2025-09-12

DC Link - Positive - Ancillary Bay (Model Y L) (Remove and Replace)

Correction code 16300501802 FRT 2.64 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Remove

  1. Remove the PCS2 Lite. See PCS2 Lite - Ancillary Bay (Model YL) (Remove and Replace).
  2. Remove the positive pack contactor. See Pack Contactor - High Voltage - Positive (Remove and Replace).
  3. Remove the HV joint insulator for the HV battery DC link positive busbar.
  4. Remove and discard the nut that attaches the DC link to the DC link positive busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  5. Remove the ancillary bay harness clips (x3) from the positive DC link.
  6. Remove the positive DC link from the ancillary bay by releasing the guide pins (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to touch rear terminal of module 4.

Replace

  1. Align the guide pins (x2) and position the positive DC link onto the ancillary bay for installation.
  2. Install the ancillary bay harness clips (x3) onto the positive DC link.
  3. Install a new nut that attaches the DC link to the DC link positive busbar.
    5 Nm (3.7 lbs-ft) + 35 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the nut after torque.
  4. Measure the resistance at the DC link to the DC link positive busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is 110 μΩ or less.
  5. Install the HV joint insulator for the HV battery DC link positive busbar.
  6. Install the positive pack contactor. See Pack Contactor - High Voltage - Positive (Remove and Replace).
  7. Install the PCS2 Lite. See PCS2 Lite - Ancillary Bay (Model YL) (Remove and Replace).