20/06/2022 14:10:36
HV Harness - Rapid Splitter to FJB - Small Drive Unit (Remove and Replace)
Correction Code 44503202
Warning
Only technicians who have been
trained in High Voltage (HV) 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 any time a high voltage cable is
handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness
Care Points" for additional safety information.
Note
This procedure only applies to vehicles built after April 10, 2016.
Special tools required for this procedure:
Note
The following tools are included in the Rapid Splitter tool kit (Tesla Part Number: 1073594-00-A).
Part Number | Description |
1073594-00-A | Tool Kit, Rapid Splitter |
Removal
- Remove the rear subframe assembly. See Small RDU.
- Remove the HV battery. See HV Battery (RWD/AWD) (Remove and Install) .
-
Remove the bolts (x2) that
attach the LV rapid mate bracket to the body of the vehicle (torque 7
Nm).
-
Release the clips that attach the HV harness to the LV rapid mate, and then
put the LV rapid mate aside.
-
Remove the barrel clip that
attaches the HV cables to the body of the vehicle.
-
Remove and discard the bolts
(x2) that attach the HV cable guide bracket to the body of the vehicle
(torque 8 Nm).
-
Remove the B- HV cable from the Rapid Splitter:
-
Repeat the previous step on the B+ HV cable.
Tip: Remove the cable tie that holds the HV cables together. Move the B- HV cable out of the working area for more access to the B+ HV cable.
-
Release the forward push
clips (x6) that attach the RH rear wheel arch liner to the vehicle.
-
Remove the forward nuts (x2)
that attach the wheel arch liner to the studs on the chassis (torque 6
Nm).
- Move the rear wheel arch liner away for access.
- Release the clips (x2) that attach the HV cable to the body of the vehicle.
- Remove the RH front wheel (refer to procedure).
-
Release the rear push clips
(x7) that attach the front wheel arch liner to the vehicle.
-
Remove the rear nut that
attaches the front wheel arch liner to the stud on the chassis (torque 6
Nm).
- Move the front wheel arch liner for access.
- If equipped, remove the bolts (x4) that attach the side sill closing panel to the wheel well (torque 25 Nm).
-
Remove the nuts (x3) that
attach the HV cable bracket to the studs on the body of the vehicle (torque
4 Nm).
NoteType and number of fasteners may vary.
-
If equipped, disconnect the electrical connector from the following:
- Powertrain coolant pump 1
- Suspension level sensor
-
Working from the wheel well,
use an extension to release the screws (x4) that attach the HV cables to the
forward junction box (FJB) (torque 7 Nm).
NoteComponents have been removed in this graphic to aid clarity.
-
Working from the rear RH
wheel well, secure the HV cables to the nylon fish tape tool using a string
or fishing line.
NoteThe nylon fish tape tool is used to pull and route the new harness through the channel during installation.NoteSecure both HV cables together and slightly staggered to reduce the likelihood of one of them getting caught in the channel.NoteThe following image shows the HV cables without the protective caps installed.
-
Gently pull the HV harness towards the front of the vehicle and through the
channel.
CAUTIONEnsure that the string or fishing line is not accidentally released from the HV cables while pulling them through the channel.
- Once the HV cables are all the way through the channel, release the string or fishing line from the cables, but do not pull the nylon fish tape tool back through the channel or remove it from the vehicle.
-
Remove the HV cables from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the following:
CAUTION
Replace all patchbolt(s).
- Install protective caps over both HV cables to protect the terminals and seals when pulling the harness through the channel.
- Attach the new HV harness to the nylon fish tape tool using string or fishing line and, from the rear RH wheel arch, gently pull the front of the nylon fish tape tool through the channel towards the rear of the vehicle and retrieve the HV harness.
-
Apply P-80 emulsion to the connector seals on the HV cables before securing
the HV cables to the FJB.
CAUTIONDo not apply P-80 emulsion to the HV terminals.
-
Install new O-rings on the
HV cables:
-
Install both B+ and B-
collars unto the end of the FJB HV cable
NoteMake sure that the B+ and B- colors match the RED and BLACK color on the HV cable.
-
Install the retaining rings
onto the end of the B+ and B- HV cables
-
Use the installation tool to install both locking collars in the Rapid Splitter.
NoteInstall both locking collars into the Rapid Mate before installing either of the HV cables.
-
Use the flare nut crowfoot wrench at 90 degrees from the torque wrench when
torquing the collar (torque 35 Nm).
CAUTIONIf the flare nut crowfoot wrench is not 90 degrees from the torque wrench, it can damage the special tool and/or the Rapid Splitter.
-
After inserting the new HV cables into the Rapid Splitter, perform pull
test to ensure that the cables are correctly installed.
NoteThe HV cables must be pulled with a force of 150N.