01/08/2024 02:46:57

Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace)

Correction code 16101052 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.

  • 2024-07-26: Added information on installing a recycling warning label with CE marking and manufacturer information, if this was present on the ancillary bay cover being replaced.
  • 2023-11-08: Added/updated HV insulating glove steps.
  • 2023-08-22: Updated images.
Additional part that may be required for this operation (for Europe only):
  • 1108781-BB-F: LABEL - RECYCLING WARNING - EU
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.

Torque Specifications

Table 1. Torque Specifications: Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (EPL10 or EPR10) that attach the ancillary bay cover to the HV battery
5 Nm (3.7 lbs-ft)
  • External Torx E10 5-Lobe
  • 4 in extension
  • Ratchet/torque wrench
Reuse Replace
Informational PurposesAn informational icon, calling your attention
Note
Torque these fasteners in the sequence specified in the installation step.
Informational PurposesAn informational icon, calling your attention
Note
These bolts are attached to the ancillary bay cover.
Bolts (EPL10 or EPR10) that attach the charge port header to the ancillary bay cover
10 Nm (7.4 lbs-ft)
  • External Torx E10 5-Lobe
  • 4 in extension
  • Flex head ratchet/flex head torque wrench
Reuse
Bolts (EPL10) that attach the 3-phase header to the ancillary bay
6 Nm (4.4 lbs-ft)
  • External Torx E10 5-Lobe
  • 4 in extension
  • Flex head ratchet/flex head torque wrench
Reuse
Bolts (E10 or EPL14) that attach the ancillary bay cover to the HV controller
10 Nm (7.4 lbs-ft)
  • External Torx E10 5-Lobe
  • Socket 3/8 in EP14
  • 4 in extension
  • ¼ in to 3/8 in adapter
  • Ratchet/torque wrench
Bolts (T20) that attach the PCS LVDC header to the ancillary bay cover
2.5 Nm (1.8 lbs-ft)
  • Torx T20 socket
  • 4 in extension
  • Flex head ratchet/flex head torque wrench

Remove

  1. Open all the doors and lower the windows.
  2. Remove the HEPA filter assembly See GUID-220D81CC-08ED-4411-8E2C-686A2C0FE633.html.
  3. Move the front seats forward.
  4. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  5. Remove the LH and RH lower c-pillar trims. See GUID-DB75BFBB-980C-4767-844D-DD5FC4AEE1F0.html.
  6. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  7. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  8. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  10. Lower vehicle until tires are touching the ground.
  11. Disconnect the HVC logic connector, and then install the logic connector cap.
  12. Disconnect the LV power connector from the HV battery.
  13. Release the red locking tab, rotate the black lever upwards, and then disconnect the 3-Phase cable connector from the ancillary bay HV header.
  14. Release the clip that attaches the LH body harness to the rear body and move aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip.
  15. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  16. Remove the bolts (x2) that attach the charge port busbars to the HV header.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  17. Lift busbar kit connector to remove it from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an inflatable air bag to suspend the busbar away from the HV header during removal and installation.
  18. Remove the NVH insulation from the ancillary bay cover.
  19. Remove the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
  20. Release the bolts (x3) that attach the PCS Low Voltage DC header to the ancillary bay cover.
  21. Release the bolts (x2) that attach the 3-phase header to the ancillary bay.
  22. Release the bolts that attach the charge port header to the ancillary bay cover, and then remove the doubler.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of small tabs on shielding.
  23. Put on HV insulating gloves and leather over gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Continue to wear the gloves until instructed to remove them.
  24. Remove the perimeter bolts (x22) that attach the ancillary bay cover to the HV battery.
  25. Remove the ancillary bay cover from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance.

Install

  1. For Europe only: Check the ancillary bay cover that is being replaced for the presence of a recycling warning label that includes a CE marking and manufacturer information.
    • If the recycling warning label with CE marking and manufacturer information is not present on the ancillary bay cover being replaced, continue to the next step.
    • If the recycling warning label with CE marking and manufacturer information is present on the ancillary bay cover being replaced:
      1. Note the area where the recycling warning label is affixed on the ancillary bay cover being replaced.
      2. Clean the corresponding area on the new ancillary bay cover with an IPA wipe and allow 1 minute dry time.
      3. Install a new recycling label with CE marking and Manufacturing Information (part number 1108781-BB-F) on the new ancillary bay cover.
  2. Inspect the inner edge of the vehicle single-piece rear casting for metal flashing. If flashing is present, put on cut-resistant gloves.
  3. Inspect the ancillary bay cover seal for damage.
    Informational PurposesAn informational icon, calling your attention
    Note
    If damage is present, replace the ancillary bay cover seal.
  4. Install the ancillary bay cover onto the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance. Guide LH side of cover into position clearing HV header. Maneuver cover past body casting and into position with charge port components.
  5. Install the perimeter bolts (x22) that attach the ancillary bay cover to the HV battery in the order as shown (torque 5 Nm).
  6. Install the doubler, and then instal the bolts (x2) that attach the charge port header to the ancillary bay cover (torque 10 Nm).
  7. Install the bolts (x2) that attach the 3-phase header to the ancillary bay (torque 6 Nm).
  8. Install the bolts (x3) that attach the PCS Low Voltage DC header to the ancillary bay cover (torque 2.5 Nm).
  9. Install the bolts (x3) that attach the ancillary bay cover to the high voltage controller (torque 10 Nm).
  10. Install the NVH insulation onto the ancillary bay cover.
  11. Connect the LV power connector to the HV battery.
  12. Connect the HVC logic connector.
  13. Install the 3-Phase cable connector to the ancillary bay HV header.
  14. Use IPA wipes to clean the busbar HV connector contact surface of any residual Penetrox.
  15. Use IPA wipes to clean the HV connector contact surface of residual Penetrox.
  16. Apply Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  17. Position the busbar kit connector and lower it onto the HV header.
  18. Install the bolts (x2) that attach the charge port busbars to the HV header (torque 9 Nm).
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  19. Put on HV insulating gloves and leather over gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
  20. Perform the Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    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.
  21. Install the bolt that closes the charge port busbar access door at the ancillary bay HV header (torque 9 Nm).
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  22. Remove HV insulating gloves.
  23. Install the clip that attaches the LH body harness onto the rear body.
  24. Raise the vehicle to a comfortable working height.
  25. Connect the RDU HV harness connector to the HV battery.
  26. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  27. Fully lower the vehicle.
  28. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  29. Install the HEPA filter assembly. See GUID-220D81CC-08ED-4411-8E2C-686A2C0FE633.html.
  30. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  31. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  32. Install the RH lower C-pillar trim. See GUID-DB75BFBB-980C-4767-844D-DD5FC4AEE1F0.html.
  33. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  34. Install the LH lower C-pillar trim. See GUID-DB75BFBB-980C-4767-844D-DD5FC4AEE1F0.html.
  35. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  36. Move the front seats to their original positions.