2025-03-12

Harness - AWD - Penthouse (Remove and Replace)

Correction code 1630011202 FRT 3.00 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 wearing proper PPE when performing the below procedure.

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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning
Only technicians who have been trained in High Voltage 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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Torque Specifications

Table 1. Torque Specifications:Penthouse - AC Filter Harness (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt securing positive fastcharge busbar DC link side
15 Nm (11.1 lbs-ft) Minus 180 degress
  • Insulated Ratchet 1/4in Dr Std
pending

Remove

Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
When servicing the ancillary bay cover and components in or around the ancillary bay, there is a possibility of encountering metal flashing on the inner edge of the vehicle single-piece rear casting. These sharp protrusions are a cut hazard, and proper PPE should be worn if there is a chance of contacting the flashing unprotected. If not already wearing leather over gloves, then at least wear cut-resistant gloves when the flashing is present.
  1. Open all the doors and lower all the windows.
  2. Remove the HEPA filter assembly. See Hepa Filter (Remove and Replace).
  3. Disconnect the LV power. See LV Power (Disconnect and Connect).
  4. Remove the 2nd row RH seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).
  5. Remove the 2nd row LH seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).
  6. Verify operation of multimeter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals.
  7. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  8. Remove pyro disconnect from ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).
  9. Use bungee to secure HVC in an upwards position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wrap bungee around RH headrest.
  10. Remove HV battery rear skid plate. See High Voltage Battery Assembly - Skid Plate - Rear (Remove and Replace).
  11. Perform Platter Enclosure Coolant Leak Test. See Platter Enclosure Coolant Leak Test (Inspection).
  12. Remove the PCS from vehicle. See Power Conversion System (Remove and Replace).
  13. Remove the positive pack contactor from ancillary bay. See .
  14. Remove DCDC pass through from ancillary bay. See Passthrough - DCDC - 12V (Remove and Replace).
  15. Remove the 3PH AC Filter harness from the vehicle. See Penthouse - AC Filter Harness (Remove and Install).
  16. Remove busbar DC input assembly from ancillary bay. See Penthouse - AC Filter Harness (Remove and Install).
  17. Remove busbar DC input assembly from ancillary bay. See Dc Input Header -2P - 600V (Remove and Replace).
  18. Remove the FC assembly from ancillary bay. See Fast Charge Contactor - High Voltage Battery (Remove and Replace).
  19. Insert UFO harness removal tool beneath daisy chain pass through housing, and then pull daisy chain pass through housing upward to remove the LH daisy chain pass through housing from ancillary bay.
  20. Remove the HVC and tray assembly from ancillary bay. See High Voltage System Controller (Remove and Replace).
  21. Remove positive DC link from ancillary bay. See HV Battery System - HV Battery Electrical Components - Ancillary Bay - DC Link - Positive (Remove and Replace).
  22. Cut cable ties securing the megaharness to charger output to DC bus harness.
  23. Remove the Ancillary bay harness assembly fixing clip from the DC link.
  24. Remove the tab from the DC link shell.
    Informational PurposesAn informational icon, calling your attention
    Note
    When removing a tab,it should break off along the bottom edge, do not leave any sharp corners that may damage the wiring harness.
  25. Remove megaharness from ancillary bay.

Install

  1. Position megaharness to ancillary bay for installation.
  2. Fix the Ancillary bay harness assembly to the DC link.
  3. Install new cable ties securing the megaharness to charger output to DC bus harness.
  4. Install the RH daisy chain pass through housing to ancillary bay.
  5. Install positive DC link to ancillary bay. See HV Battery System - HV Battery Electrical Components - Ancillary Bay - DC Link - Positive (Remove and Replace).
  6. Install the X423 connector onto the DC bus.
  7. Install the pyro disconnect logic connector.
  8. Install harness to shunt insulator.
  9. Connect shunt assembly connector.
  10. Install the X422 connector onto the DC bus.
  11. Install the X421 connector onto the DC bus.
  12. Install the LH daisy chain pass through housing to ancillary bay.
  13. Install the FC assembly to ancillary bay. See Fast Charge Contactor - High Voltage Battery (Remove and Replace).
  14. Install and torque bolt securing positive fastcharge busbar DC link side to first value, loosen 180 degrees, and then torque to final value.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
  15. Perform Hioki impedance test at the positive HV joint of the fastcharge busbar DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.025 mΩ (25 μΩ).
  16. Perform Hioki impedance test at the negative HV joint of the fastcharge busbar DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.055 mΩ (55 μΩ).
  17. Install ancillary bay left terminals cover.
  18. Install harness clips to FC contactor cover.
  19. Install ancillary bay harness clip around negative pack contactor area.
  20. Connect LV fastcharge contactor connector.
  21. Connect ancillary bay harness connectors to negative pack contactor.
  22. Remove busbar DC input assembly from ancillary bay. See Dc Input Header -2P - 600V (Remove and Replace).
  23. Install the 3PH AC Filter harness to the vehicle. See Penthouse - AC Filter Harness (Remove and Install).
  24. Install DCDC pass through to ancillary bay. See Passthrough - DCDC - 12V (Remove and Replace).
  25. Install the positive pack contactor to ancillary bay. See .
  26. Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 110 μΩ.
  27. Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), if the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  28. Install HV joint insulators onto positive pack contactor.
  29. Install ancillary bay harness clip to positive pack contactor.
  30. Connect ancillary bay harness connectors to positive pack contactor.
  31. Install the HVC and tray assembly to ancillary bay. See High Voltage System Controller (Remove and Replace).
  32. Install the PCS to vehicle. See Power Conversion System (Remove and Replace).
  33. Replace o-ring on PCS side inlet hose.
  34. Connect PCS coolant inlet hose to PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure coolant hose is fully latched, then visually verify clip is fully seated.
  35. Replace o-ring on PCS side outlet hose.
  36. Connect PCS coolant outlet hose to PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure coolant hose is fully latched, then visually verify clip is fully seated. Visually inspect area for any coolant residue, clean with shop towel if necessary.
  37. Lay HVC in original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release bungee from back of headrest.
  38. Install pyro disconnect to ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).
  39. Measure resistance from module 2 busbar to pyro disconnect.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.048 mΩ (48 μΩ). Perform zero adjust to Hioki meter prior to testing.
  40. Measure resistance from pyro disconnect to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.033 mΩ (33 μΩ). Perform zero adjust to Hioki meter prior to testing.
  41. Remove service insulator kit.
  42. Install busbar DC input assembly to ancillary bay. See Dc Input Header -2P - 600V (Remove and Replace).
  43. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step.
  44. Install fastener securing busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  45. Install HV battery ancillary bay cover. See Penthouse Cover (Remove and Replace).
  46. Install the 2nd row RH seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).
  47. Install the 2nd row LH seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).
  48. Perform Platter Enclosure Coolant drain and refill. See Platter Enclosure Coolant (Drain And Refill) (Test/Adjust).
  49. Connect the LV power. See LV Power (Disconnect and Connect).
  50. Unlock the gateway. See Gateway (Unlock).
  51. On the touchscreen, tap the Service Mode, and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  52. Select Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  53. Select Coolant Purge Start > Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  54. Exist Service Mode. See Service Mode.
  55. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  56. Install HV battery rear skid plate. See High Voltage Battery Assembly - Skid Plate - Rear (Remove and Replace).
  57. Install the HEPA filter assembly. See Hepa Filter (Remove and Replace).
  58. Move the front seats to original positions.
  59. Raise all four windows.
  60. Close all four doors.