Harness - Ancillary Bay
Correction code 1630010322 3.72 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.
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Raise and support vehicle
NoteEnsure vehicle is not charging
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Open all four doors
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Lower all four windows
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Move LH front seat forward
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Move RH front seat forward
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Release 2nd row seat cushion and disconnect harness
Note2x clips, 2x connectors, Press tabs backward then pull front edge up
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Open hood
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Remove rear underhood apron
Note14x clips
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Place vehicle in service mode
NoteVia UI > Controls > Software, Touch and hold "Model 3" for 4 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
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Unlock vehicle gateway
NoteAfter 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, follow steps on Toolbox article #5582900 for any additional information
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Run Thermal Fill Drain (Coolant Only) through the UI
NoteSelect Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has 50 minutes time limit, After 50 minutes routine must be performed again
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Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Disconnect LV battery and First Responder Loop
Note2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
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Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
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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
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
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Remove ancillary bay probe lid cover from ancillary bay cover
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Verify no high voltage
NoteMake 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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Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
NoteConfirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time
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Install bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
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Fold 2nd row 60 seat back down
NotePull release, Fold down, Protect seat cushion if necessary
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Remove LH side bolster
Note1x locator clip, 3x guide tabs, Pull outward then slightly upward to remove
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Remove bolster plastic bracket from LH side body
Note2x clips, If necessary, Depress clips from behind, this bracket may come out with bolster, Discard after removal
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Move 2nd row 60 seat back into vertical
position
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Partially release LH front primary door seal
NoteRelease lower section of LH front primary door seal
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Remove LH IP end cap
Note5x clips, 2x guide tabs
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Remove clip securing LH lower A-pillar assembly
Note1x push clip
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Remove LH lower A-pillar assembly
Note4x clips, 2x guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
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Remove LH lower B-pillar assembly
Note7x clips, 4x locator clips, Pull the trim panel outward in the direction of the arrow to release clip from lower B-pillar
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Remove bolts securing sadface bracket to vehicle
Note2x bolts, 10mm, 10 Nm
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Remove sadface bracket from vehicle
Note1x Positioning clip
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Remove fastener securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Remove bolts securing charge port busbar kit to HV header
Note2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please remove the AC charging interface
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Remove AC chargeport inlet harness clip
Note1x clip
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Lift busbar kit connector to remove from HV header
Note4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward
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Position chargeport busbar connector for access below
NoteRest on cross-member in front of penthouse
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Remove HV insulating gloves
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Disconnect HVC logic connector and install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
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Remove bolts securing ancillary bay cover to HVC
Note3x bolts, E10, 5 Nm + 30 degrees
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Remove bolts securing ancillary bay cover to HV battery
Note18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Remove ancillary bay cover from HV battery
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Inspect ancillary bay for any missing insulators
NoteInstall service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary
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Remove bolts securing pyro disconnect to ancillary bay
Note1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
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Remove pyro disconnect from ancillary bay
Note1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
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Install pyro disconnect dummy
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Use bungee to secure HVC in an upwards position
NoteWrap bungee around RH headrest
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Raise vehicle fully and lower lift onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects
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Remove rear aero shield clips
Note2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner
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Remove rear aero shield
Note11x bolts, 10mm, 5 Nm
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Release LH side hose clip from rear battery skid plate enclosure
Note1x fir tree clip
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Release RH side hose clips from rear battery skid plate enclosure
Note2x fir tree clips
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Remove lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count
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Remove upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
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Remove upper bolts securing HV battery rear skid plate enclosure
Note4x bolts, 13mm, 35 Nm
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Remove HV battery rear skid plate enclosure
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Position coolant drain container underneath LH rear of HV battery
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Remove fir tree clip securing coolant hose to rear subframe shear plate
Note1x fir tree clip
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Disconnect RDU inverter inlet tube from LH rear of HV battery
Note1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
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Attach coolant drain hose adapter to PCS outlet hose coupling
NoteUse adapter with 90 degree angle, Make sure locking tab is fully seated
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Attach coolant drain hose adapter to coolant hose extension
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Attach coolant hose extension to coolant drain hose
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Position coolant drain container underneath RH rear of vehicle
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Disconnect rear PT supply hose from rear of HV battery
Note1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
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Attach coolant pressure tester to PCS inlet hose coupling
NoteThis adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
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Attach coolant pressure tester to pressure fitting adapter
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Connect compressed air to coolant pressure tester
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Open regulator valve then slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Close regulator valve
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Open regulator valve slowly
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Close regulator valve
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Disconnect compressed air from coolant pressure tester
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Remove coolant pressure tester from PCS inlet hose coupling
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Position coolant drain container underneath LH rear of HV battery
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Remove coolant drain adapter with hose from PCS outlet hose coupling
Note1x spring clip
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Attach coolant pressure tester with hose to PCS outlet hose coupling
Note1x spring clip, Make sure the locking tab is fully seated
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Position coolant drain container underneath RH rear of vehicle
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Attach coolant drain adapter with hose to PCS inlet hose coupling
Note1x spring clip, Make sure the locking tab is fully seated
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Connect compressed air to coolant pressure tester
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Open regulator valve then slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Open 2nd valve slowly
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Close regulator valve
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Open regulator valve slowly
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Set timer for 1 minutes and select start
NoteOnce timer is complete, select Stop Reset
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Close regulator valve
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Disconnect compressed air from coolant pressure tester
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Disconnect coolant hose extension from coolant drain hose
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Disconnect coolant drain hose adapter from coolant hose extension
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Remove coolant drain hose adapter from PCS inlet hose coupling
Note1x spring clip
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Position coolant drain container underneath LH rear of HV battery
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Remove pressure fitting adapter from coolant pressure tester
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Remove coolant pressure tester from PCS outlet hose coupling
Note1x spring clip
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Remove coolant drain container from underneath vehicle
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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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Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
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Disconnect PCS coolant inlet hose from PCS
Note2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose
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Disconnect PCS coolant outlet hose from PCS
Note2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS and hose
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Disconnect PCS to DC bus HV connector
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS logic connector from PCS
Note1x connector
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Disconnect PCS LV connector from PCS
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS to AC harness connector
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Remove bolts securing PCS to HV battery
Note5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners
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Secure suction cups to PCS
NoteContinue pressing plunger until red line is no longer visible
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Lift PCS up and out of ancillary bay area and remove from vehicle
NoteSlightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary
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Install HV joint insulator for positive busbar module 2 to pyro disconnect
Note1x insulator
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Install HV joint insulator for negative busbar module 3 to shunt
Note1x insulator
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Install HV joint insulator for positive DC link to module 4
Note1x insulator
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Remove HV joint insulator for negative busbar module 3 to shunt
Note1x insulator
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Disconnect ancillary bay harness connectors from positive pack contactor
Note2x connectors
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Remove ancillary bay harness clip from positive pack contactor
Note1x clip
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Remove HV joint insulators from positive HV switch
Note2x insulators
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Remove bolt securing positive pack contactor to positive busbar
Note1x patch bolt, 13mm, 9 Nm, Discard after removal
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Remove nut securing positive pack contactor to module 4 rear terminal
Note1x patch nut, 13mm, 9 Nm, Discard after removal
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Remove nuts securing positive pack contactor to ancillary bay
Note3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
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Remove positive pack contactor from ancillary bay
Note2x guide pins
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Release positive LV output cover from PCS cable
Note1x cover
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Remove bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
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Remove nut securing DCDC ground busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Discard nut after removal
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Remove DCDC ground busbar
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Remove nut securing positive LV output from PCS cable and move cable aside
Note1x nut, 13mm, 9 Nm, Discard after removal
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Remove bolts securing DCDC pass through to ancillary bay
Note2x bolts, E10 5-Lobe, 10 Nm
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Remove DCDC pass through from ancillary bay
NoteElectrical Protective Gloves
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Remove HV joint insulator for positive DC link to module 4
Note1x insulator
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Remove AC filter harness from FC contactor cover
Note1x connector, Release locking tab, 1x harness clip
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Disconnect megaharness connector from DC input assembly
Note1x connector
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Remove the bolts securing the busbar AC input assembly to ancillary bay
Note2x bolts, E10 5-Lobe, 10 Nm, Discard after removal
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Release 3PH AC Filter Harness from 3PH 4P Header
Note2x tabs, Lift connector off HV battery for access
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Remove the 3PH AC Filter harness from the vehicle
NoteHarness must be removed through the ancillary bay, PCS connector does not fit through the header hole
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Remove insulator for DC input assembly
to both fast charge busbar inlet side
Note1x insulator
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Remove bolt securing negative fast
charge busbar inlet side and negative DC input assembly busbar
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
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Remove bolt securing positive fast
charge busbar inlet side and positive DC input assembly busbar
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
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Remove bolts securing busbar DC input assembly to ancillary bay
Note4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
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Remove Busbar DC input assembly from ancillary bay
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Disconnect ancillary bay harness connectors from negative pack contactor
Note2x connectors
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Disconnect LV fast charge contactor
connector
Note1x connector, Press tabs on both sides by hand and disconnect the connector upwards
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Remove harness clips from FC contactor cover
Note1x clip
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Remove harness clips from FC contactor cover
Note2x clips, Move the wiring harness around the FC cover aside
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Remove ancillary bay left terminals cover
Note2x tabs, 1x datum
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Remove bolt securing negative fast
charge busbar DC link side
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_007
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Remove bolt securing positive fast
charge busbar DC link side
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Discard after removal, 0300_006
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Remove bolts and nut securing FC assembly to ancillary bay
Note2x bolts, 10mm, 5.5 Nm
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Remove the FC assembly from ancillary bay
Note2x guide pins
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Remove the LH daisy chain pass through housing from ancillary bay
Note3x clips, 1x harness clip, Insert UFO harness removal tool beneath daisy chain pass through housing, Insert tab release tool to release bottom 2x clips, Release top 3x clips with trim tool, Pull daisy chain pass through housing upward to remove
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Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X480 – Shunt at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X484 – Pyro disconnect at HVC from HV Controller
Note1x connector
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Disconnect HV controller connector X479 –Main HVC connector from HV Controller
Note1x connector
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Remove megaharness clips from HV controller hinge tray
Note5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife
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Remove screws securing HVC tray assembly to ancillary bay
Note2x screws, T25, 2 Nm, 3x wires routed through RH hinge, Pull slightly forward on HVC at ~45 degree angle to access fastener between hinge and tray
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Remove the HVC and tray assembly from ancillary bay
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Remove X423 connector from DC link busbar
Note1x connector, Release locking tab1x clip
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Remove the pyro disconnect logic connector
Note1x connector, 1x clip
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Disconnect shunt assembly connector
Note1x connector, Release locking tab
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Release harness from shunt insulator
Note1x clip
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Remove X422 connector from DC link busbar
Note1x connector, Release locking tab
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Remove the X421 connector from the DC connection bus
Note1x connector, Release locking tab
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Remove RH daisy chain pass through housing from ancillary bay
Note3x clips, Insert UFO harness removal tool beneath daisy chain pass through housing, Insert tab release tool to release bottom 2x clips, Release top 3x clips with trim tool, Pull daisy chain pass through housing upward to remove
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Remove nut securing DC link to module 4
Note1x patch nut, 13mm, 9 Nm, Discard after removal
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Move positive DC link out to allow access to ancillary bay harness clips
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Remove ancillary bay harness clips from positive DC link
Note3x clips
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Remove positive DC link from ancillary bay
Note2x guide pins
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Cut cable ties securing the megaharness to charger output to DC bus harness
Note2x cable ties
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Remove the Ancillary bay harness assembly fixing clip from the DC link
Note5x clips
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Remove the tab from the DC link shell
Note1x tab, When removing a tab,it should break off along the bottom edge, Do not leave any sharp corners that may damage the wiring harness.
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Remove megaharness from ancillary bay
Note1x harness
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Position megaharness to ancillary bay for installation
Note1x harness
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Fix the Ancillary bay harness assembly to the DC link
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Install new cable ties securing the megaharness to charger output to DC bus harness
Note2x cable tie, cut off any excess cable ties
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Install the RH daisy chain pass through housing to ancillary bay
Note3x clips, 2x bottom clips
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Position the positive DC link for installation
Note2x guide pins
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Install ancillary bay harness clips to positive DC link
Note3x clips
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Install nut securing joint DC link to module 4
Note1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque
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Perform resistance measurement on DC link to module 4 and busbar
Note1x HV joint, 60μΩ or less
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Install HV joint insulator for positive DC link to module 4
Note1x insulator
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Install the X423 connector onto the DC bus
Note1x connector1x clip
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Install the pyro disconnect logic connector
Note1x connector, 1x clip
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Install harness to shunt insulator
Note1x clip
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Connect shunt assembly connector
Note1x connector
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Install the X422 connector onto the DC bus
Note1x connector
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Install the X421 connector onto the DC bus
Note1x connector
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Install the LH daisy chain pass through housing to ancillary bay
Note3x clips, 2x bottom clips, 1x harness clip
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Position FC assembly to ancillary bay for installation
Note2x guide pins
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Install bolts securing FC assembly to ancillary bay
Note2x bolts, 10mm, 5.5 Nm, Mark after torque
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Install and torque bolt securing
positive fast charge busbar DC link side to first value, loosen 180 degrees, and then
torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
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Install and torque bolt negative fast
charge busbar DC link side to first value, loosen 180 degrees, and then torque to final
value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
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Perform Hioki impedance test at the
positive HV joint of the fast charge busbar DC link side
Note1x HV joint, 25μΩ or less
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Perform Hioki impedance test at the
negative HV joint of the fast charge busbar DC link side
Note1x HV joint, 55μΩ or less
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Install ancillary bay left terminals cover
Note2x tabs, 1x datum
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Install harness clips to FC contactor cover
Note2x clips
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Install ancillary bay harness clip around negative pack contactor area
Note1x clip
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Connect LV fast charge connector
Note1x connector
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Connect ancillary bay harness connectors to negative pack contactor
Note2x connectors
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Install Busbar DC input assembly to ancillary bay
NoteEnsure seal is not damaged and seated properly
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Install bolts securing Busbar DC input assembly to ancillary bay
Note4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
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Install and torque bolt securing
negative fast charge busbar inlet and negative DC input link to first value, loosen 180
degrees, and then torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
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Install and torque bolt securing
positive fast charge busbar inlet and positive DC input link to first value, loosen 180
degrees, and then torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degrees, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
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Perform Hioki resistance test at both HV joints of DC input assembly busbar
Note2x HV joints, 60μΩ or less, Test from negative fast charge busbar to negative DC input busbar and positive fast charge busbar to positive DC input busbar
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Install insulator for DC input assembly
to both fast charge busbars inlet side
Note1x insulator
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Route 3PH AC Filter Harness from the ancillary bay up through HV battery
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Install 3PH AC Filter harness to the 3PH 4P Header
Note2x tabs, Inspect seal on 3PH header for any damage and replace as needed
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Install the bolts securing the Busbar AC input assembly to ancillary bay
Note4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
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Install AC filter harness to FC contactor cover
Note1x connector, Secure locking tab, 1x harness clip
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Connect megaharness connector to DC input assembly
Note1x connector
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Position DCDC pass through to ancillary bay for installation
NoteElectrical Protective Gloves
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Install bolts securing DCDC pass through to ancillary bay
Note2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
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Install positive LV output
Note1x nut, 13mm, 9 Nm, Make sure rubber boot is not pinched between cable terminal and pass through
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Install positive LV output cover to PCS cable
Note1x cover
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Install DCDC ground busbar
NoteSlotted hole goes to body side
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Install bolt securing DCDC ground busbar to body
Note1x bolt, 12mm, 20 Nm
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Install nut securing DCDC ground busbar to HV battery
Note1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut
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Position positive pack contactor to ancillary bay for installation
Note2x guide pins
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Install nuts securing positive pack contactor to ancillary bay
Note3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary
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Install bolt securing positive pack contactor to positive busbar
Note1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque
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Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
Note1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
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Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal
Note1x HV joint, 110μΩ or less
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Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
Note1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
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Install HV joint insulators onto positive pack contactor
Note2x insulators
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Install ancillary bay harness clip to positive pack contactor
Note1x clip
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Connect ancillary bay harness connectors to positive pack contactor
Note2x connectors
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Position HVC tray assembly in ancillary bay
Note4x locating pins, 3x wires routed through RH hinge
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Secure HVC tray assembly to ancillary bay
Note2x screws, T25, 2 Nm
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Connect HV controller connector X479 –Main HVC connector to HV Controller
Note1x connector
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Connect HV controller connector X484 – Pyro disconnect at HVC to HV Controller
Note1x connector
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Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller
Note1x connector
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Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller
Note1x connector
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Connect HV controller connector X480 – Shunt at HVC to HV Controller
Note1x connector
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Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller
Note1x connector
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Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller
Note1x connector
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Install the megaharness clips to HV
controller hinge tray
Note5x harness clips, 1x tape, Wrap harness tape around the hinge tray again
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Install HV joint insulator for negative busbar module 3 to shunt
Note1x insulator
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Position the PCS into ancillary bay
NoteEnsure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary
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Remove suction cups from PCS
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Install bolts securing PCS to HV battery
Note5x bolts, 8mm, 18 Nm
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Connect PCS to fast charge contactor HV
harness connector
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Connect PCS LV connector to PCS
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Connect PCS logic connector to PCS
Note1x connector
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Connect PCS to DC bus HV connector
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Replace o-ring on PCS side inlet hose
Note1x o-ring, Apply light amount of Krytox 203
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Connect PCS coolant inlet hose to PCS
Note2x clips, 1xplug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated
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Replace o-ring on PCS side outlet hose
Note1x o-ring, Apply light amount of Krytox 203
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Connect PCS coolant outlet hose to PCS
Note2x clips, 1x plug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Visually inspect area for any coolant residue, Clean with shop towel if necessary
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Lay HVC in original position
NoteRelease bungee from back of headrest
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Remove pyro disconnect dummy
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Clean mating surfaces
NoteAllow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect
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Set multimeter to "LoZ" (low impedance) mode
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Measure voltage between busbar and shunt
NoteWhile still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars
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Position pyro disconnect to ancillary bay for installation
Note1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
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Install bolts securing pyro disconnect to ancillary bay
Note2x patch bolts, 13mm, 9 Nm
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Measure resistance from module 2 busbar to pyro disconnect
Note1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing
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Measure resistance from pyro disconnect to shunt
Note1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing
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Remove service insulator kit
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Clean HV connector contact surface of residual Penetrox
NoteAllow 1 minute dry time, New busbar comes with penetrox applied to HV connector
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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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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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Position busbar kit connector and lower onto HV header
Note4x guide tabs, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
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Install AC chargeport inlet harness clip
Note1x clip
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Install bolts securing charge port busbar kit to HV header
Note2x bolts, 10mm, 9 Nm. If 3PH vehicles are involved, please install the AC charging interface
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Note2x HV joints, 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), 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 fastener securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Inspect ancillary bay walls for damage
NoteAny dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
-
Inspect ancillary bay cover seal to confirm it has no visual damage
NoteImage up close for clarity, Delaminated and torn seals cannot be reused
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Position ancillary bay cover to HV battery for installation
NoteEnsure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
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Remove HV insulating gloves
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Install bolts securing ancillary bay cover to HV battery
Note18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
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Install bolts securing ancillary bay cover to HVC
Note3x bolts, E10, 5 Nm + 30 degrees
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Remove logic cap and connect HVC logic connector
Note1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
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Install sadface bracket into vehicle
Note1x Positioning clip
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Install bolts securing sadface bracket to vehicle
Note2x bolts, 10mm, 10 Nm
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Install LH lower B-pillar assembly
Note7x clips, 4x locator clips, Align the locator clips to slot, Then push in the direction of the arrow to install the clips after aligning them, Make sure the seal sits overlapping the trim
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Install LH lower A-pillar assembly
Note4x clips, 2x guide tabs, Align 2 front tabs then align slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim
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Install clip securing LH lower A-pillar assembly
Note1x push clip
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Install LH IP end cap
Note5x clips, 2x guide tabs
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Install LH front primary seal
NoteVerify seal is seated properly on all trim panels
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Fold 2nd row 60 seat back down
NotePull release, Fold down, Protect seat cushion if necessary
-
Install bolster plastic bracket to LH side bolster
Note2x tabs, Install new bolster bracket
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Install LH side bolster
Note1x locator clip, 3x guide tabs, Align bottom and side tabs then push inward to install
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Return 2nd row 60 seat back to vertical
position
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Connect 2nd row seat harness and secure cushion
Note2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
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Raise vehicle fully and lower lift onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
-
Position coolant drain container underneath RH rear of vehicle
-
Install coolant pressure test plug adapter to PCS inlet hose coupling
Note1x spring clip, 1x plug, Remove plug from inlet hose coupling, Make sure the locking tab is fully seated
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Position coolant drain container underneath LH rear of HV battery
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Install coolant pressure tester to PCS outlet hose coupling
Note1x spring clip, 1x plug, Remove plug from outlet hose coupling, Make sure the locking tab is fully seated
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Install pressure fitting adapter to coolant pressure tester
-
Connect compressed air to coolant pressure tester
-
Open regulator valve then slowly adjust regulator to 50 psi
-
Slowly open valve on pressure regulator and allow pressure to reach specification
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Close the valve and let pressure settle
NoteWait 2 minutes for pressure to settle, Record the reading
-
Perform the coolant pressure leak test
NoteWait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
-
Remove pressure fitting adapter from coolant pressure tester
-
Remove coolant pressure tester from PCS outlet hose coupling
Note1x spring clip
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Remove plug from HV battery and connect RDU inverter inlet tube
Note1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged
-
Position coolant drain container underneath RH rear of vehicle
-
Remove coolant pressure test plug adapter from PCS inlet hose coupling
Note1x spring clip
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Connect rear PT supply hose to rear of HV battery and plug hose
Note1x spring clip, 1x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated. Vacuum fill required if > 1L lost during repair
-
Remove coolant drain container from underneath vehicle
-
Install fir tree clip securing coolant hose to rear subframe shear plate
Note1x fir tree clip
-
Position HV battery rear skid plate enclosure onto HV battery for installation
NoteRecommend assistance if needed
-
Install upper bolts securing HV battery rear skid plate enclosure hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
-
Install upper nut securing HV battery rear skid plate enclosure hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
-
Install lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
-
Torque bolts securing HV battery rear skid plate enclosure to vehicle
Note4x bolts, 13mm, 35 Nm
-
Torque upper nut securing HV battery rear skid plate enclosure
Note1x nut, 10mm, 13 Nm
-
Install RH side hose clips to HV battery rear skid plate enclosure
Note2x fir tree clips
-
Install LH side hose clip to HV battery rear skid plate enclosure
Note1x clip
-
Install rear aero shield
Note11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
-
Install LH and RH clips securing rear aero shield to wheel house liner
Note2x clips
-
Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Remove coolant bottle cap
-
Place empty coolant container into front storage area
-
Fill container with at least 15L of coolant
-
Place filled coolant container into front storage area
-
Install refill tool cap onto coolant bottle assembly
-
Setup vacuum refill tool
NoteVerify all valves on refill tool are in the closed position, See image for clarity
-
Install vacuum refill hose into refill cap on coolant bottle
NotePerform push-pull-push test to verify hose is fully engaged
-
Position overflow hose into empty container
-
Place refill hose inside filled coolant container
NoteMake sure hose end is fully submerged into coolant
-
Connect shop air supply to coolant refill tool
NoteIf not already done, Verify refill valve is set to off
-
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
NoteGauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
-
Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant
NoteThis purges trapped air from the hose
-
Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system
-
Reopen air inlet valve for 3 minutes to continue evacuating cooling system, then close valve
-
Slowly open refill valve to allow coolant to be drawn into system
NoteMake sure hose end of refill hose is fully submerged during entire process
-
Once gauge reads zero, close refill valve
-
Disconnect shop air supply from coolant refill tool
-
Remove coolant refill hose from coolant container
-
Remove coolant overflow hose from coolant container
-
Remove vacuum refill hose from refill cap on coolant bottle
-
Remove coolant refill tool from vehicle
-
Remove both coolant containers from inside underhood area
-
Connect First Responder Loop and LV battery
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
-
Unlock vehicle gateway
NoteAfter 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, follow steps on Toolbox article #5582900 for any additional information
-
Access Thermal System routines using UI
NoteSelect Service mode > Thermal
-
Select "Stop Thermal Fill Drain" through UI
NoteAllow routine to complete, ensure routine is successful
-
Select "Coolant Purge Start" using UI
NoteWait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time, it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
-
Exit Service Mode
NoteVia UI > Service > Exit, Press and hold "Exit Service Mode" button
-
Inspect coolant level and top off as necessary
NoteEnsure that fluid level is at Max line
-
Install coolant bottle cap
-
Install rear underhood apron
Note14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
-
Close hood
-
Move RH front seat to original position
-
Move LH front seat to original position
-
Raise all windows
-
Close all four doors
-
Remove lift arms from below vehicle
NoteLower rack arms fully and remove them from under vehicle