Correction code 16202302 3.12 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. Move LH front seat forward
10. Move RH front seat forward
11. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
12. Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
13. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
14. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (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. Open hood
17. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
18. Remove bolt securing frunk to washer fluid reservoir neck
    Note

    1x bolt, 10mm, 5 Nm

    

19. Release washer tank neck from washer tank and set aside
    Note

    1x O-ring, No need to remove hose from neck

    

    

20. Remove HEPA filter assembly
    Note

    2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly

    

    

    

21. Power off vehicle from center display
    Note

    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
22. 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

    

    

    

23. 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

    

    

24. 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
25. Remove front aero shield
    Note

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

    

    

26. Remove push clips at left and right wheel house liner to mid aero shield
    Note

    2x clips

    

    

27. Remove mid aero shield
    Note

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

    

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

    

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

    1x spring clip, Plug hose connections as needed

    

30. Install PCS flush adapter onto PT supply hose
    Note

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

    

    

    

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

    Verify regulator valve is closed, Pressure regulator is not adjustable

    

    

    

32. Position coolant drain container underneath LH RDU area
    Note

    Position neck to catch all coolant loss

    

33. Disconnect RDU inverter inlet hose from fluid coupling
    Note

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

    

34. Attach compressed air line to coolant pressure tester
    Note

    Make sure valve is closed on pressure regulator

    

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

    Allow system to drain completely

    

36. Close valve on pressure regulator once no coolant is draining from PT return hose

    

37. Disconnect compressed air from coolant pressure tester

    

38. Remove cart flush hose from PCS Flush adapter

    

39. Remove PCS flush adapter from PT supply hose
    Note

    1x spring clip, Plug hose connections as needed

    

    

40. Remove coolant drain container from underneath vehicle

    

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

    

    

42. 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

    

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

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

    

44. 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.

    

    

45. 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

    

46. 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

    

    

    

    

47. 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
48. Disconnect HVC logic connector and install logic cap
    Note

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

    

49. Disconnect power connector to HV battery
    Note

    1x connector, Pull locking tab upward then release connection

    

50. Remove bolt securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

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

    2x bolts, 10mm, 9 Nm

    

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

    1x clip

    

    

53. 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

    

    

    

54. Remove NVH insulation from ancillary bay cover
    Note

    Move insulation aside

    

    

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

    3x bolts, E10, 10 Nm

    

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

    3x bolts, T20, 2.5 Nm

    

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

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

    

    

    

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

    22x captured bolts, EPL 10, 5 Nm

    

59. 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

    

    

60. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
61. Release ancillary bay harness clip by PCS return hose
    Note

    1x clip

    

    

62. 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

    

    

    

    

63. Release PCS return hose from coolant passthrough and remove assembly
    Note

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

    

    

    

    

    

64. Position PCS return hose for installation and secure onto coolant passthrough
    Note

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

    

    

    

    

65. Secure PCS return hose onto PCS
    Note

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

    

    

    

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

    1x clip

    

    

67. 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).
68. Inspect ancillary bay phantom seal to verify no damage is present
    Note

    If damage is present, Replace ancillary bay phantom seal

    

    

    

69. 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

    

    

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

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

    

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

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

    

    

    

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

    3x bolts, T20, 2.5 Nm

    

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

    3x bolts, E10, 10 Nm

    

74. Install NVH insulation onto ancillary bay cover

    

    

75. Connect power connector to HV battery
    Note

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

    

76. Connect HVC logic connector
    Note

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

    

77. 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

    

78. 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

    

79. 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

    

    

80. Position busbar kit connector and lower onto HV header

    

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

    2x bolts, 10mm, 9 Nm

    

82. 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

    

83. Install fastener securing busbar cover access door
    Note

    1x bolt, 10mm, 9 Nm

    

84. Engage LH body harness onto rear body
    Note

    1x clip

    

    

85. Connect power connector to HV battery
    Note

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

    

86. Connect HVC logic connector
    Note

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

    

87. 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
88. 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

    

89. Remove HV insulating gloves
90. 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

    

91. 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

    

    

92. Secure pressure test fixture hose to leak test adapter

    

93. Secure compressed air line to pressure test fixture
    Note

    Make sure valves are closed on pressure regulator

    

    

94. 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

    

    

95. Open the 2nd valve slowly
    Note

    Slowly allow air to enter system

    

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

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

    

98. Record start pressure value
99. Allow 4 minutes to test
100. 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
101. Release compressed air line from pressure test fixture

     

102. Open the regulator valve slowly
     Note

     Slowly allow air to leave the system

     

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

     

104. Release coolant leak test adapter to PT supply hose

     

     

105. Release closed end cap from RDU inverter inlet hose

     

106. 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

     

107. 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

     

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

     2x clips

     

     

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

     1x spring clip, Remove plugs as needed

     

110. 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

     

     

111. Lower vehicle fully
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
112. Remove vehicle from lift
     Note

     Lower rack arms fully and remove from under vehicle
113. Remove coolant bottle cap

     

114. Fill coolant to the proper level
     Note

     Ensure that the fluid level filled to the Max line

     

115. Connect first responder loop and LV battery
     Note

     2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

     

     

     

116. 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
117. Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
118. 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
119. Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
120. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line

     

121. Install coolant bottle cap

     

122. Install HEPA filter assembly
     Note

     2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position

     

     

     

123. Secure washer tank neck onto washer tank
     Note

     1x O-ring, Ensure washer hose is properly routed

     

124. Install bolt securing frunk to washer fluid reservoir neck
     Note

     1x bolt, 10mm, 5 Nm

     

125. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
126. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
127. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
128. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
129. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
130. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
131. Move LH front seat to original position
132. Move RH front seat to original position
133. Raise LH front window
134. Close LH front door
135. Remove lift pad adapters from RH rocker
     Note

     2x lift pad adapters

     

     

136. 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"

     

     

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

     2x lift pad adapters

     

     

139. 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"

     

     

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