hose to skid plate
Note1x clip
-
Position coolant drain container
underneath center front of HV battery pack
NoteUnderneath front left manifold battery supply tube
-
Connect front left manifold battery
supply tube
Note1x spring clip, 1x clip, Remove plugs as needed
- Remove coolant drain container from underneath vehicle
-
Install LH front wheel liner to HV
battery and lower wheel well area
Note3x clips, 1x bolt, 10mm, 5 Nm
-
Install RH front wheel liner to HV
battery and lower wheel well area
Note3x clips, 1x bolt, 10mm, 5 Nm
-
Apply Loctite 222 onto front aero shield
bolts and install fasteners securing front aero shield to vehicle
Note12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
-
Lower vehicle fully and move rack arms
away from vehicle
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Push vehicle away from lift
NoteRecommend assistance, Place wheel chocks to keep vehicle from moving, Note this vehicle can only be safely pushed for a very short distance and at very slow speed
-
Open all four doors
NoteLatch rear doors to prevent accidental closure
-
Connect power connector to HV
battery
Note1x connector, Push red locking tab down to secure connection
-
Connect HVC logic connector
Note1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
-
Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
-
Apply Penetrox onto HV connector
joints
NoteApply 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
-
Position busbar kit connector and lower
onto HV header
-
Install bolts securing charge port
busbar kit to HV Header
Note2x bolts, 10mm, 9 Nm
-
Perform Hioki resistance test at each HV
joint from HV busbar lead to bolt head
Note2x 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.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
Note1x bolt, 10mm, 9 Nm
-
Engage LH body harness onto rear
body
Note1x clip
-
Connect logic connector at LH seat
frame
Note1x connector
-
Install clip securing logic connector
harness to LH seat frame
Note1x clip
-
Install LH and RH floor ducts
Note2x clips
-
Install LH and RH lower IP carrier
brackets
Note4x bolts, 10mm, 25 Nm
-
Install clip securing center console
harness to body
Note1x clip
-
Install LH front cabin carpet into
vehicle
NoteSecure all edges, Tuck short edge underneath center console
-
Install clips securing LH front cabin
carpet underneath front seat
Note4x clips
-
Install clips securing LH cabin carpet
to cabin support
Note2x push clips, 1x vertical clip, Secure vertical clip into place first, Verify fitment of carpet
-
Install RH front cabin carpet into
vehicle
NoteSecure all edges, Tuck short edge underneath center console
-
Install clips securing RH front cabin
carpet underneath front seat
Note4x clips
-
Install clips securing RH cabin carpet
to cabin support
Note2x push clips, Secure clips and verify fitment of carpet
-
Install rear main cabin carpet to
vehicle
NotePosition rear main carpet to floorboard and slide forward, Ensure rear main carpet tucks beneath front main carpet and air duct
-
Install clips securing rear main cabin
carpet to vehicle
Note3x push clips
-
Install rear floormat
- Install the RH lower B-pillar trim. See Trim - B-Pillar - Lower - LH (Structural Pack) (Remove and Replace).
- Install the RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Repeat steps 86 and 87 for the RH side of the vehicle.
- Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Install the center console. See Center Console (2.0) (Structural Pack) (Remove and Replace).
- Install RH front floor mat
- Install LH front floor mat
-
Install LH front seat into vehicle
NoteRecommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
-
Route LH front seat harness under seat
riser and secure clips onto seat riser and carpet
Note4x clips
-
Install LH front seat harness onto LH
footwell support bracket
Note2x retaining clips
-
Connect LH front seat harness to VC
left
Note1x electrical connector, Ensure the connector and lock are fully engaged, Perform pull push pull test to ensure the connector and connector lock are seated
-
Fully seat LH front cabin carpet
-
Install clip securing LH front cabin
carpet to body
- Install the LH lower A-Pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Install the LH middle A-Pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
-
Reseat LH front door seal along lower
A-pillar trim
-
Install connectors to LH footwell cover
and position for installation
Note3x tabs, 1x Ethernet connector, 1x puddle light connector
-
Install screw and clips securing LH
footwell cover
Note1x screw, T20, 2.5 Nm, 2x push clips
-
Install RH front seat into vehicle
NoteRecommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
-
Route RH front seat harness under seat
riser and secure clips onto seat riser and carpet
Note4x clips
-
Install RH front seat harness onto RH
footwell support bracket
Note2x retaining clips
-
Connect RH front seat harness to VC
right
Note1x electrical connector, Ensure the connector and lock are fully engaged, Perform pull push pull test to ensure the connector and connector lock are seated
-
Fully seat RH front cabin carpet
-
Install clip securing RH front cabin
carpet to body
Note1x clip
- Install the RH lower A-Pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Install the RH middle A-Pillar trim. See Trim - A-Pillar - Middle - LH (Remove and Replace).
-
Reseat RH front door seal along lower
A-pillar trim
- Install the passenger footwell cover. See Cover - Footwell - Passenger (LHD) (Remove and Replace).
- Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
- Connect LV power. See 12V/LV Power (Disconnect and Connect).
-
Press and hold park button to release
EPB service mode
NoteRemove wheel chocks if necessary
-
Connect to vehicle using Toolbox
3.0
NoteVehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
- Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
-
Select
‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to
complete
NoteMake sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
- Disconnect the laptop from the vehicle.
-
Inspect coolant level and top off as
necessary
NoteEnsure that the fluid level is at the Max line
-
Install coolant bottle cap
-
Install HEPA filter assembly
Note2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
-
Install washer tank neck to washer
tank
Note1x O-ring, Ensure washer hose is properly routed after installation
-
Secure frunk to washer fluid reservoir
neck
Note1x bolt, 10mm, 5 Nm
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace)
- Move LH front seat backward
-
Install LH front seat front
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
- Move LH front seat forward
-
Install LH front seat belt retractor to
seat
NoteInsert retractor into seat pre tensioner, Make sure it locks into position with push-pull-push test
-
Install LH front seat rear
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
- Move LH front seat to original position
- Move RH front seat backward
-
Install RH front seat front
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
- Move RH front seat forward
-
Install RH front seat belt retractor to
seat
NoteInsert retractor into seat pre tensioner, Make sure it locks into position with push-pull-push test
-
Install RH front seat rear
fasteners
Note2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
- Move RH front seat to original position
- Raise all four windows
-
Close all four doors
NoteIf 12V/LV is powered up, Unlatch rear doors before closing
-
Remove lift pad adapters from RH
rocker
Note2x lift pad adapters
-
Install butyl patches onto RH rocker
access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove lift pad adapters from LH
rocker
Note2x lift pad adapters
-
Install butyl patches onto LH rocker
access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).