26/07/2023 16:53:27

HV Harness - FJB to Front Drive Unit - 2nd Generation (Remove and Replace)

Correction Code 44502502

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Special tool required for this procedure:

Supplier Part Number Description
Tesla 1057672-00-A TOOL, BATTERY COOLANT FILL

Removal

  1. Open the LH front door.
  2. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift .
  3. Install a steering wheel holder on the steering wheel to make sure proper placement of the steering wheel during this procedure.
  4. Open the hood.
  5. Remove the rear underhood apron. See Underhood Apron - Center - Rear (Remove and Replace).
  6. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  7. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace) .
  8. Remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  9. Remove the HEPA filter duct. See Duct - HEPA Filter (Remove and Replace) .
  10. Remove the HEPA filter inlet duct. See .
  11. Remove the HEPA filter outlet duct. See .
  12. Disconnect the 12V power. See Disconnect 12V Power .
  13. Remove the HV battery. See HV Battery (AWD) (Remove and Install) .
  14. Remove the 12V auxiliary battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  15. Remove the coolant reservoir cap.
  16. Use the battery coolant fill tool to vacuum the coolant from the coolant reservoir, and then reinstall the coolant reservoir cap on the coolant reservoir.
  17. Disconnect the electrical connector for the coolant fluid level sensor.
  18. Release the 12V harness clip from the coolant reservoir.
  19. Remove the bolts (x4) that attach the coolant reservoir to the front crossmember.
  20. Clamp the coolant hose, and then set the coolant reservoir aside.
  21. Remove the bolt that attaches the Front Junction Box (FJB)-to-front drive unit HV harness to the front drive unit.
  22. Raise the vehicle fully.
  23. Remove the bolts (x2) that attach the skid plate to the front subframe.
  24. Remove the bolt that attaches the lower i-shaft to the steering gear, and then slide the i-shaft up and away from the steering gear.
  25. Disconnect the front drive unit HV electrical connector by releasing the locking tab, and then rotate the release lever up to disengage the electrical connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use excessive force to move the release lever in order to prevent damage to the front drive unit HV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the alignment tabs on the front drive unit header are not damaged.
  26. Lower the vehicle fully.
  27. Remove and discard the bolts (x4) that attach the FJB-to-front drive unit HV harness to the FJB.
  28. Remove the clip that attaches the front drive unit inlet coolant hose to the HV harness bracket.
  29. Remove the FJB to front drive unit HV harness from the vehicle.

Installation

  1. Position the FJB to front drive unit HV harness in the vehicle.
  2. Install the clip that attaches the front drive unit inlet coolant hose to the HV harness bracket.
  3. Install new bolts (x4) that attach the FJB-to-front drive unit HV harness to the FJB (torque 7 Nm).
  4. Install the bolt that attaches the FJB-to-front drive unit HV harness to the front drive unit (torque 10 Nm).
  5. Raise the vehicle fully.
  6. Connect the front drive unit HV electrical connector to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply slight pressure to the connector as the lever is rotated into position; move the lever to the closed position slowly and make sure that the lever teeth and manifold teeth are properly engaged.
    Informational PurposesAn informational icon, calling your attention
    Note
    There should be a very small gap between the manifold and the connector when the connector is closed.
  7. Slide the lower i-shaft onto the steering gear, and then install the bolt that attaches the lower i-shaft to the steering gear (torque 30 Nm).
  8. Install the bolts (x2) that attach the skid plate to the front subframe (torque 9 Nm).
  9. Install the HV battery. See HV Battery (AWD) (Remove and Install) .
  10. Lower the vehicle fully.
  11. Connect the coolant hose to the coolant reservoir, and then remove the hose clamp.
  12. Connect the electrical connector for the coolant fluid level sensor.
  13. Install the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm).
  14. Install the 12V auxiliary battery cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  15. Reconnect the 12V power. See Disconnect 12V Power .
  16. Install the HEPA filter outlet duct. See .
  17. Connect a laptop with Toolbox 3 to the vehicle.
  18. Unlock the gateway. See Gateway Unlock
  19. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal ➜ Actions ➜ Coolant Air Purge, click Run, and allow the routine to complete.
  20. Top off the coolant reservoir.
  21. Disconnect Toolbox and remove the laptop from the vehicle.
  22. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  23. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace) .
  24. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  25. Install the rear underhood apron. See Underhood Apron - Center - Rear (Remove and Replace).
  26. Close the hood.
  27. Touch and hold the CALIBRATE button on the Model X touchscreen until the rear doors have been fully calibrated, close completely, and the message "CALIBRATION COMPLETE" is displayed.
  28. Remove the steering wheel holder from the vehicle.
  29. Remove the vehicle from the lift.
  30. Close the LH front door.