05/06/2024 20:06:56

Ancillary Bay - Busbar, FC Contactor To DC BUS, POS (Remove and Replace)

교정 코드 1630010072 FRT 1.62 참고: 절차에서 명시적으로 언급하지 않는 한 위 교정 코드 및 FRT는 연결된 절차를 포함하여 이 절차를 수행하는 데 필요한 모든 작업을 반영합니다. 명시적으로 지시하지 않는 한 교정 코드를 누적하지 마십시오. 참고: FRT와 그 생성 방법에 대한 자세한 내용은 표준 정비 작업시간을 참조하십시오. FRT 값에 대한 피드백을 제공하려면 LaborTimeFeedback@tesla.com으로 이메일을 보내십시오. 참고: 아래 절차를 수행할 때 개인 보호을(를) 참조하여 적절한 PPE를 착용했는지 확인하십시오.

경고

이 절차는 검증되었지만 초안입니다. 경고와 주의사항이 누락되었을 수 있습니다. 고전압 시스템 및 구성 요소에서 또는 그 근처에서 작업하는 경우에는 안전 요구 사항을 준수하고 최고 수준의 주의를 기울여야 합니다. 수정 사항 및 기타 의견이 있으면 ServiceDevelopment@teslamotors.com으로 알려 주십시오.

탈거

Open all doors and lower all windows.
Move both front seats forward.
Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
Fold 2nd row 60 seatback down

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Pull release, Fold down, Protect the seat cushion if necessary
Remove LH side bolster

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1x locator clip, 3x guide tabs, Pull outward then slightly upward to remove
Remove bolster plastic bracket from LH side body

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2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
Move 2nd row 60 seatback into vertical position
Release 2nd row seat cushion and disconnect harness

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2x clips, 2x connectors, Press tabs backward then pull front edge up
Partially release LH front primary door seal

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Release the lower section of LH front primary door seal
Remove LH IP end cap

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5x clips, 2x guide tabs
Remove clip securing LH lower A-pillar assembly

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1x push clip
Remove LH lower A-pillar assembly

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4x clips, 2x guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
Remove LH lower B-pillar assembly

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7x clips, 4x locator clips, Pull the trim panel outward in the direction of the arrow to release clip from lower B-pillar
Remove bolts securing sadface bracket to vehicle

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2x bolts, 10mm, 10 Nm
Remove sadface bracket from vehicle

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1x Positioning clip
Verify operation of multimeter

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Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

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Check 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
Put on HV insulating gloves and leather over gloves

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Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

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2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from the ancillary bay cover
Verify no high voltage

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Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

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Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time
Install bolts securing ancillary bay probe lid cover to ancillary bay cover

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2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
Remove fastener securing busbar cover access door

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1x bolt, 10mm, 9 Nm
Remove bolts securing charge port busbar kit to HV header

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2x bolts, 10mm, 9 Nm
Remove AC chargeport inlet harness clip

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1x clip
Lift busbar kit connector to remove from HV header

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4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward
Position chargeport busbar connector for access below

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Rest on cross-member in front of ancillary bay
Remove HV insulating gloves
Disconnect HVC logic connector and install logic cap

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1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove fasteners securing ancillary bay cover to high voltage controller (HVC)

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3x bolts, E10, 5 Nm + 30 degrees
Remove bolts securing ancillary bay cover to HV battery

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18x 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
Inspect HV insulating gloves

참고
Check 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
Put on HV insulating gloves and leather over gloves

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Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove ancillary bay cover from HV battery
Inspect the ancillary bay for any missing insulators

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Install any missing insulators that are accessible before continuing to next step, The number of bolts on newer vehicles may vary
Remove bolts securing pyro disconnect to ancillary bay

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2x insulators, patch bolts, 13mm, 9 Nm, Discard after removal
Remove pyro disconnect from ancillary bay

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1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
Install pyro disconnect dummy
Remove ancillary bay harness clip around negative pack contactor area

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1x clip
Disconnect ancillary bay harness connectors from negative pack contactor

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2x connectors
Remove HV joint insulators from negative pack contactor

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2x insulators
Remove bolt securing negative pack contactor to DC link busbar joint

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1x patch bolt, 13mm, 9 Nm, Discard after removal
Remove nut securing negative pack contactor to HV battery tall silicon terminal

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1x patch nut, 13mm, 9 Nm, Discard after removal
Remove nuts securing the negative pack contactor to ancillary bay

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3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
Remove the negative pack contactor from ancillary bay

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2x guide pins
Disconnect LV fastcharge contactor connector

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1x connector, Press tabs on both sides by hand and disconnect the connector upwards
Disconnect PCS to AC harness connector

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1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Remove AC filter harness from FC contactor cover

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1x connector, Release locking tab, 1x harness clip
Remove harness clips from FC contactor cover

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2x clips, Move the wiring harness around the FC cover aside
Remove ancillary bay left terminals cover

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2x tabs, 1x datum
Remove bolt securing negative fastcharge busbar DC link side

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_007
Remove bolt securing positive fastcharge busbar DC link side

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_006
Disconnect megaharness connector from DC input assembly

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1x connector
Remove insulator for DC input assembly to both fastcharge busbar inlet side

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1x insulator
Remove bolt securing negative fastcharge busbar inlet side and negative DC input assembly busbar

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5 Nm + 60 degrees, Discard after removal
Remove bolt securing positive fastcharge busbar inlet side and positive DC input assembly busbar

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5 Nm + 60 degrees, Discard after removal
Remove bolts securing busbar DC input assembly to ancillary bay

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4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
Remove Busbar DC input assembly from ancillary bay
Remove bolts and nut securing FC assembly to ancillary bay

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2x bolts, 10mm, 5.5 Nm
Remove the FC assembly from ancillary bay

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2x guide pins
Remove and discard FC insulator cover from FC assembly

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8x clips, 1x alignment pin
Remove DC link positive busbar from fastcharge contactor

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_003

장착

Install and torque bolt securing DC link positive busbar to fastcharge contactor to first value, loosen 180 degrees, and then torque to final value

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
Install new FC insulator cover to FC assembly

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8x clips, 1x alignment pin
Position FC assembly to ancillary bay for installation

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2x guide pins
Install bolts securing FC assembly to ancillary bay

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2x bolts, 10mm, 5.5 Nm, Mark after torque
Install Busbar DC input assembly to ancillary bay

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Ensure seal is not damaged and seated properly
Install bolts securing Busbar DC input assembly to ancillary bay

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4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
Install and torque bolt securing negative fastcharge busbar inlet and negative DC input link to first value, loosen 180 degrees, and then torque to final value

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
Install and torque bolt securing positive fastcharge busbar inlet and positive DC input link to first value, loosen 180 degrees, and then torque to final value

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
Perform Hioki resistance test at both HV joints of DC input assembly busbar

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2x HV joints, 60_xD835__xDF07_Ω or less, Test from negative fastcharge busbar to negative DC input busbar and positive fastcharge busbar to positive DC input busbar
Install insulator for DC input assembly to both fastcharge busbars inlet side

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1x insulator
Connect megaharness connector to DC input assembly

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1x connector
Install and torque bolt securing positive fastcharge busbar DC link side to first value, loosen 180 degrees, and then torque to final value

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
Perform Hioki impedance test at the positive HV joint of the fastcharge busbar DC link side

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1x HV joint, 25_xD835__xDF07_Ω or less
Install and torque bolt negative fastcharge busbar DC link side to first value, loosen 180 degrees, and then torque to final value

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1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
Perform Hioki impedance test at the negative HV joint of the fastcharge busbar DC link side

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1x HV joint, 55_xD835__xDF07_Ω or less
Install ancillary bay left terminals cover

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2x tabs, 1x datum
Install harness clips to FC contactor cover

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2x clips
Connect LV fastcharge connector

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1x connector
Install AC filter harness to FC contactor cover

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1x connector, Secure locking tab, 1x harness clip
Connect PCS to fastcharge contactor HV harness connector

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1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Position negative pack contactor to ancillary bay for installation

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Align the 2x guide pins
Install nuts securing the negative pack contactor to ancillary bay

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3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary, Mark after torque
Install bolt securing negative pack contactor to DC link busbar joint

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1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque
Install nut securing negative pack contactor to HV battery tall terminal

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1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
Perform Hioki impedance test at the HV joint of the negative pack contactor to negative DC link busbar

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1x 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), 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 less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
Perform Hioki impedance test at the negative pack contactor to module 1 rear terminal

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1x HV joint, 110_xD835__xDF07_Ω or less
Install HV joint insulators to negative pack contactor

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2x insulators
Connect ancillary bay harness connectors to negative pack contactor

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2x connectors
Install ancillary bay harness clip around negative pack contactor area

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1x clip
Remove pyro disconnect dummy
Use IPA cleaning

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Allow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect
Set the multimeter to the "LoZ" (low impedance) mode
Measure voltage between busbar and shunt

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While 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
Position the pyro disconnect to ancillary bay for installation

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1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
Install bolts securing pyro disconnect to ancillary bay

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2x patch bolts, 13mm, 9 Nm
Measure resistance from the module 2 busbar to pyro disconnect

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1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Measure resistance from the pyro disconnect to shunt

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1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Remove ancillary bay insulators
Inspect ancillary bay walls for damage

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Any 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

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Image up close for clarity, Delaminated and torn seals cannot be reused
Position the ancillary bay cover to HV battery for installation

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Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Clean HV connector contact surface of residual Penetrox

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Allow 1 minute dry time, New busbar comes with penetrox applied to HV connector
Clean busbar HV connector contact surface of residual Penetrox

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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

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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 kit connector and lower onto HV header

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4x 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
Install AC chargeport inlet harness clip

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1x clip
Install bolts securing charge port busbar kit to HV header

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

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2x 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), 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 fastener securing busbar cover access door

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1x bolt, 10mm, 9 Nm
Remove HV insulating gloves
Install bolts securing ancillary bay cover to HV battery

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18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
Install fasteners securing ancillary bay cover to high voltage controller (HVC)

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3x bolts, E10, 5 Nm + 30 degrees
Remove the logic cap and connect the HVC logic connector.
Install sadface bracket into vehicle

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1x Positioning clip
Install bolts securing sadface bracket to vehicle

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2x bolts, 10mm, 10 Nm
Install LH lower B-pillar assembly

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7x 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
Install LH lower A-pillar assembly

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4x clips, 2x guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim
Install clip securing LH lower A-pillar assembly

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1x push clip
Install LH IP end cap

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5x clips, 2x guide tabs
Install LH front primary seal

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Verify seal is seated properly on all trim panels
Connect 2nd row seat harness and secure cushion

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2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
Fold 2nd row 60 seatback down

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Pull release, Fold down, Protect the seat cushion if necessary
Install bolster plastic bracket to LH side bolster

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2x tabs, Install new bolster bracket
Install LH side bolster

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1x locator clip, 3x guide tabs, Align the bottom and side tabs then push inward to install
Return 2nd row 60 seatback to vertical position
Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
Move both front seats to original position.
Raise all windows and close all doors.