Tesla Model 3: HV Header - HV Battery (Remove and Replace)
HV Header - HV Battery- Remove
SPECIAL TOOLS
Extractor, Battery HV Header, Model 3 (1140423-00-B)
Lever Lock, HV Connector, Model 3 (1140311-00-A)
Warning:
Only technicians who have been trained in High Voltage Awareness are
permitted to perform this procedure. 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.
Remove
- Perform the vehicle electrical isolation procedure. See
Vehicle Electrical Isolation Procedure.
- Remove the rear HV battery skid plate. See
Skid Plate - HV Battery - Rear (Remove and Replace).
.png)
- Release the clips that attach the RH inner HV battery return hose to the
HV battery.
.png)
- Remove the nuts that attach the rear drive unit HV electrical harness
bracket to the HV battery.
Torque 10 Nm
.png)
- Release the locking tab of the rear drive unit HV electrical harness.
.png)
- Raise the handle, and them disconnect the rear drive unit HV electrical
harness from the HV battery connector.

- Remove the bolts that attach the HV header to the HV battery.

- Insert the extractor tool into the HV header, push the tool handle in,
and pull on the header to remove it from the HV battery.
HV Header - HV Battery- Install
Install

- Install the HV header onto the HV battery.
Note: Push and pull on the header to make sure it is secured.

- Install and hand-tighten the bolts that attach the HV header to the HV
battery
- Tighten the bolts to proper torque.
Torque 10 Nm
- Fully raise the handle on the rear drive unit HV electrical harness.
.png)
- Attach the HV connector lever lock onto the back of the HV electrical
harness.
- Firmly connect the HV electrical harness to the HV battery connector.
Caution: Make sure that the harness fits the connector squarely
and tightly.
- While pressing the harness to the connector, remove the HV connector
lever lock.
.png)
- While pressing the harness to the connector, fully lower the handle.
.png)
- Slide the release to lock the HV electrical harness.
.png)
- Install the nuts that attach the rear drive unit HV electrical harness
bracket to the HV battery.
Torque 10 Nm
.png)
- Fasten the clips that attach the RH inner HV battery return hose to the
HV battery.
- Install the rear HV battery skid plate. See
Skid Plate - HV Battery - Rear (Remove and Replace).
- Perform a penthouse air leak test. See
Penthouse Air Leak Test.
- Connect 12V power. See
12V Power (Disconnect and Connect).
READ NEXT:
Warning:
Only technicians who have been trained in High Voltage Awareness are
permitted to perform this procedure. Proper personal protective equipment (PPE)
and insulating HV gloves with a minimum
SEE MORE:
Remove
Open the trunk.
Remove the LH trunk side
trim. See
Trim - Side - Trunk - LH
(Remove and Replace).
Disconnect 12V power.
See
12V Power (Disconnect a
Vent Assembly - HV Battery - LH- Remove
Remove
Use Toolbox to put the vehicle into Factory Mode.
Invoke diagnostics on the touchscreen.
Inspect the Notifications for either a BMS_a123 or a BMS_W123 alert.
If:
Either alert is present - Contact Service Engineering. Do not perform
this proced