2024-09-04

HV Harness - HV Battery to Rear Drive Unit (3DU) (Remove and Replace)

Correction code 44502202 0.90 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. See Ergonomic Precautions for safe and healthy working practices.

  • 1140311-00-A Lever Lock, HV Connector, Model 3
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

  • 2023-06-15: Added the whole procedure video as an overview for supplemental purposes only.

Remove

  1. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  4. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  5. Remove the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  6. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  7. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  8. Position a coolant drain under the rear drive unit inverter.
  9. Release the clip, disconnect the rear drive unit inlet hose from the inverter coolant coupling, and then immediately plug both fittings.
  10. Release the clip that attaches the rear drive unit inlet hose to the HV basttery to rear drive unit harness bracket.
  11. Release the clip that attaches the rear drive unit inlet hose to the HV battery.
  12. Move the end of the rear drive unit inlet hose between the rear drive unit and rear subframe, and then down and out between the HV battery and rear subframe.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not kink the hose.
  13. Release the clip that attaches the low voltage electrical harness to the rear drive unit inverter.
  14. Disconnect the low voltage electrical harness from the rear drive unit inverter connector.
  15. Remove the bolt that attaches the HV battery to rear drive unit harness bracket to the rear drive unit inverter.
  16. Remove the nuts that attach the HV battery to rear drive unit harness bracket to the HV battery.
  17. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  18. Fully raise the handle on the HV battery rear drive unit connector.
  19. Remove the HV battery rear drive unit connector from the HV battery header.
  20. Slide the release to unlock the rear drive unit HV connector handle of the rear drive unit to HV battery harness from the secured position.
  21. Fully raise the handle on the rear drive unit HV connector.
  22. Remove the rear drive unit HV connector from the rear drive unit HV header.
  23. Move the HV battery to rear drive unit harness down and out between the rear subframe and the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the harness as necessary to move the rear drive unit inverter connector end of the harness between the subframe and HV battery.

Install

  1. Move the rear drive unit inverter connector end of the HV battery to rear drive unit harness up and in between the rear subframe and the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the harness as necessary to move the connector between the subframe and HV battery.
  2. Fully raise the handle on the rear drive unit HV connector of the rear drive unit to HV battery harness.
  3. Install the HV connector special tool onto the rear drive unit HV connector.
  4. Use both hands to firmly connect the rear drive unit HV connector of the rear drive unit to HV battery harness to the rear drive unit HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  5. Remove the HV connector special tool from the rear drive unit HV connector.
  6. While pressing the rear drive unit HV connector onto the rear drive unit HV header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  7. Slide the release to lock the rear drive unit HV connector handle in the secured position.
  8. Verfiy that the rear drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  9. Fully raise the handle on the HV battery rear drive unit connector of the rear drive unit to HV battery harness.
  10. Install the HV connector special tool onto the HV battery rear drive unit connector.
  11. Use both hands to firmly connect the HV battery rear drive unit connector of the rear drive unit to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  12. Remove the HV connector special tool from the HV battery rear drive unit connector.
  13. While pressing the HV battery rear drive unit connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  14. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  15. Verfiy that the HV battery rear drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  16. Install the nuts that attach the HV battery to rear drive unit harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
  17. Install the bolt that attaches the HV battery to rear drive unit harness bracket to the rear drive unit inverter.
    6 Nm (4.4 lbs-ft)
  18. Connect the low voltage electrical harness to the rear drive unit inverter connector.
  19. Fasten the clip that attaches the low voltage electrical harness to the rear drive unit inverter.
  20. Move the end of the rear drive unit inlet hose up and in between the HV battery and rear subframe, and then up and in between the rear drive unit and rear subframe.
  21. Fasten the clip that attaches the rear drive unit inlet hose to the HV battery.
  22. Fasten the clip that attaches the rear drive unit inlet hose to the HV basttery to rear drive unit harness bracket.
  23. Remove the plugs from both fittings, immediately connect the rear drive unit inlet hose to the inverter coolant coupling, and then fasten the clip.
  24. Remove the coolant drain from under the vehicle.
  25. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  26. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  27. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  28. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  29. Refill the cooling system. See Cooling System (Partial Refill and Bleed).
  30. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  31. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).