2026-09-15

Retrofit PCS1 into Newer Revision HV Battery (Retrofit)

Korrekturcode S012616003 FRT 3.12 HINWEIS: Sofern im Verfahren nicht ausdrücklich anders angegeben, spiegeln der obige Korrekturcode und seine zugehörige FRT den gesamten für die Durchführung dieses Verfahrens erforderlichen Aufwand wider, einschließlich der damit verbundenen Verfahren. Schichten Sie keine Korrekturcodes, wenn Sie nicht ausdrücklich dazu aufgefordert werden. HINWEIS: Weitere Informationen über FRTs und darüber, wie sie erstellt werden, finden Sie unter Richtzeiten. HINWEIS: Siehe Persönlicher Schutz, um sicherzustellen, dass Sie die richtige persönliche Schutzausrüstung tragen, wenn Sie das folgende Verfahren durchführen. HINWEIS: Siehe Maßnahmen zur Ergonomie für sichere und gesunde Arbeitsmethoden.

Warnung
Dieses Verfahren ist ein ENTWURF. Es wurde zwar validiert, jedoch können Sicherheitshinweise und Vorsichtsmaßnahmen fehlen. Befolgen Sie die Sicherheitshinweise, und gehen Sie beim Arbeiten an oder in der Nähe von Hochspannungssystemen und -bauteilen äußerst vorsichtig vor.
Anmerkung
This procedure is performed on a new HV battery before it is installed into the vehicle.
  • 2026-09-01: Released new procedure.

Procedure

  1. Remove bolts securing ancillary bay cover to HVC
    Anmerkung
    3x bolts, E10, 5 Nm + 30 degrees
  2. Remove bolts securing ancillary bay cover to HV battery
    Anmerkung
    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover, The number of bolts on later vehicles may vary, Later production vehicles may have 18x bolts, EP10 5-Lobe, 8 Nm, 11x bolts, 8mm, 10.5 Nm
  3. Remove HVC logic cap
    Anmerkung
    1x logic cap
  4. Inspect HV insulating gloves
    Anmerkung
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.tesla.com/en-US/documents
  5. Put on HV insulating gloves and leather over gloves
    Anmerkung
    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configurationhttps://service.tesla.com/en-US/documents
  6. Remove ancillary bay cover from HV battery
  7. Install HVC logic cap
    Anmerkung
    1x logic cap
  8. Inspect ancillary bay for any missing insulators
    Anmerkung
    Install service insulator kit before continuing to next step
  9. Remove bolts securing pyro disconnect to ancillary bay
    Anmerkung
    1x insulator, 2x bolts, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard fasteners after removal
  10. Remove pyro disconnect from ancillary bay
    Anmerkung
    1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay
  11. Install pyro disconnect dummy
  12. Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller
    Anmerkung
    1x connector
  13. Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller
    Anmerkung
    1x connector
  14. Disconnect HV controller connector X480 – Shunt at HVC from HV Controller
    Anmerkung
    1x connector
  15. Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller
    Anmerkung
    1x connector
  16. Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller
    Anmerkung
    1x connector
  17. Disconnect X484 – Pyro disconnect from HVC
    Anmerkung
    1x connector
  18. Disconnect HV controller connector X479 –Main HVC connector from HV Controller
    Anmerkung
    1x connector
  19. Remove megaharness clips from HV controller hinge tray
    Anmerkung
    5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife
  20. Release HVC tray assembly from ancillary bay
    Anmerkung
    2x screws, T25, 2 Nm, 3x wires routed through RH hinge
  21. Remove HV controller and hinge tray from ancillary bay assembly
  22. Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
  23. Disconnect PCS coolant inlet hose from PCS
    Anmerkung
    2x 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
  24. Disconnect PCS coolant outlet hose from PCS
    Anmerkung
    2x 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, Discard O-ring
  25. Disconnect PCS to DC bus HV connector
    Anmerkung
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  26. Disconnect PCS logic connector from PCS
    Anmerkung
    1x connector
  27. Disconnect PCS LV connector from PCS
    Anmerkung
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  28. Disconnect AC harness connector from PCS
    Anmerkung
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  29. Remove bolts securing PCS to HV battery
    Anmerkung
    5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners, Discard after removal
  30. Secure suction cups to PCS
    Anmerkung
    Continue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss
  31. Lift PCS up and out of ancillary bay area and remove from vehicle
    Anmerkung
    Slightly 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
  32. Disconnect ancillary bay harness connectors from positive pack contactor
    Anmerkung
    2x connectors
  33. Remove ancillary bay harness clip from positive pack contactor
    Anmerkung
    1x clip
  34. Remove HV joint insulators from positive HV switch
    Anmerkung
    2x insulators
  35. Remove bolt securing positive pack contactor to positive busbar
    Anmerkung
    1x patch bolt, 13mm, 9 Nm, Discard after removal
  36. Remove nut securing positive pack contactor to module 4 rear terminal
    Anmerkung
    1x patch nut, 13mm, 9 Nm, Discard after removal
  37. Remove nuts securing positive pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
  38. Remove positive pack contactor from ancillary bay
    Anmerkung
    2x guide pins
  39. Remove HV joint insulator for positive DC link to module 4
    Anmerkung
    1x insulator cover
  40. Remove nut securing DC link to module 4
    Anmerkung
    1x patch nut, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 35 degrees, Discard after removal
  41. Remove ancillary bay harness clips from positive DC link
    Anmerkung
    3x clips
  42. Remove positive DC link from ancillary bay
    Anmerkung
    2x guide pins, Be careful not to touch rear terminal of module 4
  43. Cut cable ties securing megaharness to charger output to DC bus harness
    Anmerkung
    2x cable ties
  44. Remove protrusion on the ancillary bay harness base
    Anmerkung
    1x tab, If equipped break off tab with insulated needle nose pliers, Remove tab to allow rotation of the coolant inlet hose, Discard tab
  45. Release PCS coolant inlet hose from hose clip
    Anmerkung
    2x hose clips, Use plastic trim tool to remove hose from the card slot, And then rotate 90 degrees counterclockwise
  46. Disconnect PCS coolant inlet hose from penthouse
    Anmerkung
    2x clips,2x plugs, Place absorbent sheet under hose to catch excess coolant, There may be residual coolant inside hose, Before installation, residual coolant in hose must be cleaned, Install plugs to ancillary bay and hose, If reused, Replace both O-rings after disassembly
  47. Remove insulators for fuse and bolts
    Anmerkung
    2x insulators
  48. Remove 700V DC 63A PCS output fuse
    Anmerkung
    1x fuse, 2x patch nuts, 8mm, 4.5 Nm, Discard nuts after removal
  49. Remove 700V DC 63A compressor fuse
    Anmerkung
    1x fuse, 2x patch nuts, 8mm, 4.5 Nm, Discard nuts after removal
  50. Remove HV battery ancillary positive busbar bracket
    Anmerkung
    1x patch nut, 8mm, 4.5 Nm, Discard after removal
  51. Remove nut securing negative output harness from negative HV battery DC link busbar
    Anmerkung
    1x nut, 8mm, 4.5 Nm, Discard after removal
  52. Remove bolt securing RH ancillary bay bus cover
    Anmerkung
    1x bolt, T25, 3 Nm
  53. Lift up busbar DC link cover up
    Anmerkung
    2x clips, Be careful not to damage cover when lifting, It is recommended to assist
  54. Remove Charger Output to DC Harness from busbar DC link
    Anmerkung
    1x harness, Remove harness outward, It is not allowed to damage the insulation layer of the harness, If it is damaged, it must be replaced,
  55. Remove bolts securing DCDC pass through to ancillary bay
    Anmerkung
    2x bolts, E10 5-Lobe, 10 Nm
  56. Remove DCDC pass through from ancillary bay
    Anmerkung
    Attention: To avoid metal damage to the cable insulation layer
  57. Disconnect ancillary bay harness connectors from negative pack contactor
    Anmerkung
    2x connectors
  58. Remove HV joint insulators from negative pack contactor
    Anmerkung
    2x insulators
  59. Remove bolt securing negative pack contactor to DC link busbar joint
    Anmerkung
    1x patch bolt, 13mm, 9 Nm, Discard after removal
  60. Remove nut securing negative pack contactor to HV battery tall silicon terminal
    Anmerkung
    1x patch nut, 13mm, 9 Nm, Discard after removal
  61. Remove nuts securing negative pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
  62. Remove negative pack contactor from ancillary bay
    Anmerkung
    2x guide pins
  63. Disconnect PCS coolant outlet hose from ancillary bay
    Anmerkung
    2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Install plugs to ancillary bay and hose, If reused, Replace both O-rings after disassembly
  64. Disconnect AC filter harness connectors from FC contactor cover
    Anmerkung
    2x connectors, Release locking tab
  65. Remove AC filter harness clips from FC contactor cover
    Anmerkung
    2x clips
  66. Remove bolts securing busbar AC input assembly to ancillary bay
    Anmerkung
    2x bolts, EP10 5-Lobe, 10 Nm
  67. Release 3PH AC Filter Harness from 3PH 4P Header
    Anmerkung
    2x tabs, Lift connector off HV battery for access, Inspect the sealing ring, if damaged, It cannot be reused
  68. Remove 3PH AC Filter harness from vehicle
    Anmerkung
    Harness must be removed through ancillary bay, PCS2 Lite connector does not fit through header hole
  69. Remove leather over gloves and HV insulating gloves
    Anmerkung
    HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
  70. Remove bolts securing ancillary bay cover to HVC
    Anmerkung
    3x bolts, E10, 5 Nm + 30 degrees
  71. Remove bolts securing ancillary bay cover to HV battery
    Anmerkung
    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover, The number of bolts on later vehicles may vary, Later production vehicles may have 18x bolts, EP10 5-Lobe, 8 Nm, 11x bolts, 8mm, 10.5 Nm
  72. Remove HVC logic cap
    Anmerkung
    1x logic cap
  73. Put on HV insulating gloves and leather over gloves
    Anmerkung
    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, Perform a visual inspection of HV insulating gloves for any damage before putting on, Retest for leaks immediately following any incidents that can reasonably be suspected as causing damage to the HV insulating gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 for PPE requirements depending on vehicle configurationhttps://service.tesla.com/en-US/documents
  74. Remove ancillary bay cover from HV battery
  75. Install HVC logic cap
    Anmerkung
    1x logic cap
  76. Inspect ancillary bay for any missing insulators
    Anmerkung
    Install service insulator kit before continuing to next step
  77. Remove bolts securing pyro disconnect to ancillary bay
    Anmerkung
    1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal
  78. Remove pyro disconnect from ancillary bay
    Anmerkung
    1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay
  79. Install pyro disconnect dummy
  80. Disconnect HVC connectors
    Anmerkung
    7x connectors
  81. Remove megaharness clips from HVC skylite hinge
    Anmerkung
    8x harness clips
  82. Release HVC tray assembly from ancillary bay
    Anmerkung
    2x screws, T25, 2 Nm, 3x wires routed through RH hinge
  83. Remove HV controller and hinge tray from ancillary bay assembly
  84. Position absorbent sheets below and around PCS2 lite coolant inlet hose to avoid excess coolant dripping
  85. Disconnect PCS2 lite coolant inlet hose from PCS2 lite
    Anmerkung
    2x 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 PCS2 lite and hose, Discard O-ring
  86. Disconnect PCS2 lite coolant outlet hose from PCS2 lite
    Anmerkung
    2x 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 PCS2 lite and hose, Discard O-ring
  87. Disconnect AC filter harness connector from PCS2 Lite
    Anmerkung
    1x connector, First fully release the red lock pin. Then press the tab inward and lift connector upward to remove, As shown in the image, May need plastic trim tool to help lift the connector upward
  88. Disconnect PCS2 lite HV DC harness HV connector
    Anmerkung
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  89. Disconnect PCS2 lite logic connector from PCS2 lite
    Anmerkung
    1x connector
  90. Disconnect PCS2 lite LV connector from PCS2 lite
    Anmerkung
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  91. Remove bolts securing PCS2 lite to HV battery
    Anmerkung
    5x bolts, 8mm, 15 Nm, Minus 180 degrees, 15 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T20 fasteners, Discard after removal
  92. Secure suction cups to PCS2 lite
    Anmerkung
    Continue pressing plunger until red line is no longer visible
  93. Lift PCS2 lite up and remove it from ancillary bay
    Anmerkung
    2x datums, Slightly tilt rear of PCS2 lite 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
  94. Remove ancillary bay harness clip from positive pack contactor
    Anmerkung
    1x clip
  95. Disconnect ancillary bay harness connectors from positive pack contactor
    Anmerkung
    2x connectors
  96. Remove HV joint insulators from positive pack contactor
    Anmerkung
    2x insulators
  97. Remove bolt securing positive pack contactor to positive busbar
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degress, Discard after removal
  98. Remove nut securing positive pack contactor to HV battery tall terminal
    Anmerkung
    1x patch nut, 13mm, 5 Nm + 35 degress, Discard after removal
  99. Remove nuts securing positive pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm
  100. Remove positive pack contactor from ancillary bay
    Anmerkung
    2x guide pins
  101. Remove HV joint insulator for HV battery DC link positive busbar
    Anmerkung
    1x insulator
  102. Remove nut securing DC link to DC link positive busbar
    Anmerkung
    1x patch nut, 13mm, 5 Nm + 35 degrees, Discard after removal
  103. Remove ancillary bay harness clips from positive DC link
    Anmerkung
    3x clips
  104. Remove DC link extension positive from ancillary bay
    Anmerkung
    2x guide pins, Be careful not to touch rear terminal of module 4
  105. Disconnect PCS2 lite coolant inlet hose from ancillary bay
    Anmerkung
    2x clips,2x plugs, Place absorbent sheet under hose to catch excess coolant, There may be residual coolant inside hose, Before installation, residual coolant in hose must be cleaned, Install plugs to ancillary bay and hose, Discard O-ring
  106. Remove insulators for fuse and bolts
    Anmerkung
    2x insulators
  107. Disconnect X421 connector from DC connection bus
    Anmerkung
    1x connector, Release locking tab
  108. Remove 700V DC 63A PCS2 output fuse
    Anmerkung
    1x fuse, 2x nuts, 8mm, 4.5 Nm, Discard nuts after removal
  109. Remove nut securing negative output harness from negative HV battery DC link busbar
    Anmerkung
    1x nut, 8mm, 4.5 Nm, Discard after removal
  110. Remove 700V DC 63A compressor fuse
    Anmerkung
    1x fuse, 2x nuts, 8mm, 4.5 Nm, Discard nuts after removal
  111. Remove ancillary positive busbar bracket form positive HV battery DC link busbar
    Anmerkung
    1x nut, 8mm, 4.5 Nm, Discard after removal
  112. Remove bolt securing RH ancillary bay bus cover
    Anmerkung
    1x bolt, T25, 3 Nm
  113. Lift up DC link busbar cover
    Anmerkung
    1x clip, Be careful not to damage cover when lifting, It is recommended to assist
  114. Remove PCS2 lite HV DC harness from ancillary bay
    Anmerkung
    3x harness slots, 1x hook, First, remove the terminals from the studs, and then remove harness outward, It is not allowed to damage the insulation layer of the harness, If it is damaged, it must be replaced.
  115. Remove bolts securing DCDC pass through to ancillary bay
    Anmerkung
    2x bolts, EP10 5-Lobe, 10 Nm
  116. Remove LV DC harness of PCS2 lite from ancillary bay
    Anmerkung
    Attention: To avoid metal damage to the cable insulation layer, If damaged, Do not reuse
  117. Remove RH daisy chain pass through housing from ancillary bay
    Anmerkung
    3x location pins, Insert UFO harness removal tool beneath daisy chain pass through housing, Insert tab release tool to release bottom 2x clips, Release top 3x location pins, with trim tool, Pull daisy chain pass through housing upward to remove, If damaged during disassembly, the PCS2 Lite harness assembly needs to be replaced
  118. Disconnect ancillary bay harness connectors from negative pack contactor
    Anmerkung
    2x connectors
  119. Disconnect LV fastcharge contactor connector
    Anmerkung
    1x connector, Press tabs on both sides by hand and disconnect the connector upwardsPlastic Trim tool; Electrical Protective
  120. Remove HV joint insulators from negative pack contactor
    Anmerkung
    2x insulators
  121. Remove bolt securing negative pack contactor to DC link busbar joint
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degress, Discard after removal
  122. Remove nut securing negative pack contactor to HV battery tall silicon terminal
    Anmerkung
    1x patch nut, 13mm, 9 Nm, Discard after removal
  123. Remove nuts securing negative pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm
  124. Remove negative pack contactor from ancillary bay
    Anmerkung
    2x guide pins
  125. Disconnect PCS2 Lite coolant outlet hose from ancillary bay
    Anmerkung
    2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Install plugs to ancillary bay and hose
  126. Disconnect AC filter harness connectors from FC contactor cover
    Anmerkung
    2x connectors, Release locking tab
  127. Remove harness clips from FC contactor cover
    Anmerkung
    3x clips, Move the wiring harness around the FC cover aside
  128. Remove harness clip from left terminals cover
    Anmerkung
    1x clip
  129. Remove ancillary bay left terminals cover
    Anmerkung
    2x tabs, 1x datum
  130. Remove bolt securing negative fastcharge busbar to DC link side
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degrees, Discard after removal
  131. Remove bolt securing positive fastcharge busbar to DC link side
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degrees, Discard after removal
  132. Remove bolts securing DC input header seal from ancillary bay
    Anmerkung
    4x bolts, EP10 5-Lobe, 10 Nm
  133. Remover DC input header seal from ancillary bay
    Anmerkung
    2x location pins
  134. Remove bolts securing FC contactor assembly to ancillary bay
    Anmerkung
    2x bolts, 10mm, 5.5 Nm
  135. Remove FC contactor assembly from ancillary bay
    Anmerkung
    2x guide pins, 1x clip, Tilt upwards to remove the FC contactor assembly
  136. Remove bolts securing busbar AC input assembly to ancillary bay
    Anmerkung
    2x bolts, EP10 5-Lobe, 10 Nm
  137. Release 3PH AC Filter Harness from 3PH 4P Header
    Anmerkung
    2x tabs, Lift connector off HV battery for access, Inspect the sealing ring, if damaged, It cannot be reused
  138. Remove 3PH AC Filter harness from vehicle
    Anmerkung
    Harness must be removed through ancillary bay, PCS2 Lite connector does not fit through header hole
  139. Remove LH daisy chain pass through housing from ancillary bay
    Anmerkung
    3x location pins, 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 location pins, with trim tool, Pull daisy chain pass through housing upward to remove, If damaged during disassembly, the PCS2 Lite harness assembly needs to be replaced
  140. Remove X423 connector from DC link busbar
    Anmerkung
    1x connector, Release locking tab, 1x clip
  141. Remove pyro disconnect dummy
  142. Remove pyro disconnect logic connector
    Anmerkung
    1x connector, 1x clip
  143. Disconnect shunt assembly connector
    Anmerkung
    1x connector, Release locking tab, 1x clip
  144. Remove HV joint insulators from DC link busbar
    Anmerkung
    1x insulator
  145. Remove X422 connector from DC link busbar
    Anmerkung
    1x connector, Release locking tab, 1x clip
  146. Remove ancillary bay harness assembly fixing clip from DC link
    Anmerkung
    5x clips
  147. Remove tab from DC link shell
    Anmerkung
    1x 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
  148. Remove PCS2 Lite harness assembly from ancillary bay
    Anmerkung
    1x harness, First remove the harness from the inlet outlet pipe, and then remove the harness assembiy
  149. Position megaharness to ancillary bay for installation
    Anmerkung
    1x harness
  150. Fix the Ancillary bay harness assembly to the DC link
  151. Install the RH daisy chain pass through housing to ancillary bay
    Anmerkung
    3x clips, 2x bottom clips
  152. Connect PCS coolant inlet hose to ancillary bay
    Anmerkung
    2x clips,1x plug, Remove plug from ancillary bay, 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 latch, Then visually verify clip is fully seated verify clip is fully seated, If reuse, Install new O-rings
  153. Install Charger Output to DC Harness to Busbar DC link
    Anmerkung
    1x harness, It is not allowed to damage the insulation layer of the harness, If necessary use a 90 degree hook to assist, Ensure that harness is not pinched
  154. Install nut securing negative output harness to negative HV battery DC link busbar
    Anmerkung
    1x nut, 8mm, 4.5 Nm, Install new nut, Mark after torque
  155. Perform Hioki resistance test at negative output harness terminal to negative HV battery DC link busbar
    Anmerkung
    55μΩ or less, Perform zero adjust to Hioki meter prior to testing
  156. Install busbar DC link cover
    Anmerkung
    2x clips
  157. Install bolt securing RH ancillary bay bus cover
    Anmerkung
    1x bolt, T25, 3 Nm
  158. Install HV battery ancillary positive busbar to RH ancillary bay bus cover
    Anmerkung
    1x nut, 8mm, 4.5 Nm, Install new patch nut, Mark after torque
  159. Install 700V DC 63A PCS output fuse to RH ancillary bay bus cover
    Anmerkung
    1x fuse, 2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque
  160. Perform Hioki resistance test at 63A PCS fuse input joint
    Anmerkung
    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing
  161. Perform Hioki resistance test at 63A fuse output joint
    Anmerkung
    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing
  162. Install nuts securing 700V DC 63A compressor fuse to RH ancillary bay bus cover
    Anmerkung
    1x fuse, 2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque
  163. Perform Hioki resistance test at 63A fuse input joint
    Anmerkung
    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing
  164. Perform Hioki resistance test at 63A fuse output joint
    Anmerkung
    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing
  165. Install insulators for fuse and bolts
    Anmerkung
    2x insulators
  166. Install new cable ties securing megaharness to charger output to DC bus harness
    Anmerkung
    2x cable ties, cut off any excess cable ties
  167. Position DC link extension positive for installation
    Anmerkung
    2x guide pins
  168. Install ancillary bay harness clips to positive DC link
    Anmerkung
    3x clips
  169. Install nut securing DC link to DC link positive busbar
    Anmerkung
    1x patch nut, 13mm, 5 Nm + 35 degrees, Install new patch nut, Mark after torque
  170. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
    Anmerkung
    1x HV joint, 30μΩ or less
  171. Install HV joint insulator for HV battery DC link positive busbar
    Anmerkung
    1x insulator
  172. Install the X423 connector onto the DC bus
    Anmerkung
    1x connector1x clip
  173. Install the pyro disconnect logic connector
    Anmerkung
    1x connector, 1x clip
  174. Install harness to shunt insulator
    Anmerkung
    1x clip
  175. Connect shunt assembly connector
    Anmerkung
    1x connector
  176. Install the X422 connector onto the DC bus
    Anmerkung
    1x connector
  177. Install the X421 connector onto the DC bus
    Anmerkung
    1x connector
  178. Install the LH daisy chain pass through housing to ancillary bay
    Anmerkung
    3x clips, 2x bottom clips, 1x harness clip
  179. Install FC contacor assembly toancillary bay
    Anmerkung
    2x guide pins, 1x clip, Tilt at a certain Angle to install the FC contactor assembiy
  180. Install bolts securing FC contactor assembly to ancillary bay
    Anmerkung
    2x bolts, 10mm, 5.5 Nm, Mark after torque
  181. Install DC input header seal to ancillary bay
    Anmerkung
    2x location pins, Check if sealing ring is damaged, And replace the assembly if necessary
  182. Install bolts securing DC input header seal to ancillary bay
    Anmerkung
    4x bolts, EP10 5-Lobe, 10 Nm, Mark after torque
  183. Install bolt securing positive fastcharge busbar DC link side
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degrees, Install new patch bolt, Mark after torque
  184. Perform Hioki impedance test positive HV joint fastcharge busbar DC link side
    Anmerkung
    1x HV joint, 25μΩ or less
  185. Install bolt securing negative fastcharge busbar DC link side
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degrees, Install new patch bolt, Mark after torque
  186. Perform Hioki impedance test negative HV joint fastcharge busbar DC link side
    Anmerkung
    1x HV joint, 40μΩ or less
  187. Install ancillary bay left terminals cover
    Anmerkung
    2x tabs, 1x datum
  188. Install harness clip to left terminals cover
    Anmerkung
    1x clip
  189. Connect PCS outlet coolant hose to ancillary bay
    Anmerkung
    2x clips, 1x plug, Remove plug from ancillary bay, 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 latch, Then visually verify clip is fully seated verify clip is fully seated, If reuse, Install new O-rings
  190. Position negative pack contactor to ancillary bay for installation
    Anmerkung
    2x guide pins
  191. Install nuts securing negative pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs
  192. Install nut securing negative pack contactor to HV battery tall terminal
    Anmerkung
    1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
  193. Install bolt securing negative pack contactor to DC link busbar joint
    Anmerkung
    1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque
  194. Perform Hioki impedance test at HV joint of negative pack contactor to negative DC link busbar
    Anmerkung
    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), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  195. Perform Hioki impedance test at negative pack contactor to module 1 rear terminal
    Anmerkung
    1x HV joint, 110μΩ or less
  196. Install HV joint insulators to negative pack contactor
    Anmerkung
    2x insulators
  197. Connect ancillary bay harness connectors to negative pack contactor
    Anmerkung
    2x connectors
  198. Clean surface between the 3PH 4P Header and the ancillary bay with IPA
    Anmerkung
    Allow to 1 minute dry time
  199. Route 3PH AC Filter Harness from ancillary bay up through HV battery
  200. Install 3PH AC Filter harness to 3PH 4P Header
    Anmerkung
    2x tabs, Ensure that tabs on both sides are properly installed, Inspect seal on 3PH header for any damage and replace as needed
  201. Install bolts securing Busbar AC input assembly to ancillary bay
    Anmerkung
    2x bolts, EP10 5-Lobe, 10 Nm, Mark after torque
  202. Install harness clips to FC contactor cover
    Anmerkung
    3x clips
  203. Install AC filter harness to FC contactor cover
    Anmerkung
    2x connectors
  204. Connect LV fastcharge contactor connector
    Anmerkung
    1x connector
  205. Install positive pack contactor to ancillary bay
    Anmerkung
    2x guide pins
  206. Install nuts securing positive pack contactor to ancillary bay
    Anmerkung
    3x nuts, 10mm, 8 Nm
  207. Install bolt securing positive pack contactor to positive busbar
    Anmerkung
    1x patch bolt, 13mm, 5 Nm + 60 degress, Install new patch nut, Mark after torque
  208. Install nut securing positive pack contactor to HV battery tall terminal
    Anmerkung
    1x patch nut, 13mm, 5 Nm + 35 degress, Install new patch nut, Mark after torque
  209. Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal
    Anmerkung
    1x HV joint, 73μΩ or less
  210. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
    Anmerkung
    1x HV joint, 30μΩ or less
  211. Install HV joint insulators to positive pack contactor
    Anmerkung
    2x insulators
  212. Install ancillary bay harness clip to positive pack contactor
    Anmerkung
    1x clip
  213. Connect ancillary bay harness connectors to positive pack contactor
    Anmerkung
    2x connectors
  214. Install RH daisy chain pass through housing to ancillary bay
    Anmerkung
    3x location pins, 2x bottom clips
  215. Position DCDC pass through to ancillary bay for installation
    Anmerkung
    Attention: To avoid metal damage to the cable insulation layer
  216. Install bolts securing DCDC pass through to ancillary bay
    Anmerkung
    2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
  217. Position PCS into ancillary bay
    Anmerkung
    Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datum into PCS holes
  218. Remove suction cups from PCS
  219. Install bolts securing PCS to HV battery
    Anmerkung
    5x bolts, 8mm, 15 Nm, Minus 180 degrees, 15 Nm, Install new bolts
  220. Connect PCS to fastcharge contactor HV harness connector
    Anmerkung
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  221. Connect PCS LV connector to PCS
    Anmerkung
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  222. Connect PCS logic connector to PCS
    Anmerkung
    1x connector
  223. Connect PCS to DC bus HV connector
    Anmerkung
    1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
  224. Connect PCS coolant inlet hose to PCS
    Anmerkung
    2x clips, 1x plug, 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, install new O-ring
  225. Replace O-ring on PCS side outlet hose
    Anmerkung
    1x O-ring, Apply light amount of Krytox 203, Install new O-ring
  226. Connect PCS coolant outlet hose to PCS
    Anmerkung
    2x 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
  227. Remove foam pedestal fromt bottom of HV Controller
    Anmerkung
    3x alignment datums
  228. Position HV controller and hinge tray to penthouse assembly
    Anmerkung
    4x locating pins, 3x wires routed through RH hinge
  229. Secure HVC tray assembly to ancillary bay
    Anmerkung
    2x screws, T25, 2 Nm
  230. Install megharness clips to HV controller hinge tray
    Anmerkung
    5x harness clips, 1x tape, Wrap harness tape around the hinge tray again
  231. Connect HV controller connector X479 –Main HVC connector to HV Controller
    Anmerkung
    1x connector
  232. Connect X484 – Pyro disconnect to HVC
    Anmerkung
    1x connector
  233. Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller
    Anmerkung
    1x connector
  234. Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller
    Anmerkung
    1x connector
  235. Connect HV controller connector X480 – Shunt at HVC to HV Controller
    Anmerkung
    1x connector
  236. Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller
    Anmerkung
    1x connector
  237. Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller
    Anmerkung
    1x connector
  238. Clean mating surface of pyro
    Anmerkung
    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, If the insulation protective cover is removed
  239. Set multimeter to "LoZ" (low impedance) mode
    Anmerkung
    For Fluke 110/113/114/115/116/117 LoZ setting:start with selector switch in 'off position', press the range button and rotate the selector switch to 'diode test' then let go of the range button, press the yellow button right under the display briefly, and the display should now indicate that the LoZ function (low impedance measurement) has been activated
  240. Measure voltage between busbar and shunt
    Anmerkung
    Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points
  241. Position pyro disconnect to ancillary bay for installation
    Anmerkung
    1x connector, Measure voltage between busbar and shunt for at least 10 seconds, 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, After the second person places the pyro down on the HV bus, the first person should continue to measure the voltage for another 10 seconds
  242. Install bolts securing pyro disconnect to ancillary bay
    Anmerkung
    2x bolts, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Install new fasteners
  243. Measure resistance from module 2 busbar to pyro disconnect
    Anmerkung
    1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing
  244. Measure resistance from pyro disconnect to shunt
    Anmerkung
    1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing
  245. Remove service insulator kit
  246. Remove HVC logic cap
    Anmerkung
    1x logic cap
  247. Inspect ancillary bay walls for damage
    Anmerkung
    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
  248. Inspect ancillary bay cover seal to confirm it has no visual damage
    Anmerkung
    Image up close for clarity, Delaminated and torn seals cannot be reused, If installing new parts, Skip this step
  249. Wipe ancillary bay cover with IPA to clean surface
    Anmerkung
    Allow to 1 minute dry time
  250. Position ancillary bay cover to HV battery for installation
    Anmerkung
    Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered.
  251. Remove leather over gloves and HV insulating gloves
    Anmerkung
    HV gloves should always be stored in the original packaging and inside a storage box or bag to prevent damage, Make sure that gloves are lying flat not bent or folded
  252. Install ancillary bay cover to HV battery
    Anmerkung
    18x bolts, EP10 5-Lobe, 8 Nm, Use EP10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover,The number of bolts on later vehicles may vary, Later production vehicles may have 18x bolts, EP10 5-Lobe, 8 Nm, 11x bolts, 8mm, 10.5 Nm Follow torque sequence per image
  253. Install bolts securing ancillary bay cover to HVC
    Anmerkung
    3x bolts, E10, 5 Nm + 30 degrees
  254. Install HVC logic cap
    Anmerkung
    1x logic cap