2026-08-14

Cover - Ancillary Bay (7-Seat) (Remove and Install)

Correction code 16101031 1.14 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. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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.
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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.
Additional part that may be required for this operation (for Europe only):
  • 1108781-BB-F: LABEL - RECYCLING WARNING - EU or
  • 1108781-SH-F: LABEL - RECYCLING WARNING - EU

Remove

Warning
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.
  1. Open all four doors and lower all four windows.
  2. Move the LH front seat forward.
  3. Partially remove the LH rear door seal.
  4. Release the clips (x8) and remove the LH 7-seat lower C-pillar trim.
    Note
    The rear edge mates with the groove in the trunk side trim. Starting at the front of the LH rear sill trim, release the clips while working your way back toward the rear.
  5. Fold down the 2nd row 60 seat.
  6. Disconnect the logic connector at the LH seat frame.
    Note
    1x connector
  7. Move the 60 seat forward using towel bar, with one hand on towel bar pull up and slide the seat forward with your other hand.
  8. Remove and discard the 60 seat rear outboard track fastener.
    Note
    1x patch bolt, 11mm, 37 Nm, Discard after removal.
  9. Remove and discard the 60 seat rear inboard track fasteners.
    Note
    2x patch bolts, 11mm, 37 Nm, Discard after removal.
  10. Move the 60 seat fully rearward using towel bar, with one hand on towel bar pull up and slide the seat forward with your other hand.
  11. Release one clip and remove the 60 seat outboard track cover.
    Note
    Slide covers forward to release from 60 seat tracks.
  12. Release two clips and remove the center track cover from 2nd row seats.
    Note
    Slide covers forward to release from 2nd row seat tracks.
  13. Release the cabin carpet from the 60 seat by pulling the cabin carpet towards front of vehicle.
  14. Remove and discard the 60 seat front inboard track fasteners.
    Note
    1x bolts, 11mm, 37 Nm, Discard after removal.
  15. Remove and discard the 60 seat front outboard track fastener.
    Note
    1x bolts, 11mm, 37 Nm, Discard after removal.
  16. Remove the 2nd row 60 seat assembly from vehicle.
    Note
    Recommend assistance.
  17. Move the RH front seat forward.
  18. Partially remove the RH rear door seal.
    Note
    Pillar and sill trim have tabs seated underneath seal.
  19. Release the clips (x8) and remove the RH lower C-pillar trim.
    Note
    The rear edge mates with the groove in the trunk side trim. Starting at the front of the RH rear sill trim, release the clips while working your way back toward the rear.
  20. Remove the 40 seat outboard track cover.
    Note
    1x clip, Slide cover forward to release from 40 seat track.
  21. Release the cabin carpet from 40 seat by pulling cabin carpet towards front of vehicle.
  22. Remove and discard bolts (x2) securing the 40 seat podium to the vehicle.
    Note
    2x patch bolts, 11mm, 37 Nm. Discard bolts after removal.
  23. Fold down the 2nd row 40 seatback assembly.
    Note
    Press the button or pull the manual lever to fold forwards. If the vehicle is powered off, use the manual lever instead.
  24. Disconnect the 40 frame connector.
    Note
    1x connector
  25. Move the 40 seat forward using towel bar, with one hand on towel bar pull up and slide the seat forward with your other hand.
  26. Remove and discard bolts (x2) securing 40 seat inner and outer tracks to vehicle.
    Note
    2x patch bolts, 11mm, 37 Nm, Discard bolts after removal.
  27. Move the 40 seat fully rearward using towel bar, with one hand on towel bar pull up and slide the seat rearward with your other hand.
  28. Remove the 40 seat from vehicle.
    Note
    Recommend assistance. Do not support 40 seat by cushion pan. Support 40 seat by podium.
  29. Remove the 3rd row seat cushion and disconnect harness.
    Note
    1x connector. Pull LH and RH release lever under 3rd row seat cushion to release seat cushion.
  30. Remove 3rd row RH seat cushion bolster.
    Note
    1x bolt, 13mm, 37 Nm. Slide RH cushion bolster towards front of vehicle to remove.
  31. Remove 3rd row LH seat cushion bolster.
    Note
    1x bolt, 13mm, 37 Nm. Slide LH seat cushion bolster towards front of vehicle to remove.
  32. Release clip securing 3rd row carpet to LH support bracket.
    Note
    1x clip
  33. 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.
  34. Remove 3rd row carpet from under LH trunk side trim.
  35. Release the clip securing RH body harness to body.
  36. 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.
  37. Remove the 3rd row carpet from under RH trunk side trim.
  38. Remove the 3rd row carpet from vehicle.
  39. Open the hood.
  40. Remove the clips (x14) and remove the rear apron.
  41. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  42. Disconnect the HVC logic connector and install logic cap
    Note
    1x connector, 1x cap. Release locking tab, then push the handle downward to release the connector.
  43. Remove the 3rd row NVH insulator.
  44. Empty all pockets and remove all metal objects such as watches and jewelery.
  45. Inspect the HV insulating gloves for any damage.
  46. Put on the HV insulating gloves and leather over gloves.
  47. Remove and discard the bolts (x2) securing ancillary bay probe lid cover to ancillary bay cover.
    Note
    2x bolts, EP10 5-Lobe, 6 Nm. Discard after removal.
  48. Remove the ancillary bay probe lid cover from ancillary bay cover.
  49. 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.
  50. 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.
  51. Install the new bolts securing ancillary bay probe lid cover to ancillary bay cover.
    6 Nm (4.4 lbs-ft)
    Note
    2x bolts, EP10 5-Lobe, 6 Nm. Install new fasteners
  52. Remove HV insulating gloves.
  53. Release positive 12V output cover from PCS cable.
    Note
    1x cover
  54. Remove and discard the nut securing positive 12V output from PCS cable and move the cable aside.
    Note
    1x nut, 13mm, 15 Nm. Discard after removal.
  55. Remove the fasteners securing ancillary bay cover to high voltage controller (HVC).
    Note
    4x bolts, E10, 5 Nm + 30 degrees. Newer vehicles may be equipped with 3x bolts.
  56. Put on HV insulating gloves and leather over gloves.
    Warning
    Continue to wear the gloves until instructed to remove them.
  57. Loosen the 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.
  58. Remove the HVC logic cap.
    Note
    1x cap
  59. Remove the ancillary bay cover from the HV battery.
    Note
    Inspect the ancillary bay for any missing insulators. Install any missing insulators that are accessible before continuing to next step.

Install

  1. For Europe only: Check the ancillary bay cover that is being replaced for the presence of a recycling warning label that includes a CE marking and manufacturer information.
    Figure 1. 1108781-BB-F shown, 1108781-SH-F similar
    • If the recycling warning label with CE marking and manufacturer information is not present on the ancillary bay cover being replaced, continue to the next step.
    • If the recycling warning label with CE marking and manufacturer information is present on the ancillary bay cover being replaced:
      1. Note the area where the recycling warning label is affixed on the ancillary bay cover being replaced.
      2. Clean the corresponding area on the new ancillary bay cover with an IPA wipe and allow 1 minute dry time.
      3. Install a new recycling label with CE marking and Manufacturing Information (part number 1108781-BB-F or 1108781-SH-F) on the new ancillary bay cover.
        Note
        For the correct part number, refer to the part number printed on the label that is attached to the ancillary bay cover being replaced.
  2. If the old ancillary bay cover has volcano brackets, and the replacement ancillary bay cover does not have the same brackets, rework the High Voltage Controller (HVC) as required to achieve proper fitment between the replacement cover and HVC. If the replacement cover has volcano brackets, skip to the next step in this procedure.
    Figure 2. Replacement ancillary bay cover without volcano brackets
    Figure 3. Ancillary bay cover rework area; Cover shown installed for clarity
    Figure 4. HVC standoff to be removed; Ancillary bay cover shown removed for clarity
    1. Disconnect the ancillary bay harness from the HVC connectors.
    2. Remove the bolts that attach the HVC to the hinge tray, and then remove the controller from the vehicle.
      2 Nm (1.5 lbs-ft)
      Figure 5. 5-Bolt HVC
    3. Use a Dremel cut off wheel to remove the HVC standoff. Discard the standoff.
      Warning
      Wear appropriate personal protective equipment (PPE) including cut-resistant gloves and safety glasses when performing this procedure.
      CAUTION
      Do not damage the HVC upper surface or surrounding standoffs.
      Note
      Cut as close towards the base of the standoff as possible.
      Tip
      Use of the following tool(s) is recommended:
      • Dremel Accessory Kit, 110 Piece
    4. Apply electrical tape over the HVC standoff hole.
      Tip
      Use of the following tool(s) is recommended:
      • Electrical Tape
    5. Install the HVC into the ancillary bay, and then install the bolts that attach the HVC to the hinge tray.
      2 Nm (1.5 lbs-ft)
    6. Connect the ancillary bay harness to the HVC connectors.
  3. Inspect ancillary bay walls for any 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 an enclosure leak test when reassembled. It can still be reused.
  4. 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.
  5. If the aluminum tape retrofit patch is missing or damaged, remove the patch (if present), clean the area with an IPA wipe, apply another patch of aluminum tape, and wet out the patch with a silicone roller to set the adhesive.
    Tip
    Use of the following tool(s) is recommended:
    • 3M 425 Aluminum Foil Tape - 0601363
    Figure 6. 5-Bolt to 4-Bolt Patch 50mm x 50mm
    Figure 7. 4-Bolt to 3-Bolt Patch 30mm x 30mm
  6. 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.
  7. Install HVC logic cap.
    Note
    1x cap
  8. Install bolts securing ancillary bay cover to HV battery.
    8 Nm (5.9 lbs-ft)
    Note
    18x bolts, E10 5-Lobe, 8 Nm. Use E10 5-Lobe socket without magnet. Fasteners are captive. Follow torque sequence per image
  9. Remove HV insulating gloves.
  10. Install fasteners securing ancillary bay cover to high voltage controller (HVC).
    5 Nm (3.7 lbs-ft) + 30 degrees
    Note
    4x bolts, E10, 5 Nm + 30 degrees. Newer vehicles may be equipped with 3x bolts.
  11. Install the new nut (1523698-00-A) to secure the positive 12V output cable to the DCDC passthrough, and mark the nut with a paint pen after torque.
    9 Nm (6.6 lbs-ft)
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
    Note
    1x nut, 13mm, 9 Nm. Make sure rubber boot is not pinched between cable terminal and pass through.
  12. Install the positive 12V output cover to PCS cable
    Note
    1x cover
  13. Install the 3rd row NVH insulator.
  14. 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.
  15. Install 3rd row carpet into vehicle.
  16. Install 3rd row carpet under RH trunk side trim.
  17. Install clip securing RH body harness to body.
    Note
    1x clip
  18. Install 3rd carpet under LH trunk side trim.
  19. Install clip securing 3rd row carpet to LH support bracket.
    Note
    1x clip
  20. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  21. Install 3rd row LH seat cushion bolster.
    Note
    1x bolt, 13mm, 37 Nm. Slide LH seat cushion bolster into seat frame assembly.
  22. Install 3rd row RH seat cushion bolster.
    Note
    1x bolt, 13mm, 37 Nm. Slide RH seat cushion bolster into seat frame assembly.
  23. Install 3rd row seat cushion and connect harness.
    Note
    1x connector. Secure 3rd row seat cushion into RH and LH latches.
  24. Install 40 seat into vehicle.
    Note
    Recommend assistance. Do not support 40 seat by cushion pan. Support 40 seat by podium.
  25. Connect 40 seat frame connector to body harness.
    Note
    1x connector
  26. Install new bolts (1616775-00-B) securing 40 seat podium to vehicle hand tight.
    Note
    2x patch bolts, 11mm, 37 Nm. Torque at later step.
  27. Move 40 seat forward using towel bar, with one hand on towel bar pull up and slide the seat forward with your other hand.
  28. Install new bolts (1616775-00-B) securing 40 seat inner and outer tracks to vehicle.
    Note
    2x patch bolts, 11mm, 37 Nm.
  29. Move 40 seat back to the original position.
  30. Torque bolts securing 40 seat podium to vehicle.
    37 Nm (27.3 lbs-ft)
    Note
    2x patch bolts, 11mm, 37 Nm.
  31. Install the cabin carpet to 40 seat.
  32. Install 40 seat outboard track cover.
    Note
    1x clip
  33. Install RH lower C-pillar trim.
    Note
    8x 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.
  34. Reseat RH rear door seal.
    Note
    Seat pillar and sill trim tabs underneath seal.
  35. Move the RH front seat to its original position.
  36. Install 2nd row 60 seat assembly.
    Note
    Recommend assistance.
  37. Connect logic connector at LH 60 seat frame.
    Note
    1x connector
  38. Install new fasteners (1616775-00-B) securing 60 seat frame to body.
    Note
    5x patch bolts, 11mm, 37 Nm. Bottom seat bolts located behind main carpet. Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
  39. Secure cabin carpet to 60 seat.
    Note
    Strap velcro on.
  40. Move 60 seat to its original position.
  41. Install 60 seat outboard track cover.
    Note
    1x clip
  42. Install center track cover to 2nd row seats.
    Note
    2x clip. Slide cover straight on to clip to 2nd row seat tracks.
  43. Install LH 7-seat lower C-pillar trim.
    Note
    8x 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
  44. Reseat LH rear door seal.
    Note
    Seat pillar and sill trim tabs underneath seal.
  45. Move LH front seat to its original position.
  46. Raise all four windows and close all four windows.
    Note
    If 12V is powered up, unlatch rear doors before closing.