30/01/2023 11:53:21

HV Junction Box and HV Harness (Retrofit)

Correction code 44301506

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

Perform this retrofit to install a dual motor 2nd generation HV junction box and accommodating HV harness into a rear wheel drive vehicle.

Open all four doors
Lower all 4 windows
Move both front seats fully forward
Latch all four doors

Note
Do not slam doors while latches are engaged
Open hood

Note
Using MCU touchscreen > Controls > Frunk Trunk
Remove rear underhood apron
Remove LH underhood apron
Remove RH underhood apron
Remove front underhood apron

Note
2x push clips, 7x trim clips, Remove push clips, then pry up evenly using trim tool
Remove latch cover assembly

Note
2x clips, 2x connectors
Remove frunk carpet

Note
4x anchors, 4x carpeted trim, Anchors are twisted off from studs
Remove frunk extension

Note
4x double bolts, 10mm, 4 Nm, 5x bolts, 10mm, 4 Nm
Remove frunk

Note
4x bolts, 13mm, 8 Nm, 2x bolts, 10mm, 6 Nm, Lift frunk slightly to remove the hood latch cable then remove frunk
Remove the cabin filter and cover then lift up the RH side of cowl screen panel to access cabin filter housing

Note
2x push clips, Place shop rag under trim to support if needed
Remove bolts securing front HVAC filter housing

Note
2x bolts, 10mm, 1.5 Nm
Remove front HVAC filter housing

Note
2x tabs
Raise and support vehicle

Note
Set air suspension to "Jack Mode" if equipped Via Controls > ''Service''
Power down vehicle using MCU

Note
Controls > Safety&Security > Power Off > ''POWER OFF''
Disconnect the 12V battery negative terminal

Note
1x nut, 10mm, 5 Nm
Disconnect the first responder loop

Note
Wait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
Remove 2nd row seat bottom cushion

Note
2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
Remove NVH padding from underneath 2nd row seat cushion

Note
If equipped
Remove bolts securing seat bottom frame

Note
8x bolts, 11mm, 26 Nm
Lift up and support seat bottom frame

Note
Release harness clips if necessary
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
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
Remove the HVIL bolt from the HV junction box

Note
1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
Remove bolts securing HVJB cover to HVJB box

Note
4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, 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
Remove the ground nut from the ground stud located on the vehicle chassis

Note
1x nut, 13mm, 8 Nm
Remove the charge port HV cables

Note
2x nuts, 13mm, 9 Nm, Nuts are captured, Fasteners labeled 7/8
Remove the FJB HV cables

Note
2x bolts, 8mm, 4 Nm, Bolts are captured
Remove the drive inverter and HV battery cables

Note
2x nuts, 13mm, 9 Nm, Nuts are captured
Disconnect and remove all 4 HV harnesses from both chargers to HVJB

Note
8x connectors
Release coolant hose

Note
2x barrel clips, Move hose from covering HV junction box bolts
Remove the bolts that secure the HV junction box

Note
4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
Disconnect the HVJB connector

Note
1x electrical connector, Lift HV junction box assembly slightly for access
Remove HV junction box from vehicle
Inspect the HVJB to FJB HV harness.

Note
If the positive and negative cables of the HVJB to FJB HV harness are of different length, then replacement of the HVJB to FJB HV Harness is not necessary. Discontinue this procedure and go to the identical step in HV Junction Box (Retrofit). If the positive and negative cables are of the same length, then continue to the next step.
Remove lug nut covers from RH front wheel

Note
5x covers
Loosen RH front wheel

Note
5x nuts, 21mm, 175 Nm
Raise vehicle partially and lower onto locks

Note
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 RH front wheel

Note
5x nuts, 21mm, 175 Nm
Loosen rear side of RH front wheel arch liner

Note
5x clips, 1x nut, 10mm, 4Nm, Move rear of RH wheel arch liner toward front of vehicle
Lift RH lower c-pillar trim

Note
1x clip, The sill area need to be lifted approximately 3cm to allow carpet to release
Pull carpet away from RH lower c-pillar trim

Note
Carpet only needs to be moved enough to access the HV grommet and frame hole under rear seat area.
Release HV harness grommet

Note
1x grommet
Route HV cable for removal
Remove FJB cover

Note
6 bolts, 8mm, 6.5 Nm, Move ground strap aside
Remove HVJB harness from FJB

Note
2x bolts, 10mm, 4 Nm, Open cover to access bolts, Use plastic trim tools to release connector while applying upward force
Route cable away from firewall

Note
4x clips, Clips vary by production date and vehicle configuration remove as needed, use care while removing to prevent broken clips or connector
Release clips and route cable out of RH front fender area

Note
6x clips, Clips vary by production date and vehicle configuration remove as needed, Use care while removing to prevent broken clips or connector, Release air suspension lines from clips to allow additional space to route cable
Remove HVJB to FJB HV Harness from rocker

Note
Assistance is recommended, Remove toward rear of vehicle, Do not stretch harness, Release tension and twist harness if harness catches during removal
Install HVJB to FJB HV Harness through rocker

Note
Assistance is recommended, Starting from rear, Install harness gently backing up and twisting to allow connector and clips to pass obstructions
Route cable through fender and secure clips

Note
6x clips, Clips vary by production date and vehicle configuration install as needed, use care while installing to prevent broken clips or connector, Attach air suspension lines after HV cable is routed
Route along firewall

Note
4x clips, Clips vary by production date and vehicle configuration install as needed, use care while installing to prevent broken clips or connector
Install HV harness to FJB

Note
2x bolts, 10mm, 4 Nm, Open cover to access bolts, Clean HV cable and FJB connecting points with IPA wipes, Allow 1 min for IPA to dry, Close FJB door
Install FJB cover

Note
6 bolts, 8mm, 6.5 Nm, Secure ground strap with bolt
Install HVJB to FJB HV Harness grommet

Note
1x grommet
Route HVJB to FJB HV Harness to HVJB

Note
Route through hole and toward HVJB
Place carpet in installed position
Secure RH lower c-pillar

Note
1x clips, Align clip and press into place, adjust body seal to eliminate gaps and pinching
Secure RH front wheel arch liner

Note
5x clips, 1x nut, 10mm, 4 Nm
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Install RH front lug nut covers

Note
5x covers
Install Dual Motor HV junction box into vehicle
Connect HV junction box fan harness

Note
1x electrical connector, Lift HV junction box assembly slightly for access
Install the bolts that secure the HV junction box

Note
4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
Secure coolant hose

Note
2x barrel clips
Install the HV cables from the junction box to both chargers

Note
8x connectors
Install the charge port HV cables

Note
2x bolts, 13 mm, 9 Nm, Fasteners labeled 7/8, Clean with IPA, Allow 1 min to dry
Install drive inverter and HV battery cables

Note
2x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes , Allow 1 min to dry
Install the negative FJB HV cable

Note
1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for ipa to dry
Install the positive FJB HV cable

Note
1x bolts, 8mm, 4 Nm, Clean HV cable and HVJB connecting points with IPA wipes, Allow 1 min for IPA to dry
Install the HV junction box cover

Note
4x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
Install the HVIL bolt into the HV junction box cover

Note
1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
Cut two pieces of butyl patch

Note
2x butyl patch, Cut butyl patches into 35x35mm square pieces
Install butyl patch squares onto openings for the front drive unit cables on the HV junction box to prevent dirt/water ingress

Note
2x openings, Note always install butyl patches and install new patches if lid is removed, Butyl patches must remain installed to prevent contamination ingress
Install the ground nut from the ground stud located on the vehicle chassis

Note
1x nut, 13mm, 8 Nm
Remove the leather glove protectors and HV insulating gloves
Lower seat frame into position and secure harness clips to frame

Note
8x clips
Install and torque bolts securing seat frame to vehicle

Note
8x bolts, 11mm, 26 Nm
Place NVH padding onto seat frame
Reinstall seat bottom cushion

Note
2x clips, 7x connectors if equipped, Replace clips if necessary
Connect first responder loop

Note
1x connector, Engage red locking tab
Connect 12V battery negative terminal

Note
1x nut, 10mm, 5 Nm
Install front HVAC filter housing

Note
2x tabs
Install bolts securing front HVAC filter housing

Note
2x bolts, 10mm, 1.5 Nm
Install cabin filter and cover then secure cowl screen panel

Note
2x push clips
Install frunk

Note
4x bolts, 13 mm, 8 Nm, 2x bolts, 10 mm, 6 Nm, before seating frunk attach hood latch cable.
Install frunk extension

Note
4x double bolts, 10 mm, 4 Nm, 5x bolts, 10 mm, 4 Nm
Install frunk carpet

Note
4x anchors, 4x carpeted trim, Install side covers first, Hand tighten anchors to studs, Tuck carpet under frunk seal
Install latch cover assembly

Note
2x clips, 2x connectors
Install front underhood apron

Note
2x push clips, 7x trim clips
Install RH underhood apron
Install LH underhood apron
Install rear underhood apron

Note
8x clips
Close hood

Note
Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE''
Unlatch all doors

Note
Use a screwdriver to release latch while pulling door handle
Move both front seats to their original positions
Raise all 4 windows
Close all four doors

Model S Service Manual

HV Junction Box and HV Harness (Retrofit)

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