2025-03-14

Ancillary Bay Cover (Remove and Replace)

Correction code 1630010282 0.78 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.

  • 2025-03-13: Added high voltage controller rework steps and aluminum tape retrofit patch direction.
  • 2025-03-13: Added image depicting the ancillary bay cover bolts torque sequence.
  • 2025-02-19: Added steps to remove the incompatible HVC standoff to accommodate the newer ancillary bay cover design.
  • 2024-07-30: Added information on installing a recycling warning label with CE marking and manufacturer information, if this was present on the ancillary bay cover being replaced.
Additional parts required for this operation (for Europe only):
  • 1108781-SH-F: LABEL - RECYCLING WARNING - EU
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Torque Specifications

Table 1. Torque Specifications: Ancillary Bay Cover (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x3) that attach the ancillary bay cover to the high voltage controller
5 Nm (3.7 lbs-ft) + 30 Degrees
  • 4 in extension
  • Ratchet/torque wrench
  • Torque wrench with angle measurement
  • External Torx E10 5-Lobe
  • Cordless Ratchet/Impact Driver
 Reuse
Bolts (x18) that attach the ancillary bay cover to the HV controller
8 Nm (5.9 lbs-ft)
  • Ratchet/torque wrench
  • 10 in extension
  • External Torx E10 5-Lobe
  • Cordless Ratchet/Impact Driver
 Reuse
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
Informational PurposesAn informational icon, calling your attention
Note
Torque these fasteners in the sequence specified in the installation step.
Informational PurposesAn informational icon, calling your attention
Note
These bolts are attached to the ancillary bay cover.

Remove

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.
  1. Disconnect the LV power. See LV Battery - Li-lon (Disconnect and Connect) (Modify).
  2. Remove the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  3. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  4. Disconnect the electrical harness from the high voltage controller connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The HV battery positive contactor and negative contactor open with a clunk sound.
  5. Install the logic connector cap onto the high voltage controller connector to prevent mistaken reconnection and protect the connector.
  6. Remove the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
    • External Torx E10 5-Lobe
    • Cordless Ratchet/Impact Driver
  7. Remove the bolts (x18) that attach the ancillary bay cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • External Torx E10 5-Lobe
    • Cordless Ratchet/Impact Driver
  8. Put on HV insulating gloves and leather outer gloves before continuing this procedure.
  9. Remove the ancillary bay cover from the vehicle.
  10. Inspect whether HV insulators are present. If not present or partly present, use the Ancillary Bay Insulator kit and install the insulator caps onto the HV battery to cover live HV points. See Insulators - HV Battery (Remove and Install).
  11. Visually inspect the condition of the ancillary bay cover gasket and the HV battery mating surface for cracks, cuts, gouges, abrasions, or any damage that could affect the seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the damage to the gasket is severe, replace the ancillary bay cover. If there is minor damage (including paint) that might affect the seal, perform an ancillary bay air leak test when instructed to do so.

Install

  1. For Europe only: Check the ancillary bay cover that is being replaced for the presence of a recycling warning label that includes a CE marking and manufacturer information.
    Figure 1. 1108781-BB-F shown, 1108781-SH-F similar
    • If the recycling warning label with CE marking and manufacturer information is not present on the ancillary bay cover being replaced, continue to the next step.
    • If the recycling warning label with CE marking and manufacturer information is present on the ancillary bay cover being replaced:
      1. Note the area where the recycling warning label is affixed on the ancillary bay cover being replaced.
      2. Clean the corresponding area on the new ancillary bay cover with an IPA wipe and allow 1 minute dry time.
      3. Install a new recycling label with CE marking and Manufacturing Information (part number 1108781-SH-F) on the new ancillary bay cover.
  2. If the old ancillary bay cover has volcano brackets, and the replacement ancillary bay cover does not have the same brackets, rework the High Voltage Controller (HVC) as required to achieve proper fitment between the replacement cover and HVC. If the replacement cover has volcano brackets, skip to the next step in this procedure.
    Figure 2. Replacement ancillary bay cover without volcano brackets
    Figure 3. Ancillary bay cover rework area; Cover shown installed for clarity
    Figure 4. HVC standoff to be removed; Ancillary bay cover shown removed for clarity
    1. Disconnect the ancillary bay harness from the HVC connectors.
    2. Remove the bolts that attach the HVC to the hinge tray, and then remove the controller from the vehicle.
      2 Nm (1.5 lbs-ft)
      Figure 5. 5-Bolt HVC
    3. Use a Dremel cut off wheel to remove the HVC standoff. Discard the standoff.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      Wear appropriate personal protective equipment (PPE) including cut-resistant gloves and safety glasses when performing this procedure.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not damage the HVC upper surface or surrounding standoffs.
      Informational PurposesAn informational icon, calling your attention
      Note
      Cut as close towards the base of the standoff as possible.
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • Dremel Accessory Kit, 110 Piece
    4. Apply electrical tape over the HVC standoff hole.
      Informational PurposesAn informational icon, calling your attention
      TIp
      Use of the following tool(s) is recommended:
      • Electrical Tape
    5. Install the HVC into the ancillary bay, and then install the bolts that attach the HVC to the hinge tray.
      2 Nm (1.5 lbs-ft)
    6. Connect the ancillary bay harness to the HVC connectors.
  3. Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
  4. If the aluminum tape retrofit patch is missing or damaged, remove the patch (if present), clean the area with an IPA wipe, apply another patch of aluminum tape, and wet out the patch with a silicone roller to set the adhesive.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 3M 425 Aluminum Foil Tape - 0601363
    Figure 6. 5-Bolt to 4-Bolt Patch 50mm x 50mm
    Figure 7. 4-Bolt to 3-Bolt Patch 30mm x 30mm
  5. Remove all insulator kit covers from the HV battery. See Insulators - HV Battery (Remove and Install).
  6. Position the ancillary bay cover to the HV battery.
  7. Remove the HV insulating gloves.
  8. Install the bolts (x18) that attach the ancillary bay cover to the HV battery in the sequence as shown.
    8 Nm (5.9 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 10 in extension
    • External Torx E10 5-Lobe
    • Cordless Ratchet/Impact Driver
  9. Install the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
    5 Nm (3.7 lbs-ft) + 30 Degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
    • External Torx E10 5-Lobe
    • Cordless Ratchet/Impact Driver
  10. Remove the logic connector cap from the high voltage controller connector.
  11. Connect the electrical harness to the high voltage controller connector.
  12. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  13. Connect the LV power. See LV Battery - Li-lon (Disconnect and Connect) (Modify).