Correction code 16301622 1.32 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 LH front window
3. Move LH front seat forward
4. Move RH front seat forward
5. Remove 2nd row seat cushion
   Note

   1x connector, Lift front edge of seat cushion upward to release foam from frame

   

   

   

6. Partially remove LH rear door seal

   

7. Remove LH rear sill trim
   Note

   5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim

   

   

8. Partially remove RH rear door seal
   Note

   Pillar and sill trim have tabs seated underneath seal

   

9. Remove RH rear sill trim
   Note

   5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of RH rear sill trim working your way back towards rear of sill trim

   

   

10. Remove clips securing rear main cabin carpet to vehicle
    Note

    3x push clips

    

11. Remove fasteners securing 40 seat frame to body
    Note

    4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet

    

    

12. Fold the 40 seat in down position
    Note

    Protect the seat cushion, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame

    

13. Disconnect 40 frame connector
    Note

    1x connector

    

14. Remove 2R 40 seat assembly from vehicle
    Note

    Recommend assistance
15. Remove fasteners securing 60 seat frame to body
    Note

    5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet

    

    

    

16. Fold the 60 seat in down position
    Note

    Protect the seat back upholstery if necessary, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame

    

17. Disconnect logic connector at LH seat frame
    Note

    1x connector

    

18. Remove 2nd row 60 seat assembly from vehicle
    Note

    Recommend assistance
19. Open hood
20. Remove rear apron
    Note

    14x clips

    

    

21. Power off vehicle from center display
    Note

    Via Controls > Safety & Security > Vehicle Power > Power Off
22. Disconnect 12V negative terminal and first responders loop
    Note

    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge

    

    

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

    

    

24. 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

    

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

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

    

26. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

    

27. Remove the ancillary bay probe lid cover from the ancillary bay cover

    

28. Verify no high voltage
    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

    

    

    

    

29. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Note

    Confirm no visual damage present, Replace gasket if damage is found

    

    

30. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts

    

31. Remove HV insulating gloves
32. Disconnect the HVC logic connector and install logic cap
    Note

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

    

    

33. Remove fasteners securing ancillary bay cover to high voltage controller (HVC)
    Note

    4x bolts, E10, 5 Nm + 30 degrees, Discard after removal, Newer vehicles may be equipped with 3x bolts

    

34. Remove HVC logic cap
    Note

    1x cap

    

35. Remove bolts securing ancillary bay cover to HV battery
    Note

    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

    

    

36. 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

    

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

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

    

38. Remove ancillary bay cover from HV battery
    Note

    Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step

    

39. Install the battery pyro and shunt insulators
    Note

    2x insulators

    

40. Install the HV joint insulator onto positive pack contactor
    Note

    1x insulator

    

41. Install the HV joint insulator to negative pack contactor
    Note

    1x insulator

    

42. Install the insulator for DC input assembly to both fastcharge busbars inlet side
    Note

    2x insulators

    

43. Install the negative AC inlet terminal cover
    Note

    1x cover, 3x clips, Use caution as the clips are very easy to damage

    

44. Install the positive AC inlet terminal cover
    Note

    1x cover, 3x clips, Use caution as the clips are very easy to damage

    

45. Install fuses access insulator
    Note

    3x clips

    

46. Install HVC logic cap
    Note

    1x cap

    

47. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
48. Disconnect HV controller connectors
    Note

    7x connectors

    

    

49. Remove the megaharness clips from HV controller hinge tray
    Note

    5x harness clips

    

50. Remove bolts securing hinge tray onto HV controller
    Note

    2x bolts, E6, 2 Nm

    

    

51. Remove the HV hinge tray from ancillary bay assembly
    Note

    2x pivot clips, Pull upward and release from pivot clips

    

    

52. Install the HV hinge tray to ancillary bay assembly
    Note

    2x pivot clips, Position hinge tray onto pivot clips and push down to secure into clips

    

    

53. Install bolts securing hinge tray onto HV controller
    Note

    2x bolts, E6, 2 Nm

    

54. Connect HV controller connectors
    Note

    7x connectors

    

    

55. Install the megharness clips to HV controller hinge tray
    Note

    5x clips

    

56. Remove fuse access insulator
    Note

    3x clips, Lift straight up off of the fuses

    

57. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
58. Remove the insulator for DC input assembly to both fastcharge busbar inlet side
    Note

    2x insulators

    

59. Remove the HV joint insulator from positive pack contactor
    Note

    1x insulator

    

60. Remove the HV joint insulator from negative pack contactor
    Note

    1x insulator

    

61. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
    Note

    4x studs

    

62. Inspect ancillary bay walls for damage
    Note

    Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused

    

63. Inspect ancillary bay cover seal to confirm it has no visual damage
    Note

    Image up close for clarity, Delaminated and torn seals cannot be reused

    

    

    

    

64. Remove HVC logic cap
    Note

    1x cap

    

65. Position the ancillary bay cover to HV battery for installation
    Note

    Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.

    

66. Install HVC logic cap
    Note

    1x cap

    

67. Install bolts securing ancillary bay cover to HV battery
    Note

    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

    

    

68. Install fasteners securing ancillary bay cover to high voltage controller (HVC)
    Note

    4x bolts, E10, 5 Nm + 30 degrees, Install new bolts, Newer vehicles may be equipped with 3x bolts

    

69. Remove HV insulating gloves
70. Remove logic cap and connect the HVC logic connector
    Note

    1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

    

    

71. Install 2R 40 seat assembly into vehicle
    Note

    Recommend assistance
72. Connect 40 seat frame connector to body harness
    Note

    1x connector

    

73. Fold the 40 seat into vertical position
    Note

    Remove seat cushion protection

    

74. Secure 40 seat frame to vehicle
    Note

    4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front

    

    

75. Install RH rear sill trim
    Note

    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips

    

76. Reseat RH rear door seal
    Note

    Seat pillar and sill trim tabs underneath seal

    

77. Install 2nd row 60 seat assembly
    Note

    Recommend assistance
78. Connect logic connector at LH seat frame
    Note

    1x connector

    

79. Fold the 60 seat into vertical position
    Note

    Remove seat back protection if necessary

    

80. Install fasteners securing 60 seat frame to body
    Note

    5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front

    

    

    

81. Install LH rear sill trim
    Note

    5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of LH rear sill trim into trunk side trim and work your way forward securing clips

    

    

82. Reseat LH rear door seal
    Note

    Seat pillar and sill trim tabs underneath seal

    

83. Install clips securing rear main cabin carpet to vehicle
    Note

    3x push clips

    

84. Install 2nd row seat cushion
    Note

    1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test

    

    

    

85. Connect first responder loop and 12V negative terminal
    Note

    1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer

    

    

86. Install rear apron
    Note

    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips

    

    

87. Close hood
88. Move LH front seat to original position
89. Move RH front seat to original position
90. Raise all four windows
91. Close all four doors
    Note

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