17/06/2022 13:25:30

Harness - Thermal Bar (Remove and Replace)

Correction code 17101302 1.56 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

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads, DO NOT position the lift arm pads under the battery or side rails, as shown in red
Open LH front door
Lower LH and RH front windows
Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).

Note
Do not remove the frunk seal.
Power off vehicle via center display

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

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

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
Raise vehicle fully and lower lift 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 clips securing mid aero shield

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

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

Note
Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. 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. 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

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
Release LH RDU HV harness from HV battery

Note
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

Note
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

Note
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

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

Note
4x push clips
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Release RH wiper arm hose nozzle

Note
1x hose
Release LH wiper arm hose nozzle

Note
1x hose
Remove LH wiper arm nut cover

Note
1x cover
Remove RH wiper arm nut covers

Note
2x cover
Remove RH wiper arm nuts and release assembly

Note
2x nuts, 15mm, 32 Nm, Do not flex wiper arm to remove
Remove LH wiper arm nut and release assembly

Note
1x nut, 15mm, 32 Nm, Do not flex wiper arm to remove, Lower the hood slightly to fit wiper arm removal tool
Release cowl screen washer supply hose located above LH shock tower cover

Note
1x hose
Remove LH outer hood hinge cover

Note
1x clips
Remove RH outer hood hinge cover

Note
1x clips
Remove wiper cowl screen panel

Note
4x push clips, Pull cowl up out of lower windshield channel
Disconnect air quality sensor harness

Note
1x connector
Release coolant hose from LV battery

Note
1x clip
Remove fasteners securing the LV battery and remove assembly

Note
3x bolts, 10mm, 9 Nm, 2x locators
Remove wiper module

Note
3x bolts, 10mm, 9 Nm, 1x connector, Rotate module forward and up to access connector
Release upper connections on the front controller

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

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

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

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

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

Note
3x bolts, 10mm, 10 Nm
Remove front controller from vehicle

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

Note
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

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

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

Note
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

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

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

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

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

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

Note
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

Note
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

Note
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

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

Note
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

Note
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

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

Note
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

Note
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

Note
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

Note
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

Note
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

Note
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

Note
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

Note
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

Note
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

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

Note
Maneuver underneath wiper assembly brace and multisystem beam
Install thermal bar harness to vehicle

Note
Maneuver underneath multisystem beam and wiper assembly mount
Secure thermal bar harness guide to supermanifold

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Note
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

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

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

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

Note
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

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

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

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

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

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

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

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

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

Note
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

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

Note
2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
Install wiper module

Note
3x bolts, 10mm, 9 Nm, 1x connector, Secure connector before install, Rotate module rearward and up into place
Install LV battery to multi-system beam

Note
3x bolts, 10mm, 9 Nm. 2x locators
Secure coolant hose to LV battery

Note
1x clip
Connect air quality sensor harness

Note
1x connector
Install wiper cowl screen panel

Note
4x push clips, Secure cowl into lower windshield channel
Secure cowl screen washer supply hose located above LH shock tower cover

Note
1x hose
Install LH outer hood hinge cover

Note
1x clips
Install RH outer hood hinge cover

Note
1x clips
Install RH wiper arm assembly and secure nuts

Note
2x nuts, 15mm, 32 Nm, Line up wiper to reference mark on windshield
Install LH wiper arm assembly and secure nut

Note
1x nut, 15mm, 32 Nm
Secure LH wiper arm hose nozzle

Note
1x hose, Hose is routed above the arm pivot
Secure RH wiper arm hose nozzle

Note
1x hose, Hose is routed below the arm pivot
Install RH wiper arm nut covers

Note
2x cover
Install LH wiper arm nut cover

Note
1x cover
Connect First Responder Loop and LV battery connector

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

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Calibrate RH falcon wing door

Note
Hold the upper B-pillar button in the down position to manually calibrate
Calibrate LH falcon wing door

Note
Hold the upper B-pillar button in the down position to manually calibrate
Close LH front door

Model X Service Manual

Harness - Thermal Bar (Remove and Replace)

Figure 1

Figure 2

Figure 3