23/07/2024 17:31:42
HV Harnesses - HV Connector Header, Plug, 300mm2 (Remove and Install)
Correction code 4450074011 4450074012 FRT 1.14 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.
- 2024-05-08: Procedure overhaul based on latest re-validation.
- 2024-04-08: Cleaned up topic.
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.
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.
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Open LH front door
NotePush LH B-pillar door trigger to release
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Lower LH front window
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Raise and support vehicle
NoteSet air suspension to "Jack Mode"
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Open tonneau cover
NotePress forward arrow on LH bed rail
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Open tailgate
NotePress button to release
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Remove fastener covers from bed floor
assembly
Note6x covers
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Remove bed floor assembly
Note10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
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Release RH tonneau NVH cover
Note6x 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
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Remove RH tonneau NVH cover
NoteRelease rearward then slide over LH side NVH cover before removing upward
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Release LH tonneau NVH cover
Note5x bolts, 10mm, 5Nm
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Remove LH tonneau NVH cover
NoteSlide towards center, Ensure busbar clearance during removal to avoid damage to NVH material
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Open powered front trunk
NoteVia exterior switch or UI
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Remove rear underhood apron
Note9x clips
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Power down vehicle via UI
NoteVerify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
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Unlock fireman's loop connector and
disconnect, Slide eCPA to left on the MV battery connector then lift lever to
release
Note2x 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
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Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
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Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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Remove Mid-aero shield
Note6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
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Remove all items from pockets and ensure
not wearing metal items
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Inspect HV insulating gloves
NoteCheck 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
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Put on HV insulating gloves and leather
over gloves
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Verify no HV - Install amp clamp to RDU
HV harness
NoteVerify 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
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Secure RDU header connector to
ancillary
Note1x 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
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Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove bolt securing busbar HV connector
lid
Note1x bolt, EP10, 9 Nm
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Remove bolts securing HV connector to DC
FC header
Note2x bolts, 10mm, 9 Nm
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Release HV connector from DC FC
header
Note1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
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Raise CP busbar connector
Note2x inflatable bags, Install bags, Do not open tonneau to prevent damage
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Remove screws securing HV connector to
CP busbars
Note2x screws, T20, 1.5 Nm, Position mirror as needed
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Remove HV connector from CP
busbars
NoteGently pry between orange clips and primary heat sink, Pull evenly
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Position HV connector onto CP busbars
NotePush evenly, Make sure orange clips are flush with primary heat sink
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Install screws securing HV connector to
CP busbars
Note2x screws, T20, 1.5 Nm, Position mirror as needed
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Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
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Apply Penetrox onto HV connector
joints
NoteApply 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
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Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
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Lower CP busbar connector
Note2x inflatable bags, Remove bags, Do not open tonneau to prevent damage
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Position busbar connector and lower onto
HV header
NoteRelease bungee cord
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Install bolts securing charge port
busbar kit to HV Header
Note2x bolts, 10mm, 9 Nm
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Perform Hioki resistance test at each HV
joint from HV busbar lead to bolt head
Note2x 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), stop work and escalate the Toolbox session.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
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Install bolt securing busbar HV
connector lid
Note1x bolt, EP10, 9 Nm
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Slide eCPA to the right and ensure it is
seated against the black lever, Connect fireman's loop 20 seconds after eCPA
engagement
Note2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
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Install LH tonneau NVH cover
NoteEnsure busbar clearance during install to avoid damage to NVH material
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Secure LH tonneau NVH cover
Note5x bolts, 10mm, 5Nm
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Install RH tonneau NVH cover
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Secure RH tonneau NVH cover
Note6x bolts, 10mm, 5Nm
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Install bed floor assembly
Note10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
-
Install fastener covers onto bed floor
assembly
Note6x covers
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Install rear underhood apron
Note9x clips, Adjust windshield seal as required
-
Close powered front trunk
NoteVia exterior switch or UI
-
Close tonneau cover
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Close tailgate
-
Raise vehicle fully
NoteSet to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
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Install Mid-aero shield
Note6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aeroshield bolts and install fasteners
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Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
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Raise LH front window
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Close LH front door