23/07/2024 17:25:23

HV Harness - AC Junction Box To PCS (Remove and Replace)

Correction code 1630010171 1630010172 FRT 2.46 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.

  • 2024-04-10: Added step to install Ancillary Access Bench (2035746-00-A)
Warning IconA warning icon, calling your attention to a possibly risky situation
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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  3. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  4. Remove the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.
  5. Remove the RH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release rearward, and then slide over the LH side NVH cover before removing upward.
  6. Remove the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  7. Remove the LH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
  8. Remove the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
  9. Clean all debris from the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    During the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
  10. Release the pressurize pack air line from the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 connector
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
  11. Remove the VOSS fitting from the Pressurize Pack air line to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  12. Disconnect the electrical connector, and then remove the bolt that attaches the pressurize pack valve block to the air suspension reservoir.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
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    Note
    Release the lock before disengaging the connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cut the zip tie at the reservoir/ancillary air line bundle.
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    Note
    Release the harness clip at the bracket.
  13. Release the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
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    Note
    Rotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave all air lines and connections secured, and then set the assembly aside.
  14. Remove the nuts (x2) that attach the air suspension reservoir to the body.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  15. Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise and swing the air suspension reservoir to the side of the bed.
  16. Open the powered frunk.
  17. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  18. Disconnect MV power. See Disconnect MV Power.
  19. Verify operation of multimeter
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
  20. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  21. Remove Mid-aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  22. Disconnect the pressurized pack lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
  23. Remove the VOSS fitting from pressurized pack air lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  24. Remove all items from pockets and ensure not wearing metal items
  25. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  26. Put on HV insulating gloves and leather over gloves
  27. Verify no HV - Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    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.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake 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
  28. Secure the RDU header connector to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 connector
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the lever is in the upright and open position. Carefully seat connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any pins.
  29. Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
  30. Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  31. Lower the vehicle until the tires are touching the ground.
  32. Disconnect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking. Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector. Wait 1 second between locking tab release to discharge and prevent arcing.
  33. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  34. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  35. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  36. Support the HV busbar assembly to maintain clearance with a bungee cord.
  37. Remove the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  38. Remove the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  39. Remove the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use E10 5-Lobe socket without magnet.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  40. Remove the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a suction cup and maneuver around the busbar and the tonneau cage.
  41. Disconnect the AC junction box to PCS HV electrical harness electrical connectors (x2), and then remove the harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab, and then pull each electrical connector out of its respective header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not pull on the electrical harness.
  42. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Install the AC junction box to PCS HV electrical harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 electrical connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure at the AC junction box first, and then fold the harness over to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the locking tab on both electrical connectors.
  2. Install the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a suction cup.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver around the busbar and tonneau cage.
  3. Install the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use E10 5-Lobe socket without magnet.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  4. Install the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  5. Install the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  6. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  7. Clean the HV connector contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
  8. Clean the busbar HV connector contact surface of residual Penetrox with IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during re-use of the busbar.
  9. Apply Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  10. Position the busbar connector, and then lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the bungee cord.
  11. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket (insulated)
  12. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  13. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 HV joints
    Informational PurposesAn informational icon, calling your attention
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), the Hioki test passed. proceed to the next step.
  14. Remove the leather over gloves and HV insulating gloves.
  15. Connect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
  16. Install the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Supports install in the same direction of the fasteners.
  17. Install the LH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the busbar clearance during installation to avoid damage to the NVH material.
  18. Install the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  19. Install the RH tonneau NVH cover.
  20. Install the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  21. Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
  22. Install the nuts (x2) that attach the air suspension reservoir.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  23. Secure the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position air lines and connections into place for installation.
  24. Install a new VOSS air fitting to the pressurize pack valve block at the ANC circuit.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurize pack line install.
  25. Secure the pressurize pack air line from the ancillary to the valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 line
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  26. Install the bolt that attaches the pressurize pack valve block to the air suspension reservoir, and then connect the electrical connector.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the reservoir and ancillary air lines at the white marked sections.
  27. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  28. Fully raise the vehicle.
  29. Remove all items from pockets and ensure not wearing metal items
  30. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
  31. Put on the HV insulating gloves and leather over gloves.
  32. Clean the mating surfaces of the pyro.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use any other types of cleaner.
  33. Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  34. Remove the leather over gloves and HV insulating gloves.
  35. Install new VOSS fittings and nut to the pyro cover.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm 12-point deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurized pack line installation.
  36. Install the bolts (x4) that attach the pyro fuse access cover.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the seal is fully seated and undamaged.
  37. Install the pressurized pack lines (x2).
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm 6 point flare nut wrench
    • 12 mm flare nut crowfoot socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  38. Install the mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    x6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto mid aero shield bolts and install the fasteners.
  39. Fully lower the vehicle.
  40. Connect MV power. See Disconnect MV Power.
  41. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  42. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
  43. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.