SB-10057517-9286
SB-15-44-001

Tesla Motors, Inc.

January 13, 2015

Service Bulletin

Loose Screw on Front Drive Unit HVIL Switch
Classification

Campaign Bulletin

Section/Group

44 - High Voltage
System

Country/Region

United States,
Canada

Year

2014

Model

Model S

Version

P85D

Bulletin Classification: This campaign bulletin addresses a known non-safety-related condition and provides
recommended technical diagnosis and repair procedures. Apply this procedure to all vehicles in the affected VIN range
listed. These instructions assume knowledge of motor vehicle and high voltage electrical component repairs, and should
only be executed by trained professionals. Tesla Motors assumes no liability for injury or property damage due to a failure
to properly follow these instructions or repairs attempted by unqualified individuals.

Condition
On some dual motor performance vehicles, the screw that secures the HVIL (High Voltage Interlock Loop) switch to the
front drive unit fuse bracket might come loose. This might result in an HVIL fault.

Correction
Replace the screw and secure it with a backing nut.

Required Part(s): Part Number
1010047-00-A
2000869

Description
SCREW, M3 X 13MM TORX 10, PAN HEAD W/PATCH
NUT,HEX,M3X0.5,NYLOC,FULL,DIN 985,STL,ZN

Quantity
1
1

These part numbers were current at the time of publication. Use the revisions listed or later,
unless otherwise specified in the Parts Manual.
Special Tool(s):

223-28550-TSL
223-28556-TSL

WIHA (TORQUE SCREWDRIVER .1 - .6NM)
WIHA (T10 TORX TORQUE CONTROL BLADE)

Correction Description

Correction

Time

Vehicle Inspection Only; Resecuring HVIL Switch Screw Not Necessary

S011544001

0.10

Resecure HVIL Switch Screw

S021544001

0.65

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Procedure
CAUTION: This procedure requires a tool that can accurately measure 0.60 Nm of torque. If no such tool is available,
do not perform this procedure.
1. Remove the 2

nd

row seat frame (refer to Service Manual procedure 13023002).

TIP: It is possible to remove the 8 bolts that secure the 2
nd
the 2 row seat backrest for access.

nd

row seat frame (Figure 1) and temporarily secure the frame to

Figure 1
2. Disconnect the HVIL connector (Figure 2).

Figure 2 (Shown with seat frame installed)

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3. Remove the 3 bolts that secure the HVIL fuse bracket (Figure 3).

Figure 3
4. Measure the clearance between the HVIL switch body and the boss on the bracket (Figure 4). Record this value; it will
be used in a later step.

Boss on HVIL
fuse bracket
Record
clearance
HVIL
switch

Figure 4
5. Remove and discard the screw that secures the HVIL switch to the bracket (Figure 5).

Figure 5
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6. Check the value recorded in step 4:
• If the clearance was between 2.5 mm and 3.9 mm, continue to the next step in this procedure.
• If the clearance was less than 2.5 mm, bend the bracket downward so that the clearance will be within
2.5‒3.9 mm after the HVIL switch is reinstalled.
• If the clearance was greater than 3.9 mm, bend the bracket upward so that the clearance will be within
2.5‒3.9mm after the HVIL switch is reinstalled.
CAUTION: Do not apply more than 0.60 Nm of torque in the next step.
7. Reinstall the HVIL switch to the bracket:
CAUTION: The patched screw and nyloc nut are one-time use parts.
a. Position the HVIL switch onto the bracket. Ensure that the post compresses against the bracket boss into the
plastic housing to prevent an HVIL fault (Figure 6) and that the peg on the HVIL switch bracket is inserted into
the non-threaded portion of the bracket (Figure 7).
Post compresses
against boss on
bracket into plastic
housing

Figure 6

Figure 7

b. Insert the screw fully through the hole in the bracket so that the head of the screw is flush with the HVIL
switch.
c. Tighten the nut by hand until it is fully seated on the screw.
d. Hold the screw in place with the torque screwdriver and tighten the nut until the torque screwdriver breaks
torque.
8. Ensure that there is no gap between the bracket and the HVIL switch and the bracket and the nut. Ensure that the
locating peg is not visible (Figure 8).

No gap
No gap

Figure 8
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9. Repeat step 4. If the clearance is not between 2.5 mm‒3.9 mm, repeat steps 5‒8 until the clearance is within
2.5 mm‒3.9 mm.
CAUTION: The patched screw and nyloc nut are one-time use parts.
10. Reinstall the 3 bolts that secure the HVIL fuse bracket (torque 9 Nm) (Figure 3).
11. Reconnect the HVIL connector (Figure 2).
12. Reinstall all components that were removed for access.
13. Use Toolbox to clear any HVIL alerts.
14. Test drive the vehicle.

Affected VIN(s)

Some Performance Dual Motor Vehicles built before January 1, 2015.
NOTE: This is a simplified summary of the affected VIN list. Refer to the VIN/Bulletin Tracker or
Customer/Vehicle profile to determine applicability of this bulletin for a particular vehicle.

For feedback on the accuracy of this document, email [email protected].

SB-15-44-001

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