Correction code 16301702 0.90 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.

1. Open all four doors
2. Lower all four windows
3. Move LH front seat forward
4. Move RH front seat forward
5. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
7. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
8. Power off vehicle from center display
   Note

   Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
9. Disconnect LV battery connector and First Responder Loop
   Note

   2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

   

   

   

10. Verify operation of multimeter
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals

    

    

11. Raise and support vehicle
    Note

    Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
12. 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
13. Remove push clips at left and right wheel house liner to mid aero shield
    Note

    2x clips

    

    

14. 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

    

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

    

    

16. 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

    

17. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

18. 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.

    

    

19. 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

    

20. 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

    

    

    

    

21. 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
22. Remove clip securing logic connector harness to LH seat frame
    Note

    1x clip, Pinch tabs on clip to avoid damage

    

23. Remove bolt securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

24. Disengage LH body harness from rear body and move aside
    Note

    1x clip

    

    

25. 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

    

    

    

26. Release fasteners securing charge port header to ancillary bay cover and remove doubler
    Note

    2x bolts, 10 EPL, 10 Nm, Release charge port header from ancillary bay and remove plastic doubler, Take note of small tabs on shielding

    

    

    

27. Secure doubler and install fasteners securing charge port header to ancillary bay cover
    Note

    2x bolts, 10 EPL, 10 Nm, Secure doubler onto header and install bolts, Take note of small tabs on shielding

    

    

    

28. 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

    

29. 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

    

30. 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

    

    

31. Position busbar kit connector and lower onto HV header

    

32. Install bolts securing charge port busbar kit to HV Header
    Note

    2x bolts, 10mm, 9 Nm

    

33. 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

    

34. Install fastener securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

35. Engage LH body harness onto rear body
    Note

    1x clip

    

    

36. Install clip securing logic connector harness to LH seat frame
    Note

    1x clip

    

37. 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
38. 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

    

39. Remove HV insulating gloves
40. 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

    

41. Install push clips at left and right wheel house liner to mid aero shield
    Note

    2x clips

    

    

42. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
43. Remove breather from pyro cover
    Note

    1x breather, Discard after removal

    

44. Install the enclosure leak test adapter to ancillary bay probe lid cover and connect it to regulator test tool

    

45. Connect regulator to air supply

    

46. Turn right side regulator valve to the open position
    Note

    By turning the valve knob to a horizontal position, The valve is fully open

    

47. Set regulator to 0.150 psi

    

48. Placeholder - Open the left side regulator valve to inject air into the ancillary bay
    Note

    Close right side regulator valve when the pressure reaches 0.150 psi and stabilizes - MYSP needs validation- currently leaks due to design

    

    

    

49. Wait 45 seconds for pressure to settle
50. Record value of starting pressure
51. Wait 60 seconds to test pressure
52. Record value of end pressure
    Note

    If pressure did not drop more than 0.0231 psi, continue to next step. If pressure dropped more than 0.0231 psi, then inspect for leaks.
53. Disconnect air supply from regulator tool

    

54. Install breather onto pyro cover
    Note

    1x breather, Install new breather

    

55. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
56. Connect first responder loop and LV battery
    Note

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

    

    

    

57. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
58. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
59. Close hood
60. Remove vehicle from lift
    Note

    Lower rack arms fully and remove from under vehicle
61. Move RH front seat to original position
62. Move LH front seat to original position
63. Raise all four windows
64. Close all four doors
    Note

    If 12V is powered up, Unlatch rear doors before closing