Correction code 16301012 3.54 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. Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
2. Remove butyl patches covering LH rocker access holes
   Note

   2x butyl patches, Clean excess butyl from area

   

   

3. Install lift pad adapters onto LH rocker
   Note

   2x lift pad adapters

   

   

4. Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
5. Remove butyl patches covering RH rocker access holes
   Note

   2x butyl patches, Clean excess butyl from area

   

   

6. Install lift pad adapters onto RH rocker
   Note

   2x lift pad adapters

   

   

7. Open all four doors
8. Lower all four windows
9. Place vehicle in service mode through UI
   Note

   Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
10. Move LH front seat forward
11. Move RH front seat forward
12. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
13. Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
14. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
15. Raise and support vehicle
    Note

    Verify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels

    

    

    

16. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
17. Remove the HEPA filter assembly. See eAssembly - Filter - HEPA (Remove and Install).
18. Power off vehicle from center display
    Note

    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
19. 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

    

    

    

20. 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

    

    

21. 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
22. Remove the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
23. Remove push clips at left and right wheel house liner to mid aero shield
    Note

    2x clips

    

    

24. Remove mid aero shield
    Note

    11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip

    

25. Position coolant drain container underneath LH front of HV battery

    

26. Disconnect PT supply hose at LH front side of vehicle
    Note

    1x spring clip, Plug hose connections as needed

    

27. Install PCS flush adapter onto PT supply hose
    Note

    Remove plugs as needed, Verify fully seated, Perform push-pull-push test

    

    

    

28. Secure coolant cart flush hose to regulator and PCS flush adapter
    Note

    Verify regulator valve is closed, Pressure regulator is not adjustable

    

    

    

29. Position coolant drain container underneath LH RDU area
    Note

    Position neck to catch all coolant loss

    

30. Disconnect RDU inverter inlet hose from fluid coupling
    Note

    1x spring clip, 2x plugs, Plug drive unit coupling

    

31. Attach compressed air line to coolant pressure tester
    Note

    Make sure valve is closed on pressure regulator

    

32. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
    Note

    Allow system to drain completely

    

33. Close valve on pressure regulator once no coolant is draining from RDU inverter inlet hose

    

    

34. Disconnect compressed air from coolant pressure tester

    

35. Remove cart flush hose from PCS Flush adapter

    

36. Remove PCS flush adapter from PT supply hose
    Note

    1x spring clip, Plug hose connections as needed

    

    

37. Remove coolant drain container from underneath vehicle

    

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

    

    

39. 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

    

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

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

    

41. 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.

    

    

42. 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

    

43. 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

    

    

    

    

44. 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
45. Disconnect HVC logic connector and install logic cap
    Note

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

    

46. Disconnect power connector to HV battery
    Note

    1x connector, Pull locking tab upward then release connection

    

47. Remove bolt securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

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

    1x clip

    

    

50. 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

    

    

    

51. Remove NVH insulation from ancillary bay cover
    Note

    Move insulation aside

    

    

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

    3x bolts, E10, 10 Nm

    

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

    3x bolts, T20, 2.5 Nm

    

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

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

    

    

    

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

    22x captured bolts, EPL 10, Torque 5 Nm

    

56. 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 and HV header

    

    

57. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
58. Disconnect HV controller connectors
    Note

    7x connectors, Lift hinge upwards to release levered connection

    

    

59. Release harness clips from HVC hinge tray and route harness away
    Note

    3x clips

    

60. Remove the HVC and tray assembly from ancillary bay

    

61. Disconnect PCS to DC bus HV connector
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

62. Disconnect PCS logic connector from PCS
    Note

    1x connector

    

63. Disconnect PCS LV connector from PCS
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

64. Disconnect AC filter harness
    Note

    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

    

65. Release PCS supply hose from PCS
    Note

    1x hose, Carefully release PCS hose using the special tool, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required, Plug PCS

    

    

    

    

66. Release ancillary bay harness clip by PCS return hose
    Note

    1x clip

    

    

67. Release PCS return hose from PCS
    Note

    1x hose, Carefully release PCS hose using the special tool, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required, Plug PCS

    

    

    

    

68. Remove bolts securing PCS to HV battery
    Note

    6x bolts, 8mm, 6 Nm, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners

    

69. Secure suction cups to PCS
    Note

    Continue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss, Verify fully secured

    

70. Remove PCS from vehicle
    Note

    Recommend assistance, Carefully lift PCS up and remove from vehicle, Place on safe working bench

    

    

    

71. Remove suction cups from the old PCS

    

72. Secure suction cups to PCS
    Note

    Continue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss, Verify fully seated

    

73. Position PCS into vehicle
    Note

    Recommend assistance, Carefully lift PCS up and position into vehicle, Verify it is orientated correctly

    

    

    

74. Install bolts securing PCS to HV battery
    Note

    6x bolts, 8mm, 6 Nm

    

75. Remove PCS plugs from new PCS
    Note

    2x plugs

    

    

76. Secure PCS return hose onto PCS
    Note

    1x hose, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated

    

    

    

77. Secure ancillary bay harness clip by PCS return hose
    Note

    1x clip

    

    

78. Secure PCS supply hose onto PCS
    Note

    2 tabs, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated

    

    

    

79. Connect PCS to fastcharge contactor HV harness connector
    Note

    1x connector, Secure connector and enage red locking tab, Make sure the connector is fully seated

    

80. Connect PCS LV connector to PCS
    Note

    1x connector, Secure connector and enage red locking tab, Make sure the connector is fully seated

    

81. Connect PCS logic connector to PCS
    Note

    1x connector

    

82. Connect PCS to DC bus HV connector
    Note

    1x connector, Secure connector and engage red locking tab, Make sure the connector is fully seated

    

83. Secure HVC hinge tray onto hinge clips and install into vehicle
    Note

    2x hinge clips, Position assembly into vehicle, Take note of the way the harness will route over the hinge, Carefully secure hinge tray onto hinge clips, Verify fully seated

    

    

    

    

    

84. Secure HV controller connectors
    Note

    7x connectors, Lift hinge upwards and secure levered connector

    

    

85. Secure harness clips onto HVC hinge tray and route harness
    Note

    3x clips, Secure harness onto guides and secure clips

    

86. 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).
87. Inspect ancillary bay phantom seal to verify no damage is present
    Note

    If damage is present, Replace ancillary bay phantom seal

    

    

    

88. Install ancillary bay cover onto HV battery
    Note

    Recommend assistance, Guide LH side of cover into position clearing HV header, Maneuver cover past body casting and into position with charge port components

    

    

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

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

    

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

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

    

    

    

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

    3x bolts, T20, 2.5 Nm

    

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

    3x bolts, E10, 10 Nm

    

93. Install NVH insulation onto ancillary bay cover

    

    

94. Connect power connector to HV battery
    Note

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

    

95. Connect HVC logic connector
    Note

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

    

96. 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

    

97. 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

    

98. 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

    

    

99. Position busbar kit connector and lower onto HV header

    

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

     2x bolts, 10mm, 9 Nm

     

101. 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

     

102. Install fastener securing busbar cover access door
     Note

     1x bolt, 10mm, 9 Nm

     

103. Engage LH body harness onto rear body
     Note

     1x clip

     

     

104. Connect power connector to HV battery
     Note

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

     

105. Connect HVC logic connector
     Note

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

     

106. 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
107. 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

     

108. Remove HV insulating gloves
109. Secure closed end cap to RDU inverter inlet hose
     Note

     1x hose, Plug hose with cap from the coolant hose plug kit, Plug hose so it will not leak air, Perform push-pull-push test

     

110. Secure coolant leak test adapter to PT supply hose
     Note

     This adapter is connected to regulated air line adapter, Make sure the locking tab is fully seated, Perform push-pull-push test

     

     

111. Secure pressure test fixture hose to leak test adapter

     

112. Secure compressed air line to pressure test fixture
     Note

     Make sure valves are closed on pressure regulator

     

     

113. Open the regulator valve then slowly adjust regulator to 50 psi
     Note

     Use caution due to high pressure, Make sure to wear safety glasses and personal protection equipment

     

     

114. Open the 2nd valve slowly
     Note

     Slowly allow air to enter system

     

115. Allow 1 minutes and 50 seconds for the pressure to stabilize
     Note

     Allow 1 minutes and 50 seconds (110 seconds) for pressure to stabilize
116. Close the regulator valve

     

117. Record start pressure value
118. Allow 4 minutes to test
119. Record end pressure value
     Note

     If pressure did not drop more than 0.35 psi, continue to next step, If pressure dropped more than 0.35 psi, then inspect for leaks and retest
120. Release compressed air line from pressure test fixture

     

121. Open the regulator valve slowly
     Note

     Slowly allow air to leave the system

     

122. Release pressure test fixture hose from coolant leak test adapter

     

123. Release coolant leak test adapter to PT supply hose

     

     

124. Release closed end cap from RDU inverter inlet hose

     

125. Remove hose plugs and connect coolant inlet hose to rear drive unit
     Note

     1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated

     

126. 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

     

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

     2x clips

     

     

128. Connect PT supply hose at LH front side of vehicle
     Note

     1x spring clip, Remove plugs as needed

     

129. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
     Note

     12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks

     

     

130. Lower vehicle fully
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
131. Remove coolant bottle cap

     

132. Fill coolant to the proper level
     Note

     Ensure that the fluid level filled to the Max line

     

133. Connect first responder loop and leave LV battery disconnected
     Note

     1x connectors, Secure FRL only, Leave LV battery disconnected

     

134. Connect 12V maintainer
     Note

     Release positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time

     

     

     

     

135. Connect to vehicle using Toolbox 3.0
     Note

     Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
136. Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
137. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia 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
     ’, click ‘Run’, and allow routine to complete
     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
138. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line

     

139. Install coolant bottle cap

     

140. Select ‘Actions/Autodiag’ and search for ‘Redeploy’
141. Select ‘SERVICE CAN REDEPLOY’, click ‘Run’, and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete, Routine will state pass but update will continue to run in the background, UI will indicate status of update
142. Verify CAN redeploy has completed on center display
     Note

     Verify can redeploy has completed, Release notes may not be present, Verify that the progress bar is no longer existing and vehicle is done updated

     

143. Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
144. Connect LV battery
     Note

     1x connector, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

     

     

145. Disconnect 12V maintainer
     Note

     Unplug maintainer and release connections from vehicle, Re-secure positive terminal cover

     

     

     

146. Install the HEPA filter assembly. See eAssembly - Filter - HEPA (Remove and Install).
147. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
148. Remove vehicle from lift
     Note

     Lower rack arms fully and remove from under vehicle
149. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
150. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
151. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
152. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
153. Install clips securing rear main cabin carpet to vehicle
     Note

     3x push clips

     

154. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
155. Move LH front seat to original position
156. Move RH front seat to original position
157. Exit Service Mode through UI
     Note

     Controls > Service Mode > Exit Service Mode
158. Raise LH front window
159. Close LH front door
160. Remove lift pad adapters from RH rocker
     Note

     2x lift pad adapters

     

     

161. 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"

     

     

162. Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
163. Remove lift pad adapters from LH rocker
     Note

     2x lift pad adapters

     

     

164. 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"

     

     

165. Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).