Correction code 16301102 2.04 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. Place vehicle in service mode with touchscreen
   Note

   Hold Tesla T icon at top of center display for four seconds and then type "service" into dialog box
4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
5. Remove bolt securing frunk to washer fluid reservoir neck
   Note

   1x bolt, 10mm, 5 Nm

   

6. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
7. Move LH front seat forward
8. Move RH front seat forward
9. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
10. Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
11. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
12. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
13. Power off vehicle from center display
    Note

    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
14. 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

    

    

    

15. 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

    

    

16. Raise and support vehicle
    Note

    Ensure vehicle is not charging before lifting it off the ground
17. 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
18. Remove push clips at left and right wheel house liner to mid aero shield
    Note

    2x clips

    

    

19. 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

    

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

    

    

21. 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

    

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

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

    

23. 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.

    

    

24. 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

    

25. 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

    

    

    

    

26. 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

    

    

27. Remove bolts securing HV header connector to HV battery
    Note

    2x bolts, 8mm, 6 Nm

    

28. 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
29. Disconnect HVC logic connector and install logic cap
    Note

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

    

30. Disconnect power connector to HV battery
    Note

    1x connector, Pull locking tab upward then release connection

    

31. Remove bolt securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

32. Remove bolts securing charge port busbar kit to HV header
    Note

    2x bolts, 10mm, 9 Nm

    

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

    1x clip

    

    

34. 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

    

    

    

35. Remove NVH insulation from ancillary bay cover
    Note

    Move insulation aside

    

    

36. Remove fasteners securing ancillary bay cover to high voltage controller
    Note

    3x bolts, E10, 10 Nm

    

37. Release fasteners securing PCS LVDC header to ancillary bay cover
    Note

    3x bolts, T20, 2.5 Nm

    

38. 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

    

    

    

39. Release perimeter bolts securing ancillary bay to HV battery
    Note

    22x captured bolts, EPL 10, 5 Nm

    

40. Remove ancillary bay cover from HV battery
    Note

    Recommend assistance, Lift up on the RH side and pivot the cover, Maneuver away from body casting and charge port components

    

    

41. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
42. Remove 63A fuse cover
    Note

    2x securing tabs

    

43. Remove 63A fuse from ancillary bay
    Note

    2x nuts, 8mm, 2.5 Nm, Discard after removal

    

44. Remove 63A fuse from ancillary bay
    Note

    2x nuts, 8mm, 2.5 Nm, Discard after removal

    

45. Remove HV battery heat pump HV harness from tray stud

    

46. Remove HV battery heat pump HV harness from plastic bobbin stud
    Note

    1x nut, 7mm, 1.5 Nm, 1x washer

    

47. Disconnect HVIL connector from HV heatpump harness
    Note

    1x connector

    

48. Release HVIL assembly connector from tray
    Note

    1x tab, Slide connector upward to release from tray

    

    

49. Remove heat pump internal HV harness from ancillary bay
    Note

    4x securing tabs, Gently release tabs and raise upward to remove

    

    

50. Secure heat pump internal HV harness
    Note

    4x securing tabs, Push down to engage locking tabs

    

    

51. Secure HVIL connector onto tray
    Note

    1x tab, Slide connector downward

    

    

52. Connect HVIL connector onto tray
    Note

    1x connector

    

53. Install HV battery heat pump HV harness onto plastic bobbin stud
    Note

    1x nut, 7mm, 1.5 Nm, 1x washer

    

54. Position HV battery heat pump HV harness onto tray stud

    

55. Install 63A fuse into ancillary bay
    Note

    2x nuts, 8mm, 2.5 Nm, Install new nuts

    

    

56. Install 63A fuse into ancillary bay
    Note

    2x nuts, 8mm, 2.5 Nm, Install new nuts

    

    

57. Install 63A fuse cover
    Note

    2x securing tabs

    

58. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
59. Inspect ancillary bay phantom seal to verify no damage is present
    Note

    If damage is present, Replace ancillary bay phantom seal

    

    

    

60. Install ancillary bay cover onto HV battery
    Note

    Recommend assistance, Guide LH side in, Maneuver cover past body casting and into position with charge port components

    

    

61. Install perimeter bolts securing ancillary bay to HV battery
    Note

    22x captured bolts, EPL 10, 5 Nm, Thread bolts in evenly and torque

    

62. 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

    

    

    

63. Install fasteners securing PCS LVDC header to ancillary bay cover
    Note

    3x bolts, T20, 2.5 Nm

    

64. Install fasteners securing ancillary bay cover to high voltage controller
    Note

    3x bolts, E10, 10 Nm

    

65. Install NVH insulation onto ancillary bay cover

    

    

66. Connect power connector to HV battery
    Note

    1x connector, Push red locking tab down to secure connection

    

67. Connect HVC logic connector
    Note

    1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed

    

68. 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

    

69. 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

    

70. 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

    

    

71. Position busbar kit connector and lower onto HV header

    

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

    2x bolts, 10mm, 9 Nm

    

73. 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

    

74. Install fastener securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

75. Remove HV insulating gloves
76. Engage LH body harness onto rear body
    Note

    1x clip

    

    

77. 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
78. Install bolts securing HV header connector to HV battery
    Note

    2x bolts, 8mm, 6 Nm

    

79. 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

    

    

80. 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

    

81. 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

    

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

    2x clips

    

    

83. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
84. 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

    

    

    

85. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
86. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
87. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
88. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
89. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
90. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
91. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
92. Move LH front seat to original position
93. Move RH front seat to original position
94. Exit Service Mode through UI
    Note

    Controls > Service Mode > Exit Service Mode
95. Remove vehicle from lift
    Note

    Lower rack arms fully and remove from under vehicle
96. Raise all four windows
97. Close all four doors
    Note

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