2025-10-10

HV Battery (AWD) (7-Seat) (Remove and Install)

Correction code 16010231 3.96 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. See Ergonomic Precautions for safe and healthy working practices.

2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
2025-10-06: Removed redundant step to install LH footwell cover.
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.
2023-08-29: Updated EPB Service Mode reference.

Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

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.

Remove

Relmove the LH and RH 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.
Open all doors and lower the windows.
Chock LH rear wheel.
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release)
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Start Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Note
This will ensure the octovalve is in the Series position, Coolant pumps will also be disabled. Once run is selected, the routine is in progress despite the prompt with loading circle. The routine will time out after several hours and will return valves to the parallel position if unattended. Select 'X' at top right of window to close once routine is complete.
Remove the rear underhood apron.
Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
Move the LH front seat backward.

Note
Ensure profile is saved to allow seat position to be restored
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 console side panel carpet

Note
11x clips, 2x guide pins, Use trim tool starting at top edge to release upper clips, then pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
Remove clip securing LH front cabin carpet to body

Note
1x clip
Fold LH front cabin carpet rearward

Note
Maneuver carpet below brake pedal and accelerator pedal, Newer Vins may be equipped with additional foam installed below carpet
Remove foam plugs to access LH front inner HV battery bolts

Note
2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
Remove both LH front inner HV battery bolts

Note
2x bolts, EP20, 136 Nm
Raise LH front seat cushion to maximum height

Note
This will allow access to HV battery bolts at LH front foot well and below LH front seat
Remove RH IP end cap

Note
3x clips
Remove RH mid A-pillar assembly

Note
1x clip, 1x tab, Release the upper clip then pull mid A-pillar upward to remove
Remove clip securing RH lower A-pillar trim

Note
1x push clip
Remove RH lower A-pillar trim

Note
6x clips, 2 guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release trim panel
Move the RH front seat back.
Remove clips securing RH footwell assembly

Note
4x push clips, Clip count may vary depending on region
Remove RH footwell assembly

Note
2x connectors
Remove RH front floormat
Remove RH console side panel carpet

Note
12x clips, 2x locating pins, Use trim tool starting at top edge to release upper clips, Pull bottom to release remaining clips, Use caution and pull panel straight away from console, if panel is peeled off it could be damaged
Remove clip securing RH front cabin carpet to body

Note
1x clip
Fold RH front cabin carpet rearward

Note
Newer Vins may be equipped with additional foam installed below carpet
Remove foam plugs to access RH front inner HV battery bolts

Note
2x plugs, Push pick through foam and turn roughly 45 degrees to grab onto foam insert and pull straight out, Newer vins may be equipped with 1x foam plug
Remove both RH front inner HV battery bolts

Note
2x bolts, EP20, 136 Nm
Raise RH front seat cushion to maximum height

Note
This will allow access to HV battery bolts at RH front foot well and below RH front seat
Remove 2nd row floor mat from vehicle
Separate carpet perforation below RH front seat to access RH middle inner HV battery bolt

Note
Located below rear of RH front seat
Remove RH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Separate carpet perforation below LH front seat to access LH middle inner HV battery bolt

Note
Located below rear of LH front seat
Remove LH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Partially remove LH rear door seal
Remove LH 7s lower C-pillar trim

Note
8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips
Fold down 2nd row 60 seatback assembly

Note
Press button, fold forwards
Move 60 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove 60 seat rear outboard track fastener

Note
1x patch bolt, 11mm, 37 Nm, Discard after removal
Remove 60 seat rear inboard track fasteners

Note
2x patch bolts, 11mm, 37 Nm, Discard after removal
Move 60 seat fully rearward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove 60 seat outboard track cover

Note
1x clip, Slide covers forward to release from 60 seat tracks
Remove center track cover from 2nd row seats

Note
2x clips, Slide covers forward to release from 2nd row seat tracks
Release cabin carpet from 60 seat

Note
Pull cabin carpet towards front of vehicle
Remove 60 seat front inboard track fasteners

Note
1x bolts, 11mm, 37 Nm, Discard after removal
Remove 2nd row 60 seat frame front outboard track fasteners

Note
1x bolts, 11mm, 37 Nm, Discard after removal
Disconnect 2nd row 60 seat connector

Note
1x connector
Remove 2nd row 60 seat assembly from vehicle

Note
Recommend assistance
Partially remove RH rear door seal

Note
Pillar and sill trim have tabs seated underneath seal
Remove RH 7s lower C-pillar trim

Note
8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips
Remove 40 seat outboard track cover

Note
1x clip, Slide cover forward to release from 40 seat track
Release cabin carpet from 40 seat

Note
Pull cabin carpet towards front of vehicle
Remove bolts securing 40 seat podium to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
Fold 2nd row 40 seat down
Move 40 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Remove bolts securing 40 seat inner and outer tracks to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
Move 40 seat fully rearward using towel bar

Note
With one hand on towel bar pull up and slide the seat rearward with your other hand
Disconnect 2nd row 40 seat connector

Note
1x connector
Remove 40 seat from vehicle

Note
Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
Position object beneath rear cabin carpet to raise and allow access to rear inner HV battery bolts

Note
Use shop towel or similar
Remove RH rear inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below RH rear main carpet
Remove LH rear inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
Power off the vehicle using the touchscreen.
Disconnect the 12V negative battery cable and First Responder Loop.
Make a slit in 3rd row carpet around LH seat belt

Note
Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
Make a slit in 3rd row carpet around RH seat belt

Note
Cut a thin straight line on 3rd row carpet from seat belt opening to edge of carpet
Move 3rd row carpet aside
Move 3rd row NVH insulation aside

Note
Use seatbelt or bungee strap as needed
Empty all pockets and remove all metal objects such as watches and jewelery.
Inspect the HV insulating gloves for any damage.
Put on the HV insulating gloves and leather over gloves.
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
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
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
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
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
Lift busbar kit connector to remove from HV header
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 the HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove DCDC ground strap from HV battery

Note
1x nut, 13mm, 15 Nm, Discard after removal
Release positive 12V output cover from PCS cable

Note
1x cover
Remove PCS cable from 12V passthrough output

Note
1x nut, 13mm, 15 Nm, Discard nut after removal
Close all four doors

Note
Latch rear doors to prevent accidental closure
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
Fully raise the vehicle, and then lower the lift onto the locks.
Remove the outer fasteners from the front aero shield.
Remove the remaining nuts (x2), and then remove the front aero shield from the vehicle.
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 bolts securing front skid plate

Note
4x bolts, EP10, 13 Nm
Remove skid plate from HV battery
Disconnect both AC compressor and PTC heater HV harness connectors on HV battery

Note
2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
Secure LH front wheel liner away from HV battery
Secure RH front wheel liner away from HV battery
Position coolant drain container underneath RH front of HV battery
Disconnect PT return hose at RH side of vehicle and plug female side of hose

Note
1x spring clip, 1x hose clip, 1x plug
Disconnect rear PT supply hose at RH side of vehicle and plug male side of hose

Note
1x spring clip, 1x hose clip, 1x plug
Position coolant drain container underneath LH front of HV battery
Disconnect HV battery return hose at LH side of vehicle and plug male side of hose

Note
1x spring clip, 1x plug
Position coolant drain container below HV battery manifold hose
Remove HV battery front manifold hose clips from body

Note
2x clips, Newer vehicles may be equipped with 1x clip
Disconnect HV battery front manifold hose and plug both hose ends

Note
1x spring clip, 2x plugs
Remove coolant drain container from underneath vehicle
Remove mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
Position support stand to support front portion of rear subframe
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Remove smaller fasteners for LH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard at later step
Hand tighten bolt securing LH side of subframe to body

Note
1x bolt, 21mm, 130 Nm
Release clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Remove smaller fasteners for RH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard at later step
Hand tighten bolt securing RH side of subframe to body

Note
1x bolt, 21mm, 130 Nm
Remove support stand from under vehicle
Release LH side hose clip from rear battery skid plate

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate

Note
2x fir tree clips
Remove lower bolts securing rear battery enclosure skid plate

Note
2x bolts, EP10, 13 Nm
Remove upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Remove upper bolts securing rear battery enclosure skid plate from HV battery

Note
4x bolts, 13mm, 35 Nm
Remove rear battery enclosure skid plate from HV battery pack
Position coolant drain container underneath LH rear of HV battery
Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends

Note
1x spring clip, 2x plugs
Position coolant drain underneath RH rear of HV battery
Remove nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Disconnect RDU HV cable 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
Place battery table into position and lower vehicle to support battery

Note
Recommend assistance, Line up table so center 4 bolts are accessible through opening in table, Adjust final battery table position using adjustable caster jacks on table
Remove central bolts securing HV battery through center ski cover

Note
4x bolts, EP14, 34 Nm
Remove bolts securing LH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Remove bolts securing RH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Remove LH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Remove RH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Raise vehicle to free from HV battery

Note
Recommend assistance
Remove battery from under vehicle

Note
Recommend assistance
Remove ancillary bay perimeter seal from HV battery pack

Note
Discard after removal

Install

Install ancillary bay perimeter seal to HV battery pack

Note
Install new perimeter seal every time the HV battery is removed and reinstalled
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
Install HV battery alignment rods

Note
2x rods, Located on body at front of vehicle, 2x rods, Located at rear of HV battery near ancillary bay
Lower vehicle onto HV battery and align holes

Note
Recommend assistance, Use alignment rods, Be sure coolant hoses do not get caught on alignment rods, Caution not to damage HV cable, Do not fully lower vehicle onto battery (this will help with installing battery bolts)
Install bolts securing HV battery to body at LH shear plate area hand tight

Note
2x bolts, 13mm, 35 Nm, Torque at later step
Install bolts securing HV battery to body at RH shear plate area hand tight

Note
2x bolts, 13mm, 35 Nm, Torque at later step
Loosely install RH bolts securing HV battery to vehicle hand tight

Note
8x bolts, 13mm, 35 Nm
Loosely install LH bolts securing HV battery to vehicle hand tight

Note
8x bolts, 13mm, 35 Nm
Remove HV battery front alignment rods

Note
2x rods
Install bolts securing RH front support bracket to vehicle hand tight

Note
4x bolts, 16mm, 110 Nm, Torque at later step
Install bolts securing LH front support bracket to vehicle hand tight

Note
4x bolts, 16mm, 110 Nm, Torque at later step
Install central bolts securing HV battery through center ski cover hand tight

Note
4x bolts, EP14, 34 Nm, Torque at later step
Open LH rear door

Note
Use caution while working around this area not to damage any components
Remove HV battery alignment rod from LH rear inner bolt location

Note
1x rod
Install LH rear inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
Install LH middle inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Close LH rear door

Note
Do not latch
Open LH front door

Note
Use caution while working around this area not to damage any components
Install both LH front inner HV battery bolts hand tight

Note
2x bolts, EP20, 136 Nm, Torque at later step
Close LH front door

Note
Do not latch
Open RH rear door

Note
Use caution while working around this area not to damage any components
Remove HV battery alignment rod from RH rear inner bolt location

Note
1x rod
Install RH rear inner battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Lift up LH rear main carpet for access, Torque at later step
Install RH inner HV battery bolt hand tight

Note
1x bolt, 16mm, 66 Nm, Torque at later step
Close RH rear door
Open RH front door

Note
Use caution while working around this area not to damage any components
Install both RH front inner HV battery bolts hand tight

Note
2x bolts, EP20, 136 Nm, Torque at later step
Close RH front door

Note
Do not latch
Lower vehicle onto pack completely

Note
Recommend assistance
Torque RH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque LH bolts securing HV battery to vehicle

Note
8x bolts, 13mm, 35 Nm
Torque bolts securing RH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque bolts securing LH front support bracket to vehicle

Note
4x bolts, 16mm, 110 Nm
Torque central bolts securing HV battery through center ski cover

Note
4x bolts, EP14, 34 Nm
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
Position support stand to support front section of rear subframe
Install bolt and shear plate to LH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Torque at later step
Install bolts securing LH rear shear plate to body hand tight

Note
2x bolts, 13mm, 35 Nm, Torque at later step
Torque bolt securing subframe and LH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm, Mark bolt after torque
Torque small fasteners securing LR rear shear plate to body

Note
2x bolts, 13mm, 35 Nm
Install bolt and shear plate to RH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Torque at later step
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm, Torque at later step
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, 35 Nm
Remove support stand from under vehicle
Install clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Connect RDU HV cable to HV battery

Note
1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
Install nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm
Position coolant drain underneath RH rear of HV battery
Remove hose plugs and connect coolant outlet hose to rear PT return hose

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated, Use shop towel to clean any coolant residue if necessary.Loss of coolant greater than 1L requires coolant vacuum fill
Position coolant drain container underneath LH rear of HV battery
Remove plugs and connect RDU inverter inlet hose to rear of HV battery

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated,Loss of coolant greater than 1L requires coolant vacuum fill
Remove coolant drain container from underneath vehicle
Position rear battery enclosure skid plate to HV battery for installation
Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing rear battery enclosure skid plate hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Torque at later step, Earlier vins may be equipped with additional bolts
Torque bolts securing HV battery and rear skid plate to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Torque at later step, Earlier vins may be equipped with additional bolts
Install RH side hose clips to rear battery skid plate

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
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 has one less bolt and one extra clip
Position coolant drain container underneath LH front of HV battery
Remove plugs then connect HV battery coolant return hose

Note
1x spring clip,1x plug
Position coolant drain container below HV battery manifold hose
Remove plugs then connect HV battery front manifold coolant hose

Note
1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
Install HV battery front manifold hose clips to body

Note
2x clips, Newer vehicles may be equipped with 1x clip
Position coolant drain container underneath RH front of HV battery
Remove plugs then connect PT supply hose

Note
1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
Remove plugs and connect PT return hose

Note
1x spring clip, 1x hose clip, 2x plugs, Perform push-pull-push test to make sure hose is fully seated.Loss of coolant greater than 1L requires coolant vacuum fill
Remove coolant drain container from underneath vehicle
Connect both AC compressor and PTC heater HV harness connectors on HV battery

Note
2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
Install FDU ground strap and bolt to HV battery

Note
1x bolt, 10mm, 10 Nm
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, EP10, 10 Nm
Install front skid plate onto HV battery

Note
2x tabs, Slide tabs onto front of HV battery
Install the bolts securing the front skid plate to the HV battery

Note
4x bolts, EP10, 13 Nm
Release LH front wheel liner from bungee strap

Note
Remove strap from vehicle
Install LH front wheel liner to HV battery and lower wheel well area

Note
3x clips, 1x bolt, 10mm, 5 Nm
Release RH front wheel liner from bungee strap

Note
Remove strap from vehicle
Install RH front wheel liner to HV battery and lower wheel well area

Note
3x clips, 1x bolt, 10mm, 5 Nm
Position the front aero shield on the vehicle, and then install the nuts that attach the aero shield to the vehicle.
Apply Loctite 222 on the front aero shield bolts, and then install the bolts on the aero shield.
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
Install positive 12V output

Note
1x nut, 13mm, 9 Nm, Install new nut, Make sure rubber boot is not pinched between cable terminal and pass through
Install positive 12V output cover to PCS cable

Note
1x cover
Install nut securing DCDC ground strap to HV battery

Note
1x nut, 13mm, 15 Nm, Install new nut
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
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
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
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
Remove HV insulating gloves
Install fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
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.
Move 3rd row NVH insulation back into position
Move 3rd row carpet back into position
Install 2nd row 60 seat assembly

Note
Recommend assistance
Connect 2nd row 60 seat connector

Note
1x connector
Install fasteners securing 60 seat frame to body

Note
5x patch bolts, 11mm, 37 Nm, Install new patch bolts, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
Install 40 seat into vehicle

Note
Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
Connect 2nd row 40 seat connector

Note
1x connector
Install bolts securing 40 seat podium to vehicle hand tight

Note
2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step
Move 40 seat forward using towel bar

Note
With one hand on towel bar pull up and slide the seat forward with your other hand
Install bolts securing 40 seat inner and outer tracks to vehicle

Note
2x patch bolts, 11mm, 37 Nm, Install new bolts
Move 40 seat to original position
Torque bolts securing 40 seat podium to vehicle

Note
2x patch bolts, 11mm, 37 Nm
Secure cabin carpet to 60 seat

Note
Strap velcro on
Install cabin carpet to 40 seat
Install 60 seat outboard track cover

Note
1x clip
Install center track cover to 2nd row seats

Note
2x clip, Slide cover straight on to clip to 2nd row seat tracks
Install 40 seat outboard track cover

Note
1x clip
Install RH 7s lower C-pillar trim

Note
8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips
Reseat RH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Install LH 7s lower C-pillar trim

Note
8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips
Reseat LH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Torque LH rear inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below LH rear main carpet
Torque RH rear inner battery bolt

Note
1x bolt, 16mm, 66 Nm, Located below RH rear main carpet for access
Torque LH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Fold LH side of rear main carpet to its original position
Torque RH middle inner HV battery bolt

Note
1x bolt, 16mm, 66 Nm
Fold RH side of rear main carpet to its original position
Install 2nd row floor mat into vehicle
Torque both RH forward HV battery bolts

Note
2x bolts, EP20, 136 Nm
Install RH front cabin carpet support access plugs

Note
2x plugs, Newer Vins may be equipped with 1x foam plug
Fold the RH front main cabin carpet back to original position
Install clip securing RH front cabin carpet to body

Note
1x clip
Install clip securing RH lower A-pillar trim

Note
1x clip
Install RH mid A-pillar assembly

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Make sure the seal seat on top of the trim
Install RH console side panel carpet

Note
12x clips, 2x locating pins, Position side panel and align the front locator, then the rear locator, Push side panel towards console to install
Install RH front floor mat
Position RH footwell assembly

Note
2x connectors
Install clips securing RH footwell assembly

Note
4x push clips, 2x connectors, Puddle lamp and speaker
Torque both LH front inner HV battery bolts

Note
2x bolts, EP20, 136 Nm
Install LH front cabin carpet support access plugs

Note
2x plugs, Newer vins may be equipped with 1x foam plug
Fold the LH front main cabin carpet back to original position
Install LH console side panel carpet

Note
11x clips, 2x locating pins, Position side panel and align the front into front locator, then the rear locator, Push side panel towards console to install
Install LH front floor mat

Note
2x velcro patches, Ensure mat does not interfere with pedal operation
Install screw and clips securing LH footwell cover

Note
1x screw, T20, 2.5 Nm, 2x push clips
Install LH lower A-pillar trim

Note
6x clips, 2 locating pins, Align front locating pin first
Install clip securing LH lower A-pillar trim

Note
1x push clip
Install LH mid A-pillar assembly

Note
1x clip, 1x tab, Align the bottom tab then push the top clip to fully seat mid A-pillar, Pull seal over trim
Remove coolant bottle cap
Place empty coolant container into front storage area
Fill container with at least 15L of coolant
Place filled coolant container into front storage area
Close air inlet and coolant refill valves
Install refill tool cap onto coolant bottle assembly
Setup vacuum refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Place end of overflow hose into empty container
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open refill valve to allow coolant to be drawn into system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once gauge reads zero, close refill valve
Slowly open the coolant refill valve to allow coolant to be drawn into the system

Note
Make sure end of coolant refill hose is fully submerged during entire process
Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
Disconnect shop air supply from coolant refill tool
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect the First Responder Loop and 12V negative battery cable.
Press and hold park button to release EPB service mode

Note
Remove wheel chocks if necessary
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
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
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
Inspect coolant level and top off as necessary

Note
Ensure coolant is filled using G-48 coolant
Install coolant bottle cap
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE
via Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
Note
Select ‘X’ at top right of window to close once complete.
Install the rear apron.
Close the hood.
Raise all four windows
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"
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing
Install RH rocker carrier onto body

Note
10x clips
Install bolts securing RH rocker carrier to body

Note
2x bolts, 10mm, 5 Nm
Install RH rocker panel onto RH rocker carrier

Note
11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
Install clips securing RH rocker cover to front and rear wheel liner

Note
4x push clips
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 LH rocker carrier onto body

Note
10x clips
Install bolts securing LH rocker carrier to body

Note
2x bolts, 10mm, 5 Nm
Install LH rocker panel onto LH rocker carrier

Note
11x clips, 11x tabs, Recommend assistance, Tabs go into cavities on the rocker carrier and cannot be accessed from outer side of trim
Install clips securing LH rocker cover to front and rear wheel liner

Note
4x push clips

2020–2024 Model Y Service Manual

HV Battery (AWD) (7-Seat) (Remove and Install)

Remove

Install

Figure 1

Figure 2

Figure 3