17/06/2022 13:25:53

Harness - Thermal Bar (Remove and Replace)

Correction code 17101302 1.10 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 proper PPE is worn when performing the below procedure.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Raise and support vehicle

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Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Remove the underhood storage unit. See
Power off vehicle from center display

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Via Controls > Safety & Security > Power Off
Disconnect LV battery connector and First Responder Loop

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2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
Verify operation of multimeter

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Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
Release clip securing the supermanifold to battery pump supply hose from LV battery

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1x clip
Remove fasteners securing the LV battery and move aside

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3x bolts, 10mm, 9 Nm, 2x datums, Take note of datums and carefully move assembly aside
Release air quality sensor connection

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1x connector
Remove HEPA filter assembly cover

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2x tabs, 2x datums, 2x slots, , Be cautious and do not damage the mounting clips, Maneuver cover forward and up in front of V-brace cross member
Remove LV battery from vehicle
Raise vehicle fully and lower lift onto locks

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Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove clips securing mid aero shield

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4x push clips
Remove bolts securing mid aero shield and remove from vehicle

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16x bolts, 10mm, 6 Nm
Install amp clamp to LH RDU HV harness

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Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction._x000A__x000A_ If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required_x000A__x000A_If current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
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, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
Release LH RDU HV harness from HV battery

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1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up
Verify no high voltage at LH rear RDU HV header

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Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Secure LH RDU HV harness to battery pack

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1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Remove the leather glove protectors and HV insulating gloves
Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle

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16x bolts, 10mm, 6 Nm
Install clips securing mid aero shield

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4x push clips
Lower vehicle fully

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Release upper connections on the front controller

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2x locking connectors, Push in locking tabs and lift levers to release
Release LH middle connection on the front controller

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1x locking connector, Push in locking tab and lift lever to release
Release RH middle connections on the front controller

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2x locking connectors, Slide locking mechanism outwards to release
Release lower connections on the front controller

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2x locking connectors, Slide red locking tab outwards to release
Remove bolt securing front controller ground cable

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1x bolt, 10mm, 10 Nm
Remove bolts securing front controller

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3x bolts, 10mm, 10 Nm
Remove front controller from vehicle and release ground cable from multi system beam

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2x locating tabs, 1x ground cable
Disconnect AC compressor logic connector

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1x locking electrical connector, Do not push down on red tab, Pull to disengage lock, Pull again to release connector
Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket

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1x fir tree clip
Remove fastener securing AC compressor HV harness bracket to AC compressor

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1x bolt, 13mm, 9 Nm
Disconnect HV harness connector from AC compressor

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1x locking electrical connector, Move black locking tab away form the AC compressor, Push down on locking connector to release and pull straight out of socket
Remove AC compressor ground strap

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1x bolt, T25, 7 Nm
Release clip securing the coolant hose to the AC compressor bracket

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1x fir tree clip
Remove PT coolant pump from AC compressor bracket

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Slide pump assembly away from compressor off lower bracket
Release the HV heat pump bracket from the compressor eyelet

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1x tab, Release bracket tab and rotate rearward and up to clear compressor eyelet
Set HV heat pump bracket aside

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Negotiate underneath high pressure pipe
Release compressor bracket from multi-system beam

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2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle and under the multi-system beam, Be cautious around the coolant hose and supermanifold harness, Place fender cover on fan housing and gently place AC compressor assembly down
Disconnect the sensor for the powertrain supply hose

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect low pressure PT sensor connector

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1x locking electrical connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Release harness from supermanifold
Release thermal harness from Supermanifold

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1x fir clip, 1x clip
Release thermal harness from PT coolant pump, Chiller pump, and Octovalve

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3x locking electrical connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Move harness away from rear of supermanifold
Disconnect the coolant bottle level sensor connector

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1x locking electrical connector, 1x clip, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Remove clips securing heat pump harness at the bottom of coolant bottle

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2x fir tree clips, Access from RH side of supermanifold
Disconnect high pressure PT High sensor connector

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from electronic expansion valve recirc

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from electronic expansion valve liquid cooled condenser

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from the shut off valve liquid cooled condenser

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from the electronic expansion valve cabin condenser right

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from High pressure PT sub cool sensor

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from the electronic expansion valve cabin condenser left

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect electronic expansion valve chiller connector

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Disconnect connector from the electronic expansion valve evap

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1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Release thermal bar harness guide from supermanifold

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1x clip, Release clip and slide forward
Remove thermal bar harness from vehicle

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Maneuver underneath coolant bottle and multisystem beam
Install thermal bar harness to vehicle

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Maneuver underneath multisystem beam and coolant bottle into position
Secure thermal bar harness guide to supermanifold

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1x clip, Secure clip and slide rearward
Connect connector for the electronic expansion valve evap

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1x electrical connector, Engage locking tab
Connect electronic expansion valve chiller connector

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1x electrical connector, Engage locking tab
Connect connector for the electronic expansion valve cabin condenser left

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1x electrical connector, Engage locking tab
Connect connector for the electronic expansion valve right

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1x electrical connector, Engage locking tab
Connect connector to High pressure PT sub cool sensor

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1x electrical connector, Engage locking tab
Connect connector for the shut off valve liquid cooled condender

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1x electrical connector, Engage locking tab
Connect connector for the electronic expansion valve liquid cooled condenser

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1x electrical connector, Engage locking tab_x000A_
Connect connector for the electronic expansion valve recirc

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1x electrical connector, Engage locking tab
Connect high pressure PT sensor connector

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1x electrical connector, Engage locking tab
Secure clips securing heat pump harness at the bottom of coolant bottle

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2x fir tree clips
Connect the coolant bottle level sensor and secure harness

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1x locking electrical connector, 1x clip, Engage locking tab
Install thermal harness to PT coolant pump, Chiller pump, and Octovalve

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3x locking electrical connectors, Engage locking tabs
Secure thermal harness to Supermanifold

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1x fir clip, 1x clip
Connect low pressure PT sensor connector

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1x locking electrical connector, Secure harness to supermanifold, Engage locking tab
Connect the sensor for the powertrain supply hose

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1x locking electrical connector, Engage locking tab
Position AC compressor bracket assembly into vehicle and secure AC compressor assembly to multi-system beam

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2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Carefully install the AC compressor and AC compressor bracket towards the rear of the vehicle and under the multi-system beam, Negotiate bracket around coolant hose and supermanifold harness, Hand start bolts
Torque AC compressor bracket bolts to multi-system beam

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2x bolts, 15mm, 31 Nm
Position HV heat pump bracket

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Negotiate underneath high pressure pipe
Secure HV heat pump bracket to AC compressor eyelet

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Ensure locking tab engages eyelet
Connect HV harness connector to AC compressor

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1x locking electrical connector, 3 stage locking connector, After fully seating the connector onto the AC compressor engage the black locking tab by pushing toward the AC compressor, Perform push-pull-push test to ensure proper seating
Install fastener securing AC compressor HV harness bracket to AC compressor

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1x bolt, 13mm, 9 Nm
Install AC compressor ground strap

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1x bolt, T25, 7 Nm
Secure PT coolant pump onto AC compressor bracket

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Slide pump assembly onto compressor lower bracket
Install clip securing the coolant hose to the AC compressor bracket

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1x fir tree clip
Position front controller for installation and position ground cable

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2x locating tabs, 1x ground cable
Install bolts securing front controller

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3x bolts, 10mm, 10 Nm. Start with the side bolt
Install bolt securing front controller ground cable

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1x bolts, 10mm, 10 Nm
Secure lower connections on the front controller

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2x locking connectors, Engage red locking tab
Secure RH middle connections on front controller

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2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage
Secure LH middle connection for front controller

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1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
Secure upper connections for the front controller

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2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
Position LV battery into vehicle

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Position LV battery to the left and allow space for HEPA cover to be installed
Install HEPA filter assembly cover

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2x tabs, 2x datums, 2x slots, Maneuver cover down and under V-brace cross member, Fully engage seal and locking tabs
Secure air quality sensor connection

Note
1x connector
Install fasteners securing LV battery to multi-system beam

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3x bolts, 10mm, 9 Nm, 2x datums, Shift into position and install fasteners
Install clip securing the supermanifold to battery pump supply hose onto LV battery

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1x clip
Connect First Responder Loop and LV battery connector

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2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Install the underhood storage unit. See .
Remove vehicle from lift

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Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"