26/11/2024 11:01:19
Harness - Ancillary Bay (Remove and Replace)
Correction code 1710118011 1710118012 FRT 2.82 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.
- 2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
- 2024-04-10: Updated steps to disconnect and connect the PCS MV connector.
- 2024-04-10: Added step to install Ancillary Access Bench (2035746-00-A)
Warning
Cybertruck electronics are powered by a
48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing
MV components requires extra knowledge and care in order to avoid personal and/or
vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any
required MV-related training courses have been completed, as applicable.
Warning
DO NOT SKIP the
steps to remove the tonneau slats. Work on or around the ancillary bay REQUIRES the
removal of the tonneau slats. Failure to remove the tonneau slats while working on or
around the ancillary bay will result in conditions that may cause personal injury.
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
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
-
Remove the bolts (x6) that attach the
RH tonneau NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal. -
Remove the RH tonneau NVH cover.
NoteRelease rearward, and then slide over the LH side NVH cover before removing upward.
-
Remove the bolts (x5) that attach the
LH tonneau NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the LH tonneau NVH cover.
NoteSlide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
-
Remove the screws (x8) that attach the
tonneau coverbox cross supports.Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
-
Clean all debris from the ancillary
cover.
NoteDuring the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
-
Release the pressurize pack air line
from the ancillary.
Notex1 connectorCAUTIONDo not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
-
Remove the VOSS fitting from the
Pressurize Pack air line to the ancillary.
Notex1 VOSS fittingNoteSlide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
-
Disconnect the electrical connector,
and then remove the bolt that attaches the pressurize pack valve block to the air
suspension reservoir.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Notex1 clip, x1 zip tieNoteRelease the lock before disengaging the connector.NoteCut the zip tie at the reservoir/ancillary air line bundle.NoteRelease the harness clip at the bracket. -
Release the air suspension valve
block.
Notex3 rubber grommetsNoteRotate 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.NoteLeave all air lines and connections secured, and then set the assembly aside.
-
Remove the nuts (x2) that attach the
air suspension reservoir to the body.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Notex2 fir tree clips -
Put the air suspension reservoir in
service position, and then install the Ancillary Access Bench (2035746-00-A).
NoteRaise and swing the air suspension reservoir to the side of the bed.
- Open the powered frunk.
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power.
- Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
-
Disconnect the pressurized pack
lines.
Notex2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
-
Remove the VOSS fitting from
pressurized pack air lines.
Notex2 VOSS fittingNoteSlide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
-
Secure the RDU header connector to the
ancillary.
Notex1 connectorNoteVerify 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.CAUTIONDo not damage any pins.
- Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
- Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
- Lower the vehicle until the tires are touching the ground.
-
Disconnect the ancillary bay MV
electrical connector.
NoteDouble locking: Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector.CAUTIONWait 1 second between locking tab release to discharge and prevent arcing.
-
Remove the bolt that attaches the
busbar HV connector lid.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the bolts (x2) that attach the
HV connector to the DC FC header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Release the HV connector
from the DC FC header, and then use an inflatable airbag to suspend the
busbar assembly above the ancillary assembly.
NoteUpon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
-
Support the HV busbar assembly to
maintain clearance with a bungee cord.
-
Remove the bolts (x2) that attach the
fast charger header doubler.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
-
Remove the bolts (x2) that attach the
low voltage header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Release fasteners securing ancillary
cover to HV battery
Note22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order
-
Remove the ancillary cover.
NoteUse a suction cup and maneuver around the busbar and the tonneau cage.
-
Inspect the HV insulating
gloves.
NoteCheck gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
-
Put on the HV insulating gloves and
leather over gloves.
-
While supporting the harness end of
the PCS MV connector, press the release, and then slide the red lock plate away from the
black handle.
CAUTIONDo not slide the red lock plate without supporting the PCS MV connector.
-
Continue to support the harness end of
the PCS MV connector, raise the black handle to its vertical position to release, and
then pull straight up on the black handle to disconnect the PCS MV connector from the MV
header of the PCS.
CAUTIONThe MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
-
Remove the bolt that attaches the PCS
MV harness.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Notex1 clip -
Release the edge clip and fir tree
clip that attaches the MV header to the HV battery, and then release the header from the
vehicle.Release the MV header.
-
Release the clips (x2) and disconnect
the HVC connectors (x3).
NoteRelease the connector locks. Press the levers and pull at connector. Do not pull from harness.NoteIf RTV is present at 2 connectors, using a ceramic knife (1076856-00-A) cut through and remove RTV until connector can be disconnected.
-
Disconnect the BMB passthrough
electrical connectors (x2).
NoteRelease the connector locks. Press levers and pull at connector. Do not pull from harness.
-
Disconnect the ACJB LV connector and
ACJB to device cluster HV electrical connector, and then release the harness (x2).
NoteRelease the connector locks. Press levers and pull at connectors. Do not pull at harness.
-
Remove the ancillary harness.
-
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.
NoteDo not allow the grease to contact the busbar HV mating surfaces.
Install
-
Position the ancillary harness.
-
Connect the ACJB LV and HV electrical
connectors (x2).
Notex2 clipsNoteSecure the connector locks.
-
Connect the BMB passthrough electrical
connectors (x2).
NoteSecure the connector locks.CAUTIONConnectors are poke yoked. Do not force engagement. Ensure locking tabs are facing the front of vehicle when connecting.
-
Connect the HVC electrical connectors
(x3).
Notex2 clipsCAUTIONRelease the connector locks. Press levers and pull at connector. Do not pull from harness.NoteApply sealant to connectors at device cluster if it was present during disassembly (1080593-00-A, 1682237-00-G).
-
Secure the MV header.
Notex4 datums, x1 edge clip, x1 fir tree clip
-
Install the bolt that attaches the PCS
MV harness.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Notex1 clip -
Raise the black handle of the PCS MV
connector so that it is at 90 degrees to the body of the connector.
-
Position the PCS MV connector over the
MV header so that the red positive lead of the connector is closest to the edge of the
PCS and over the text "LV+" scribed on the PCS cover.
NoteThe MV header is symmetrical, and it is possible to connect the PCS MV connector backwards.
-
Holding only the electrical harness
and the black handle, connect the PCS MV connector to the MV header.
-
Use two fingers centered directly over
the pins of the MV header (under the arch of the black handle) to press and hold the PCS
MV connector to the MV header, and then carefully lower the black handle until it is
flat.
CAUTIONThe MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
-
While supporting the harness end of
the PCS MV connector, slide the red lock plate to the black handle.
CAUTIONDo not slide the red lock plate without supporting the PCS MV connector.
-
Inspect the PCS MV connector that it
is not tilted, but is parallel to the top surface of the PCS.
NoteIf the PCS MV connector is tilted, there may be damage to the MV header inside the PCS. This damage may cause the PCS to go MIA, or deassert the DCDC enable line. Check for respective alerts and faults.
-
Install the ancillary cover.
NoteUse a suction cup.NoteManeuver around the busbar and tonneau cage.
- Remove the leather over gloves and HV insulating gloves.
-
Install the bolts (x22) that attach
the ancillary cover to the HV battery.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
NoteUse E10 5-Lobe socket without magnet.NoteThe bolts are captive and will stay attached to the ancillary cover. Follow fastening order. -
Install the bolts (x2) that attach the
low voltage header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the bolts (x2) that attach the
fast charger header doubler.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
-
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.
NoteThe grease is part number 1089958-00-A and is available from eProcurement.
-
Clean the HV connector contact surface
of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
NoteAllow 1 minute dry time after removing Penetrox.
-
Clean the busbar HV connector contact
surface of residual Penetrox with IPA wipe.
NoteAllow 1 minute dry time after removing Penetrox.NoteIt is necessary to clean the HV connector during re-use of the busbar.
-
Apply Penetrox onto the HV connector
joints.
NoteApply 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.
-
Position the busbar connector, and
then lower it onto the HV header.
NoteRemove the bungee cord.
-
Install the bolts (x2) that attach the
charge port busbar kit to the HV header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket (insulated)
-
Inspect the HV insulating
gloves.
NoteCheck the gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
-
Put on the HV insulating gloves and
leather over gloves.
-
Perform a Hioki resistance test at
each HV joint from the HV busbar lead to the bolt head.
Notex2 HV jointsNoteWhen using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.NoteThe 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.
- Remove the leather over gloves and HV insulating gloves.
-
Install the bolt that attaches the
busbar HV connector lid.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Connect the ancillary bay MV
electrical connector.
NoteDouble locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
-
Install the screws (x8) that attach
the tonneau coverbox cross supports.Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
NoteSupports install in the same direction of the fasteners. -
Install the LH tonneau NVH
cover.
NoteMake sure the busbar clearance during installation to avoid damage to the NVH material.
-
Install the bolts (x5) that attach the
LH tonneau NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the RH tonneau NVH
cover.
-
Install the bolts (x6) that attach the
RH tonneau NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the Ancillary Access Bench, and
then put the air suspension reservoir into position for installation.
-
Install the nuts (x2) that attach the
air suspension reservoir.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Notex2 fir tree clips -
Secure the air suspension valve
block.
Notex3 rubber grommetsNoteRotate 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.NotePosition air lines and connections into place for installation.
-
Install a new VOSS air fitting to the
pressurize pack valve block at the ANC circuit.Tip: Use of the following tool(s) is recommended:
- 12 mm socket
Notex1 VOSS fittingNoteDo not remove the VOSS plastic plug until the pressurize pack line install. -
Secure the pressurize pack air line
from the ancillary to the valve block.
Notex1 lineNoteRemove 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.
-
Install the bolt that attaches the
pressurize pack valve block to the air suspension reservoir, and then connect the
electrical connector.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Notex1 clip, x1 zip tieNoteSecure the reservoir and ancillary air lines at the white marked sections. - Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
- Fully raise the vehicle.
- Remove all items from pockets and ensure not wearing metal items.
-
Inspect the HV insulating
gloves.
NoteCheck gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
-
Put on the HV insulating gloves and
leather over gloves.
-
Clean the mating surface of the
pyro.
NoteUse a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.CAUTIONDo not use any other types of cleaner.
- Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
- Remove the leather over gloves and HV insulating gloves.
-
Install new VOSS fittings and nut to
the pyro cover.Tip: Use of the following tool(s) is recommended:
- 12 mm 12-point deep socket
Notex2 VOSS fittingsNoteDo not remove the VOSS plastic plug until the pressurized pack line installation. -
Install the bolts (x4) that attach the
pyro fuse access cover.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
NoteMake sure that the seal is fully seated and undamaged. -
Install the pressurized pack lines
(x2).Tip: Use of the following tool(s) is recommended:
- 12 mm 6 point flare nut wrench
- 12 mm flare nut crowfoot socket
Notex2 VOSS fittingsNoteRemove 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. -
Install the mid aero shield.
Notex6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 NmNoteApply Loctite 222 onto mid aero shield bolts and install the fasteners.
- Lower the vehicle until the tires are touching the ground.
- Connect MV power. See Disconnect MV Power.
- Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Close the powered frunk.
- Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.