Cover - Ancillary Bay (Remove and Replace)
Correction code 16101002 1.08 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so.NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-04-04: Added information on installing and removing acillary bay kit insulators.
- 2023-11-08: Added/updated HV insulating glove steps.
- 2023-06-09: Corrected paint pen colors.
- 2023-05-22: Added caution for correct positive DC cable connection.
- 2023-06-29: Added a video at Step 6 in Install part.
- 2023-07-06: Added a video in step 11 of Install part.
- 1127845-00-A Asy, Service Cover, Penthouse, Model 3
- 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
- 1076971-02-A Wrench, Torque + Angle, 1/4" Dr
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
Only
technicians who have been trained in High Voltage Awareness and
have completed all required certification courses (if applicable) are permitted to
perform this procedure. Proper personal protective equipment
(PPE) and insulating HV gloves with a minimum rating
of class 0 (1000V) must be worn at all times a high voltage
cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness
Care Points
for additional safety
information.
Remove
- Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the foam cover from the LH side of the ancillary bay.
- Remove the LH 2nd row buckle. See Buckle - 2nd Row - LH (Remove and Replace).
- Remove the center 2nd row buckle. See Buckle - 2nd Row - Center (Remove and Replace).
- Remove the bolts that attach the ancillary bay rails to the body and ancillary bay cover, and then remove the rails from the vehicle.
- If the ancillary bay cover is to be replaced with a new cover, turn the adjustable elements (x4) clockwise to remove them from the ancillary bay cover.
-
Remove and discard the bolts
that attach the high voltage controller internally to the ancillary bay
cover.
- Release the cover on the positive 12V output cable, at the DCDC passthrough.
-
Remove and discard the nut
that attaches the positive 12V output cable to the DCDC passthrough, and
then remove the cable from the passthrough.
NoteInspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
-
Put on HV insulating gloves and leather over gloves.
WarningContinue to wear the gloves until instructed to remove them.
-
Fully loosen and remove (if
possible) the bolts that attach the ancillary bay cover to the HV battery.
NoteDifferent ancillary bay cover revisions have 28, 18, or 16 bolts.
- Remove the logic connector cap from the high voltage controller connector.
- Remove the ancillary bay cover from the vehicle.
- Reinstall the logic connector cap onto the high voltage controller connector.
- Inspect whether HV insulators are present. If not present or partly present, use the Ancillary Bay Insulator kit and install the insulator caps onto the HV battery to cover live HV points. See Insulators - HV Battery (Install and Remove).
-
Visually inspect the
interior of the ancillary bay for any presence of leaked coolant.
NoteAreas of interest are the coolant input and output tubes and fittings, and around the perimeter of the ancillary bay.CAUTIONIf any leaked coolant is found, escalate a Toolbox session.
Install
- Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
-
Visually inspect the
condition of the ancillary bay cover gasket and the HV battery mating surface
for cracks, cuts, gouges, abrasions, or any damage that could affect the
seal.
NoteIf the damage to the gasket is severe, replace the ancillary bay cover. If there is minor damage (including paint) that might affect the seal, perform an ancillary bay air leak test when instructed to do so.
- Use an IPA wipe to clean any residue from the high voltage controller mounting bolt holes and both the inside and outside of the ancillary bay cover at the bolt holes.
-
If the aluminum tape
retrofit patch is damaged, remove it, clean the area with an IPA wipe, apply
another patch of aluminum tape, and wet out the patch with a silicone roller
to set the adhesive.
- Remove the logic connector cap from the high voltage controller connector.
- Remove all insulator kit covers from the HV battery. See Insulators - HV Battery (Install and Remove).
-
Install the ancillary bay cover
on the HV battery, and then hand-tighten the bolts.
NoteDifferent ancillary bay cover revisions have 28, 18, or 16 bolts.
- Remove HV insulating gloves.
- Reinstall the logic connector cap onto the high voltage controller connector.
-
Torque the ancillary bay cover
bolts in the sequence shown, and mark each with an orange paint pen as they
are torqued.CAUTIONUse an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
- 4 in extension
- Ratchet/torque wrench
-
Connect the positive 12V
output cable to the DCDC passthrough, install a new nut to attach the cable,
and mark the nut with a pink/violet paint pen after torque.CAUTIONMake sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.CAUTIONMake sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
- If removed, replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
-
Install and hand-tighten new
bolts that attach the high voltage controller internally to the ancillary bay
cover.
CAUTIONDo not remove the LH upper A-pillar trim tether from the body side. If removed from the body side, the tether will have to be replaced.
-
Torque the high voltage
controller to ancillary bay cover bolts in the sequence shown, and mark each
bolt with an orange paint pen as they are torqued.CAUTIONInsufficient torque of bolts 1 and 2 opens the high voltage interlock loop circuit.Tip: Use of the following tool(s) is recommended:
- External Torx E10
- 4 in extension
- Ratchet/torque wrench
- Torque wrench with angle measurement
- If damage was found on the ancillary bay cover gasket or the HV battery mating surface, or if the aluminum tape retrofit patch was replaced, or if another procedure instructed to perform an ancillary bay air leak test, do that now. See Ancillary Bay Air Leak Test.
-
Install and hand-tighten the
adjustable elements (x4) on the ancillary bay cover counter-clockwise so
that they are fully engaged.
CAUTIONHand-tighten only.
- Remove the logic connector cap from the high voltage controller connector.
- Connect the electrical harness to the high voltage controller connector.
- Install the ancillary bay rails to the body and ancillary bay cover, but do not install the bolts at this time.
- Install the center 2nd row buckle. See Buckle - 2nd Row - Center (Remove and Replace).
-
This video shows how to properly stack the 2nd row LH seat buckle onto the
2nd row center seat belt anchor:
- Set the 2nd row center seat belt anchor onto the 2nd row LH inner ancillary bay rail, with the belt to the RH side.
- Make sure that the belt is not twisted, and lays flat against the 2nd row seatback.
- Set the guide pin of the 2nd row LH seat buckle bracket into the hole of the 2nd row LH inner ancillary bay rail, and pivot the bracket down onto the anchor, aligning the guide pin to the slot in the anchor.
-
Install a new bolt to attach
the seat buckle bracket, the seat belt anchor, and the inner ancillary bay rail
to the body.
- Verify the stacking.
- Install the plastic bracket that attaches the female side of the electrical connector to the body studs.
- Connect the electrical harness to the LH rear seat belt buckle connector.
- Install and hand-tighten the bolts that attach the rails to the ancillary bay cover and body.
-
Torque the bolts to
specification.
- Install the foam cover to the LH side of the ancillary bay.
- Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Connect 12V power. See 12V/LV Power (Disconnect and Connect).