2025-09-05

Ancillary Bay Air Leak Test (Structural Pack)

Correction code 16100420 0.55 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2025-09-05: Cleaned up procedure and removed redundant illustration.

Procedure

  1. Open all doors and lower the windows.
  2. Open the hood.
  3. Remove the rear apron.
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips
  4. Remove the bolt that attaches the underhood storage unit to the washer fluid reservoir neck.
  5. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace)
  6. Move LH front seat forward
  7. Move RH front seat forward
  8. Disconnect LV power. See 12V/LV Power (Disconnect and Connect)
  9. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Structural Pack)
  10. Remove the push clips at the left and right wheel house liner to mid aero shield.
  11. Lower the vehicle until the tires are touching the floor.
  12. If present, cut away the insulation that covers the pyro cover.
  13. Remove and discard the breather from the pyro cover.
  14. Install the air splitter hose onto the pyro cover.
  15. Connect the regulator to air supply.
  16. Turn the right side regulator valve to the open position.
  17. Set the regulator to 0.3 psi.
  18. Open the left side regulator valve to inject air into the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 30 seconds fill time. Close the right side regulator valve when the pressure reaches 0.3 psi.
  19. Wait 15 seconds for the pressure to settle.
  20. Record the value of the starting pressure.
  21. Wait 30 seconds to test pressure.
  22. Record the value of the end pressure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Subtract ending pressure from starting pressure. If the difference is greater than 0.0484 psi, then inspect the tools and retest. If the difference is still greater than 0.0484 psi, then proceed to the Combined Platter and Ancillary Bay leak down test. If difference is 0.0484 psi or less, then proceed with the current procedure.
  23. Disconnect air supply from regulator tool
  24. Install a new breather onto the pyro cover.
  25. Raise the vehicle.
  26. Connect the RDU HV harness to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and make sure that the red tab is locked.
  27. Install the mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm. Model Y Structural Pack will have one less bolt and one extra clip.
  28. Install the push clips (x2) at the left and right wheel house liner to the mid aero shield.
  29. Connect LV power. See 12V/LV Power (Disconnect and Connect)
  30. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace)
  31. Attach the washer tank neck onto the washer tank.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x O-ring. Make sure that the washer hose is properly routed.
  32. Install the bolt that attaches the underhood storage unit to the washer fluid reservoir neck.
    5 Nm (3.7 lbs-ft)
  33. Install the rear apron.
  34. Close the hood.
  35. Install the 2nd row seat cushion.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector. Slide the rear cushion rearward, then align foam with the seat rail. Make sure that the cushion is fully seated with push & pull test.
  36. Move LH and RH front seats to their original position.