04/06/2024 18:02:44

AC Junction Box (Remove and Install)

Correction code 1630010221 1630010222 FRT 2.64 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

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.

Raise and support vehicle

Note
Set air suspension to "Jack Mode" if equipped
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
Unlock vehicle gateway

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes
Remove bed floor assembly

Note
10x bolts, 15mm, 56 Nm, Lift front edge with trim tool then remove panel, Recommend assistance to hand off panel
Release RH tonneau NVH cover

Note
6x bolts, 10mm, 5Nm, 2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal
Remove RH tonneau NVH cover

Note
Release rearward then slide over LH side NVH cover before removing upward
Release LH tonneau NVH cover

Note
5x bolts, 10mm, 5Nm
Remove LH tonneau NVH cover

Note
Slide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
Remove tonneau coverbox cross supports

Note
8x screws, T25, 5 Nm
Clean all debris from ancillary cover

Note
During removal of ancillary cover any debris on top of the cover may be deposited into the ancillary bay
Release pressurized pack air line to Ancillary

Note
1x connector, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released.
Remove VOSS fitting from pressurized pack air line to Ancillary

Note
1x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
Release pressurized pack valve block from air suspension reservoir

Note
1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Release lock before connector disengagement, Cut zip tie at reservoir/ancillary air line bundle, Release harness clip at bracket
Release air suspension valve block

Note
3x rubber grommets, Rotate clockwise until top 2 rubber feet have released from bracket, Pull upwards at 45 degree angle to release bottom rubber foot from bracket, Leave all air lines and connections secured and set assembly aside
Release air suspension reservoir

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips
Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).

Note
Raise and swing the air suspension reservoir to the side of the bed.
Open powergate

Note
Via exterior switch
Power down vehicle through center display

Note
Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Remove rear underhood apron

Note
9x clips
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

Note
2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Disconnect pressurized pack lines

Note
2x VOSS fittings, 12mm, 8Nm, Discard and replace
Remove VOSS fitting from pressurized pack air lines

Note
2x VOSS fitting, Slide threaded section back, Remove the collet, Then slide threaded section off of air line, Discard after removal
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves
Verify no HV - 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.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
Secure RDU header connector to ancillary

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
Remove Pyro Fuse Access cover

Note
4x bolts, E-Torx 5 lobe, 10Nm
Remove primary pyro fuse

Note
2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
Remove secondary pyro fuse

Note
2x bolts, 13mm, 5 Nm + 60 Degrees, Support pyro fuse while removing bolts
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
Disconnect ancillary bay MV connector

Note
1x connector, Double locking, Release tab then pivot lever, Release second tab to disengage connector, Wait 1 second between locking tab release to discharge and prevent arcing
Remove bolt securing busbar HV connector lid

Note
1x bolt, 10mm, 9 Nm
Remove bolts securing HV connector to DC FC header

Note
2x bolts, 10mm, 9 Nm
Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.

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.
Support HV Busbar assembly

Note
Suspend assembly to maintain clearance
Remove fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10Nm
Release low voltage header

Note
2x bolts, 10mm, 6 Nm
Release fasteners securing ancillary cover to HV battery

Note
22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary cover, Follow fastening order
Remove ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
Remove ACJB to PCS HV jumper harness

Note
2x connectors, Release locking tab and pull connector out of respective header, Do not pull on harness
Release ACJB LV connector & ACJB to device cluster HV connector

Note
2x connectors, Release connector locks, Depress levers and pull at connectors, Do not pull at harness
Release ancillary connectors to center console outlet and bed outlet

Note
2x connectors, Release locking tabs, Slide locks to release
Release ACJB header fastener

Note
1x bolt, T25, Torque??
Release ACJB fasteners

Note
6x bolts, E10 5 Lobe Torx, 6Nm
Release ACJB from ancillary tray

Note
2x clips, 2x datums, Release clips at headers, Slide ACJB inboard on datums
Remove ACJB from ancillary tray

Note
Lift over and out of PCS once headers clear outboard side of ancillary tray
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.

Note
Do not allow the grease to contact the busbar HV mating surfaces.
Install ACJB to ancillary tray

Note
Align headers and slide openings to datums in ancillary tray
Slide ACJB into ancillary tray until header clips are fully engaged

Note
Ensure all fastener holes are aligned
Secure ACJB fasteners

Note
6x bolts, E10 5 Lobe Torx, 6Nm
Secure ACJB header fastener

Note
1x bolt, T25, Torque??
Secure ancillary connectors to center console outlet and bed outlet

Note
2x connectors, Slide locks to fully engage, Secure locking tabs
Install ACJB to PCS HV jumper harness

Note
2x connectors, Secure at ACJB first then fold harness over to PCS, Secure locking tab on both connectors
Secure ACJB LV harness connector & ACJB HV harness to device cluster connector

Note
2x connectors, Secure connector locks
Install ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
Secure fasteners of cover to HV battery

Note
22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary cover, Follow fastening order
Secure low voltage header

Note
2x bolts, 10mm, 6 Nm
Secure fast charger header doubler

Note
2x bolts, E10 5 Lobe Torx, 10Nm
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.

Note
The grease is part number 1089958-00-A and is available from eProcurement.
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
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
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
Position busbar connector and lower onto HV header

Note
Release bungee cord
Install bolts securing charge port busbar kit to HV Header

Note
2x bolts, 10mm, 9 Nm
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

Note
2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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
Install bolt securing busbar HV connector lid

Note
1x bolt, 10mm, 9 Nm
Remove leather over gloves and HV insulating gloves
Connect Ancillary bay MV connector

Note
1x connector, double locking, Rotate lever into 2nd lock, Perform a pull test to ensure connector engaged correctly
Secure tonneau coverbox cross supports

Note
8x screws, T25, 5 Nm, Supports install in the same direction of the fasteners
Install LH tonneau NVH cover

Note
Ensure busbar clearance during install to avoid damage to NVH material
Secure LH tonneau NVH cover

Note
5x bolts, 10mm, 5Nm
Install RH tonneau NVH cover
Secure RH tonneau NVH cover

Note
6x bolts, 10mm, 5Nm
Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
Secure air suspension reservoir

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips
Secure air suspension valve block

Note
3x rubber grommets, Rotate counter-clockwise until top 2 rubber feet are secured onto bracket, Push downwards at 45 degree angle to secure bottom rubber foot into bracket, Position air lines and connections into place for installation
Install new VOSS air fitting to pressurized pack valve block at ANC circuit

Note
1x VOSS fitting, 12mm, 8 Nm, Do not remove VOSS plastic plug until pressurized pack line install
Secure pressurized pack air line from Ancillary to valve block

Note
1x line, Remove plastic cap from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
Secure pressurized pack valve block to air suspension reservoir

Note
1x bolt, 10mm, 5 Nm, 1x connector, 1x clip, 1x zip tie, Secure reservoir and ancillary air lines at white marked sections
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, Recommend assistance for installation
Raise vehicle fully
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves
Clean mating surface of the pyro

Note
Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner
Install secondary pyro fuse

Note
2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
Install primary pyro fuse

Note
2x bolts, 13mm, 5 Nm + 60 degrees, Support pyro fuse while installing bolts
Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar

Note
4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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
Remove leather over gloves and HV insulating gloves
Install Pyro Fuse Access cover

Note
4x bolts, E-Torx 5 lobe, 10Nm, Ensure seal is fully seated and undamaged
Install pressurized pack lines

Note
2x VOSS fittings, 12mm, 8 Nm, Remove plastic caps from VOSS fittings, Press air lines into fitting until mark aligns with top of fitting, Verify line is properly secured by performing push and pull test
Install Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 70 Nm, 3x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

Note
2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection
Install rear underhood apron

Note
9x clips
Close powergate

Note
Via exterior switch
Re-install software via UI

Note
Via Controls > Service Mode > Software Reinstall
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
Exit Service mode

Note
Press and hold the Exit Service Mode button for 3 seconds
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"