07/11/2024 13:32:14

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.

2024-11-07: Added 3-phase harness disconnect/connect steps.
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.

Warning

This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Warning

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.

CAUTION

If the vehicle will be stored outdoors without the HV battery installed, seal the floor opening to prevent water and/or animal ingress. Collision wrap material is recommended.

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

Note
2x 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)
Warning
DO NOT use any other lift pad adapters.

Note
Outside 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.

Note
In 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:
1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
2. 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.
3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
  Warning
  Make sure the adapter is install in the correct orientation.
4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
5. Lift the lift arms to fully seat the lift pads into the vehicle.
6. 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

Note
2x 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)
Warning
DO NOT use any other lift pad adapters.

Note
Outside 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.

Note
In 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:
1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
2. 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.
3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
  Warning
  Make sure the adapter is install in the correct orientation.
4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
5. Lift the lift arms to fully seat the lift pads into the vehicle.
6. 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:
1. Select the Actions tab and search for "Fluid fill drain"
2. Select the ODIN routine PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain, click on the link of the routine, and then select "Fluid Fill/Drain".
3. Under "Action", select "Start".
4. In "Fluid Fill Target", select "Coolant".
  
  CAUTION
  Ensure that the charge cable is not connected before continuing to the next step in this procedure.
5. Click RUN, and allow the routine to complete.
Remove laptop from vehicle

Note
Do 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

Note
1x 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

Note
Insert special removal tool into the bottom of the retractor to release

Figure 1. LH shown; RH similar
Remove LH front seat rear fasteners

Note
2x patch bolts, T45P, 33.5 Nm, Discard after removal
Move LH front seat backward
Remove screw and clips securing LH footwell cover

Note
2x push clips, 1x screw, T20, 2.5 Nm
Remove connectors from LH footwell cover and remove from vehicle

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector
Remove LH front floormat
Remove LH front seat front fasteners

Note
2x patch bolts, T45P, 33.5 Nm, Discard after removal
Adjust position of LH front seat for easy removal

Note
Move seat to middle of track at most upright position
Remove RH front seat rear fasteners

Note
2x patch bolts, T45P, 33.5 Nm, Discard after removal

Figure 2. LH seat shown; RH similar
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

Note
2x patch bolts, T45P, 33.5 Nm, Discard after removal

Figure 3. LH shown; RH similar
Adjust position of RH front seat for easy removal

Note
Move 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

Note
Set 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

Note
1x 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

Note
2x retaining clips
Position LH front seat up and tilt backwards

Note
Carefully 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

Note
2x 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

Note
4x clips
Remove LH front cabin carpet from vehicle

Note
1x 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

Note
3x clips, Lean seat back as required, Route harness out and release clips
Remove LH front seat from vehicle

Note
Recommend assistance, Assistant should be ready to support seat back, Caution not to damage any trim
Disconnect RH front seat harness from VC right

Note
1x 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

Note
2x retaining clips
Position RH front seat up and tilt backwards

Note
Carefully 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

Note
2x clips
Release clips securing RH front cabin carpet underneath front seat

Note
4x clips
Remove RH front cabin carpet from vehicle

Note
1x 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

Note
3x clips, Lean seat back as required, Route harness out and release clips
Remove RH front seat from vehicle

Note
Recommend 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

Note
3x push clips
Remove rear main cabin carpet from vehicle

Note
Pull up at the rear of rear main carpet and slide back, Remove from LH rear door
Remove clip securing center console harness to body

Note
1x clip
Remove LH and RH lower IP carrier brackets

Note
4x bolts, 10mm, 25 Nm
Remove LH and RH floor ducts

Note
2x clips
Loosen rear inner HV battery bolts with ratchet and remove with battery powered drill

Note
4x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 35 to 38
Remove wheel chocks and push vehicle onto lift

Note
Recommend 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

Note
Verify 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

Note
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
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

Note
3x clips, 1x bolt, 10mm, 5 Nm
Release LH front wheel liner from HV battery and lower wheel well area

Note
3x clips, 1x bolt, 10mm, 5 Nm
Remove mid aero shield

Note
11x 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

Note
Check 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

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Install amp clamp to RDU HV harness

Note
Verify 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

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Verify no high voltage at RDU HV header

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
Remove HV insulating gloves
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Disconnect logic connector at LH seat frame

Note
1x connector
Remove clip securing logic connector harness to LH seat frame

Note
1x clip, Pinch tabs on clip to avoid damage
Remove bolt securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Remove bolts securing charge port busbar kit to HV header

Note
2x bolts, 10mm, 9 Nm
Disengage LH body harness from rear body and move aside

Note
1x clip
Lift busbar kit connector to remove from HV header

Note
Use inflatable air bag to suspend busbar away from HV header during removal and installation
If there is a 3-phase (AC) connection between the charge port and HV battery, disconnect it:
1. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
2. Fully raise the handle on the 3-phase connector.
3. Remove the 3-phase connector from the ancillary bay 3-phase header.
Disconnect HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
Disconnect power connector to HV battery

Note
1x connector, Pull locking tab upward then release connection
Close all four doors

Note
Unlatch rear doors at later step
Raise vehicle fully and lower lift onto locks

Note
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 coolant drain container underneath LH front of HV battery
Disconnect PT supply hose at LH front side of vehicle

Note
1x spring clip, Plug hose connections as needed
Position coolant drain container underneath LH RDU area

Note
Position neck to catch all coolant loss
Disconnect RDU inverter inlet hose from fluid coupling

Note
1x spring clip, 2x plugs, Plug ends as needed
Remove clip securing RDU inverter inlet hose to RDU HV cable

Note
1x clip
Position coolant drain container underneath center front of HV battery pack

Note
Underneath front left manifold battery supply tube
Disconnect front left manifold battery supply tube

Note
1x spring clip, 1x clip, Plug hose connections as needed
Disconnect HV battery RH front inlet hose

Note
1x spring clip, Plug hose connections as needed
Remove clip securing HV battery RH front inlet hose to skid plate

Note
1x clip
Disconnect PT return hose at RH front side of vehicle

Note
1x spring clip, Plug hose connections as needed
Remove clip securing PT return hose to RH front side of HV battery pack

Note
1x clip
Remove coolant drain container from underneath vehicle
Remove bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 6 Nm
Disconnect FDU HV harness connector

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
Remove FDU HV harness connector from FDU and move aside

Note
1x connector
Release PT coolant hose from LH side of front HV battery bash plate

Note
1x clip
Release compressor HV harness connection from HV battery

Note
1x 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

Note
4x clips
Position coolant drain container underneath LH rear of HV battery
Remove RDU inverter inlet hose

Note
1x spring clip, 1x clip, Rotate between subframe and battery out of vehicle
Release RDU oil cooler outlet pipe

Note
2x spring clips, 5x clips, Plug hose connections as needed
Remove RDU oil cooler outlet pipe

Note
Rotate down over RDU and rearward around subframe
Remove coolant drain container from underneath vehicle
Remove bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Disconnect RDU HV cable from RDU

Note
1x 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

Note
Rotate cable underneath logic cable harness between subframe and HV battery
Remove smaller fasteners for LH and RH shear plates

Note
4x bolts, 13mm, 47 Nm, Bolt position 8-9 and 14-15

Note
Some 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

Note
1x 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

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Place battery table into position and lower vehicle to support battery

Note
Recommend 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

Note
6x bolts, 16mm, 90 Nm, Bolt location 23 to 28
Loosen bolts securing skid plate to vehicle with ratchet and remove with battery powered drill

Note
6x bolts, 13mm, 62 Nm, Bolt location 29-34
Loosen bolts securing rear HV battery to vehicle with ratchet and remove with battery powered drill

Note
4x bolts, 13mm, 62 Nm, Bolt position 10-13

Note
Some 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

Note
7x bolts, 15mm, 56 Nm, Bolt position 16-22
Loosen RH bolts securing HV battery to vehicle with ratchet and remove with battery powered drill

Note
7x bolts, 15mm, 56 Nm, Bolt position 1-7
Raise vehicle to free from HV battery

Note
Recommend assistance
Remove battery from under vehicle

Note
Recommend assistance
Inspect and clean body side of HV battery wade seal interface.

Note
Clean with water and dry surface completely

Install

Note

If any of the threads in the Front Under Body (FUB) or Rear Under Body (RUB) casting is damaged, refer to TN-15-92-001 - Installing Heli-Coil Inserts for repair instructions using heli-coil inserts.

CAUTION

For repairs to the threads in the FUB or RUB, only use heli-coils inserts with TPN 1056157-09-A.

Note

If thread repair has been carried out, add correction code 70060005 - Thread Repair as a separate activity to the Service Visit.

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

Note
2x rods, Use smaller rods only, Thread onto RH front most and LH rear most side holes
Position HV battery pack under vehicle

Note
Recommend assistance
Lower vehicle onto HV battery pack and align battery holes with rods

Note
Recommend assistance, Use smaller rods only, Be sure coolant hoses and harnesses do not get pinched
Remove HV battery alignment rods from body

Note
2x rods, Remove rods once the HV battery is aligned
Thread in by hand all bolts securing HV battery to vehicle - (Except for shear plates)

Note
34x 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

Note
Recommend assistance
Seat all bolts securing HV battery to vehicle with battery powered drill - (Except for shear plates)

Note
34x 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

Note
7x bolts, 15mm, 56 Nm, Bolt position 1-7
Fully torque RH bolts securing HV battery to vehicle

Note
7x bolts, 15mm, 56 Nm, Bolt position 16-22
Fully torque front bolts securing HV battery through bash plate openings

Note
6x bolts, 16mm, 90 Nm, Bolt location 23 to 28
Fully torque front bolts securing bash plate to vehicle

Note
6x bolts, 13mm, 62 Nm, Bolt location 29-34
Fully torque rear bolts securing HV battery to vehicle

Note
4x bolts, 13mm, 62 Nm, Bolt position 10-13

Note
Some 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

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, Bolt position 8-9, Torque at later step

Note
Some 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

Note
1x bolt, 21mm, 130 Nm
Torque small fasteners securing RH rear shear plate to body

Note
2x bolts, 13mm, 62 Nm, Bolt position 8-9

Note
Some 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

Note
1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
Install bolts securing LH rear shear plate to body hand tight

Note
2x bolts, 13mm, 62 Nm, Bolt position 14-15, Torque at later step

Note
Some 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

Note
1x bolt, 21mm, 130 Nm
Torque small fasteners securing LH rear shear plate to body

Note
2x bolts, 13mm, 62 Nm, Bolt position 14-15

Note
Some 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

Note
Use caution while working around this area not to damage any components
Fully torque LH rear inner bolts securing HV battery to vehicle

Note
2x bolts, 13mm, 49 Nm, Located below rear main carpet, Bolt position 35-36
Close LH rear door

Note
Do not latch
Open RH rear door

Note
Use caution while working around this area not to damage any components
Fully torque RH rear inner bolts securing HV battery to vehicle

Note
2x 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

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

Note
Rotate up over RDU and rearward around subframe to oil cooler
Secure RDU oil cooler outlet pipe

Note
2x spring clips, 5x clips, Remove plugs as needed
Position RDU HV cable up to RDU

Note
Rotate cable underneath logic cable harness between subframe and HV battery
Connect RDU HV cable onto RDU

Note
1x 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

Note
1x bolt, 10mm, 6 Nm
Install RDU inverter inlet hose

Note
1x 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

Note
1x clip
Secure RDU HV harness onto HV battery

Note
1x 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

Note
4x clips
Secure HV compressor connection to HV battery

Note
1x 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

Note
11x 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

Note
1x spring clip, Remove plugs as needed
Secure PT coolant hose onto LH side of front HV battery bash plate

Note
1x clip
Position FDU HV harness connector up to FDU

Note
1x connector
Install FDU HV harness connector onto FDU

Note
1x 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

Note
1x 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

Note
1x bolt, 10mm, 6 Nm
Position coolant drain container underneath RH front of HV battery
Connect PT return hose at RH front side of vehicle

Note
1x spring clip, Remove plugs as needed
Install clip securing PT return hose to RH front side of HV battery pack

Note
1x clip
Connect HV battery RH front inlet hose

Note
1x spring clip, Remove plugs as needed
Install clip securing HV battery RH front inlet hose to skid plate

Note
1x clip
Position coolant drain container underneath center front of HV battery pack

Note
Underneath front left manifold battery supply tube
Connect front left manifold battery supply tube

Note
1x 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

Note
3x clips, 1x bolt, 10mm, 5 Nm
Install RH front wheel liner to HV battery and lower wheel well area

Note
3x clips, 1x bolt, 10mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
Lower vehicle fully and move rack arms away from vehicle

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Push vehicle away from lift

Note
Recommend 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

Note
Latch rear doors to prevent accidental closure
Connect power connector to HV battery

Note
1x connector, Push red locking tab down to secure connection
Connect HVC logic connector

Note
1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
Clean busbar HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
Clean HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
Apply Penetrox onto HV connector joints

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
Position busbar kit connector and lower onto HV header
Install bolts securing charge port busbar kit to HV Header

Note
2x bolts, 10mm, 9 Nm
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

Note
2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), 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

Note
1x bolt, 10mm, 9 Nm
Engage LH body harness onto rear body

Note
1x clip
If there is a 3-phase (AC) connection between the charge port and HV battery, connect it:
1. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
2. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
  
  CAUTION
  Make sure that the connector fits the header squarely and tightly.
3. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
  
  CAUTION
  Make sure that the handle does not bind as it is lowered.
4. Slide the release to lock the 3-phase connector handle in the secured position.
5. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
  
  Note
  An improperly seated connector might lead to connector damage and charging problems later on.
Connect logic connector at LH seat frame

Note
1x connector
Install clip securing logic connector harness to LH seat frame

Note
1x clip
Install LH and RH floor ducts

Note
2x clips
Install LH and RH lower IP carrier brackets

Note
4x bolts, 10mm, 25 Nm
Install clip securing center console harness to body

Note
1x clip
Install LH front cabin carpet into vehicle

Note
Secure all edges, Tuck short edge underneath center console
Install clips securing LH front cabin carpet underneath front seat

Note
4x clips
Install clips securing LH cabin carpet to cabin support

Note
2x push clips, 1x vertical clip, Secure vertical clip into place first, Verify fitment of carpet
Install RH front cabin carpet into vehicle

Note
Secure all edges, Tuck short edge underneath center console
Install clips securing RH front cabin carpet underneath front seat

Note
4x clips
Install clips securing RH cabin carpet to cabin support

Note
2x push clips, Secure clips and verify fitment of carpet
Install rear main cabin carpet to vehicle

Note
Position 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

Note
3x 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 87 and 88 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

Note
Recommend 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

Note
4x clips
Install LH front seat harness onto LH footwell support bracket

Note
2x retaining clips
Connect LH front seat harness to VC left

Note
1x 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

Note
3x tabs, 1x Ethernet connector, 1x puddle light connector
Install screw and clips securing LH footwell cover

Note
1x screw, T20, 2.5 Nm, 2x push clips
Install RH front seat into vehicle

Note
Recommend 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

Note
4x clips
Install RH front seat harness onto RH footwell support bracket

Note
2x retaining clips
Connect RH front seat harness to VC right

Note
1x 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

Note
1x 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

Note
Remove wheel chocks if necessary
Connect to vehicle using Toolbox 3.0

Note
Vehicle 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-PURGE
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
’, click ‘Run’, and allow routine to complete
Note
Make 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

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Install HEPA filter assembly

Note
2x 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

Note
1x O-ring, Ensure washer hose is properly routed after installation
Secure frunk to washer fluid reservoir neck

Note
1x 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

Note
2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
Move LH front seat forward
Install LH front seat belt retractor to seat

Note
Insert retractor into seat pre tensioner, Make sure it locks into position with push-pull-push test
Install LH front seat rear fasteners

Note
2x 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

Note
2x patch bolts, T45P, 33.5 Nm, Install new patch bolts
Move RH front seat forward
Install RH front seat belt retractor to seat

Note
Insert retractor into seat pre tensioner, Make sure it locks into position with push-pull-push test
Install RH front seat rear fasteners

Note
2x 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

Note
If 12V/LV is powered up, Unlatch rear doors before closing
Remove lift pad adapters from RH rocker

Note
2x lift pad adapters
Install butyl patches onto RH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch 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

Note
2x lift pad adapters
Install butyl patches onto LH rocker access holes

Note
2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).