17/06/2024 14:33:17
Leistungswandlersystem (Strukturpack) (Ausbauen und Ersetzen)
Korrekturcode 16301012 3.54 HINWEIS: Sofern im Verfahren nicht ausdrücklich anders angegeben, spiegeln der obige Korrekturcode und die FRT den gesamten für die Durchführung dieses Verfahrens erforderlichen Aufwand wider, einschließlich der damit verbundenen Verfahren. Schichten Sie keine Korrekturcodes, wenn Sie nicht ausdrücklich dazu aufgefordert werden.HINWEIS: Unter Richtzeiten erfahren Sie mehr über FRTs und wie sie erstellt werden. Für Rückmeldungen zu den FRT-Werten senden Sie bitte eine E-Mail an LaborTimeFeedback@tesla.com. HINWEIS: Siehe Persönlicher Schutz, um sicherzustellen, dass Sie die richtige persönliche Schutzausrüstung tragen, wenn Sie das folgende Verfahren durchführen.
- 2023-09-18: Updated torque information.
Warnung
Bei diesem Verfahren handelt es sich um einen ENTWURF, der jedoch bereits validiert wurde. Warn- und Sicherheitshinweise sind möglicherweise nicht vorhanden. Befolgen Sie die Sicherheitshinweise, und gehen Sie beim Arbeiten an oder in der Nähe von Hochspannungssystemen und -bauteilen äußerst vorsichtig vor. Übermitteln Sie Verbesserungsvorschläge und Feedback an ServiceDevelopment@teslamotors.com.
- Remove the LH rocker panel carrier. See Träger – Trittbrett – LH (Strukturpack) (Ausbauen und Ersetzen).
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Remove butyl patches covering LH rocker access holes
Anmerkung2x butyl patches, Clean excess butyl from area
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Install lift pad adapters onto LH rocker
Anmerkung2x lift pad adapters
- Remove the RH rocker panel carrier. See Träger – Trittbrett – LH (Strukturpack) (Ausbauen und Ersetzen).
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Remove butyl patches covering RH rocker access holes
Anmerkung2x butyl patches, Clean excess butyl from area
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Install lift pad adapters onto RH rocker
Anmerkung2x lift pad adapters
- Open all four doors
- Lower all four windows
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Place vehicle in service mode through UI
AnmerkungSelect vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
- Move LH front seat forward
- Move RH front seat forward
- Remove the 2nd row lower seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen).
- Remove the LH and RH lower c-pillar trims. See Verkleidung – C-Säule – Unten – LH (Ausbauen und Ersetzen).
- Remove the RH 2nd row seat back. See Rückenlehne – 2. Sitzreihe – RH (Ausbauen und Ersetzen).
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Raise and support vehicle
AnmerkungVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
- Remove the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
- Remove the HEPA filter assembly. See eBaugruppe – Filter – HEPA (Aus- und Einbauen).
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Power off vehicle from center display
AnmerkungVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Disconnect LV battery connector and First Responder Loop
Anmerkung2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
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Verify operation of multimeter
AnmerkungSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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Raise vehicle fully and lower lift onto locks
AnmerkungSet 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 the front aero shield panel. See Verkleidung – Windabweiser – Vorne (Strukturpack) (Ausbauen und Ersetzen).
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Remove push clips at left and right wheel house liner to mid aero shield
Anmerkung2x clips
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Remove mid aero shield
Anmerkung11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
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Position coolant drain container underneath LH front of HV battery
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Disconnect PT supply hose at LH front side of vehicle
Anmerkung1x spring clip, Plug hose connections as needed
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Install PCS flush adapter onto PT supply hose
AnmerkungRemove plugs as needed, Verify fully seated, Perform push-pull-push test
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Secure coolant cart flush hose to regulator and PCS flush adapter
AnmerkungVerify regulator valve is closed, Pressure regulator is not adjustable
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Position coolant drain container underneath LH RDU area
AnmerkungPosition neck to catch all coolant loss
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Disconnect RDU inverter inlet hose from fluid coupling
Anmerkung1x spring clip, 2x plugs, Plug drive unit coupling
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Attach compressed air line to coolant pressure tester
AnmerkungMake sure valve is closed on pressure regulator
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Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
AnmerkungAllow system to drain completely
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Close valve on pressure regulator once no coolant is draining from RDU inverter inlet hose
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Disconnect compressed air from coolant pressure tester
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Remove cart flush hose from PCS Flush adapter
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Remove PCS flush adapter from PT supply hose
Anmerkung1x spring clip, Plug hose connections as needed
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Remove coolant drain container from underneath vehicle
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
AnmerkungCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
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Put on HV insulating gloves and leather over gloves
AnmerkungMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Install amp clamp to RDU HV harness
AnmerkungVerify 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. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
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Release RDU HV harness from HV battery
Anmerkung1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
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Verify no high voltage at RDU HV header
AnmerkungMake 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
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Lower vehicle until tires are touching the ground
AnmerkungRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Disconnect HVC logic connector and install logic cap
Anmerkung1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
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Disconnect power connector to HV battery
Anmerkung1x connector, Pull locking tab upward then release connection
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Remove bolt securing busbar cover access door
Anmerkung1x bolt, 10mm, 9 Nm
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Remove bolts securing charge port busbar kit to HV header
Anmerkung2x bolts, 10mm, 9 Nm
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Disengage LH body harness from rear body and move aside
Anmerkung1x clip
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Lift busbar kit connector to remove from HV header
AnmerkungUse inflatable air bag to suspend busbar away from HV header during removal and installation
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Remove NVH insulation from ancillary bay cover
AnmerkungMove insulation aside
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Remove fasteners securing ancillary bay cover to high voltage controller
Anmerkung3x bolts, E10, 10 Nm
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Release fasteners securing PCS LVDC header to ancillary bay cover
Anmerkung3x bolts, T20, 2.5 Nm
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Release fasteners securing charge port header to ancillary bay cover and remove doubler
Anmerkung2x bolts, EPL 10, Torque 10 Nm, Release charge port header from ancillary bay and remove plastic doubler, Take note of small tabs on shielding
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Release perimeter bolts securing ancillary bay to HV battery
Anmerkung22x captured bolts, EPL 10, Torque 5 Nm
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Remove ancillary bay cover from HV battery
AnmerkungRecommend assistance, Lift up on the RH side and pivot the cover, Maneuver away from body casting and charge port components and HV header
- Entfernen Sie den Pyro-Batterietrennschalter. Siehe Pyrotechnischer Batterie-Trennschalter (Strukturpack) (Ausbauen und Einbauen).
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Disconnect HV controller connectors
Anmerkung7x connectors, Lift hinge upwards to release levered connection
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Release harness clips from HVC hinge tray and route harness away
Anmerkung3x clips
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Remove the HVC and tray assembly from ancillary bay
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Disconnect PCS to DC bus HV connector
Anmerkung1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS logic connector from PCS
Anmerkung1x connector
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Disconnect PCS LV connector from PCS
Anmerkung1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect AC filter harness
Anmerkung1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Release PCS supply hose from PCS
Anmerkung1x hose, Carefully release PCS hose using the special tool, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required, Plug PCS
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Release ancillary bay harness clip by PCS return hose
Anmerkung1x clip
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Release PCS return hose from PCS
Anmerkung1x hose, Carefully release PCS hose using the special tool, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required, Plug PCS
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Remove bolts securing PCS to HV battery
Anmerkung6x bolts, 8mm, 6 Nm, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners
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Secure suction cups to PCS
AnmerkungContinue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss, Verify fully secured
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Remove PCS from vehicle
AnmerkungRecommend assistance, Carefully lift PCS up and remove from vehicle, Place on safe working bench
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Remove suction cups from the old PCS
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Secure suction cups to PCS
AnmerkungContinue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss, Verify fully seated
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Position PCS into vehicle
AnmerkungRecommend assistance, Carefully lift PCS up and position into vehicle, Verify it is orientated correctly
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Install bolts securing PCS to HV battery
Anmerkung6x bolts, 8mm, 6 Nm
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Remove PCS plugs from new PCS
Anmerkung2x plugs
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Secure PCS return hose onto PCS
Anmerkung1x hose, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated
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Secure ancillary bay harness clip by PCS return hose
Anmerkung1x clip
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Secure PCS supply hose onto PCS
Anmerkung2 tabs, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated
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Connect PCS to fastcharge contactor HV harness connector
Anmerkung1x connector, Secure connector and enage red locking tab, Make sure the connector is fully seated
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Connect PCS LV connector to PCS
Anmerkung1x connector, Secure connector and enage red locking tab, Make sure the connector is fully seated
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Connect PCS logic connector to PCS
Anmerkung1x connector
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Connect PCS to DC bus HV connector
Anmerkung1x connector, Secure connector and engage red locking tab, Make sure the connector is fully seated
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Secure HVC hinge tray onto hinge clips and install into vehicle
Anmerkung2x hinge clips, Position assembly into vehicle, Take note of the way the harness will route over the hinge, Carefully secure hinge tray onto hinge clips, Verify fully seated
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Secure HV controller connectors
Anmerkung7x connectors, Lift hinge upwards and secure levered connector
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Secure harness clips onto HVC hinge tray and route harness
Anmerkung3x clips, Secure harness onto guides and secure clips
- Messen Sie die Spannung an den Befestigungspunkten des Pyro-Batterietrennschalters, und montieren Sie den Pyro-Batterietrennschalter. Siehe Pyrotechnischer Batterie-Trennschalter (Strukturpack) (Ausbauen und Einbauen).
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Inspect ancillary bay phantom seal to verify no damage is present
AnmerkungIf damage is present, Replace ancillary bay phantom seal
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Install ancillary bay cover onto HV battery
AnmerkungRecommend assistance, Guide LH side of cover into position clearing HV header, Maneuver cover past body casting and into position with charge port components
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Install perimeter bolts securing ancillary bay to HV battery
Anmerkung22x captured bolts, EPL 10, Torque 5 Nm, Thread bolts in evenly and torque
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Secure doubler and install fasteners securing charge port header to ancillary bay cover
Anmerkung2x bolts, EPL 10, Torque 10 Nm, Secure doubler onto header and install bolts, Take note of small tabs on shielding
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Install fasteners securing PCS LVDC header to ancillary bay cover
Anmerkung3x bolts, T20, 2.5 Nm
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Install fasteners securing ancillary bay cover to high voltage controller
Anmerkung3x bolts, E10, 10 Nm
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Install NVH insulation onto ancillary bay cover
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Connect power connector to HV battery
Anmerkung1x connector, Push red locking tab down to secure connection
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Connect HVC logic connector
Anmerkung1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
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Clean busbar HV connector contact surface of residual Penetrox
AnmerkungAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
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Clean HV connector contact surface of residual Penetrox
AnmerkungAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
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Apply Penetrox onto HV connector joints
AnmerkungApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
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Position busbar kit connector and lower onto HV header
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Install bolts securing charge port busbar kit to HV Header
Anmerkung2x bolts, 10mm, 9 Nm
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Anmerkung2x HV joints, 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.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
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Install fastener securing busbar cover access door
Anmerkung1x bolt, 10mm, 9 Nm
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Engage LH body harness onto rear body
Anmerkung1x clip
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Connect power connector to HV battery
Anmerkung1x connector, Push red locking tab down to secure connection
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Connect HVC logic connector
Anmerkung1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
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Raise vehicle fully and lower lift onto locks
AnmerkungSet 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
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Secure RDU HV harness onto HV battery
Anmerkung1x 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 HV insulating gloves
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Secure closed end cap to RDU inverter inlet hose
Anmerkung1x hose, Plug hose with cap from the coolant hose plug kit, Plug hose so it will not leak air, Perform push-pull-push test
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Secure coolant leak test adapter to PT supply hose
AnmerkungThis adapter is connected to regulated air line adapter, Make sure the locking tab is fully seated, Perform push-pull-push test
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Secure pressure test fixture hose to leak test adapter
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Secure compressed air line to pressure test fixture
AnmerkungMake sure valves are closed on pressure regulator
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Open the regulator valve then slowly adjust regulator to 50 psi
AnmerkungUse caution due to high pressure, Make sure to wear safety glasses and personal protection equipment
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Open the 2nd valve slowly
AnmerkungSlowly allow air to enter system
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Allow 1 minutes and 50 seconds for the pressure to stabilize
AnmerkungAllow 1 minutes and 50 seconds (110 seconds) for pressure to stabilize
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Close the regulator valve
- Record start pressure value
- Allow 4 minutes to test
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Record end pressure value
AnmerkungIf pressure did not drop more than 0.35 psi, continue to next step, If pressure dropped more than 0.35 psi, then inspect for leaks and retest
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Release compressed air line from pressure test fixture
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Open the regulator valve slowly
AnmerkungSlowly allow air to leave the system
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Release pressure test fixture hose from coolant leak test adapter
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Release coolant leak test adapter to PT supply hose
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Release closed end cap from RDU inverter inlet hose
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Remove hose plugs and connect coolant inlet hose to rear drive unit
Anmerkung1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
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Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Anmerkung11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
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Install push clips at left and right wheel house liner to mid aero shield
Anmerkung2x clips
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Connect PT supply hose at LH front side of vehicle
Anmerkung1x spring clip, Remove plugs as needed
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Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
Anmerkung12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
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Lower vehicle fully
AnmerkungRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove coolant bottle cap
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Fill coolant to the proper level
AnmerkungEnsure that the fluid level filled to the Max line
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Connect first responder loop and leave LV battery disconnected
Anmerkung1x connectors, Secure FRL only, Leave LV battery disconnected
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Connect 12V maintainer
AnmerkungRelease positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time
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Connect to vehicle using Toolbox 3.0
AnmerkungVehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
- Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
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Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
AnmerkungMake sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
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Inspect coolant level and top off as necessary
AnmerkungEnsure that the fluid level is at the Max line
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Install coolant bottle cap
- Select ‘Actions/Autodiag’ and search for ‘Redeploy’
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Select ‘SERVICE CAN REDEPLOY’, click ‘Run’, and allow routine to complete
AnmerkungSelect ‘X’ at top right of window to close once complete, Routine will state pass but update will continue to run in the background, UI will indicate status of update
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Verify CAN redeploy has completed on center display
AnmerkungVerify can redeploy has completed, Release notes may not be present, Verify that the progress bar is no longer existing and vehicle is done updated
- Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
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Connect LV battery
Anmerkung1x connector, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
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Disconnect 12V maintainer
AnmerkungUnplug maintainer and release connections from vehicle, Re-secure positive terminal cover
- Install the HEPA filter assembly. See eBaugruppe – Filter – HEPA (Aus- und Einbauen).
- Install the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
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Remove vehicle from lift
AnmerkungLower rack arms fully and remove from under vehicle
- Install the RH 2nd row seat back. See Rückenlehne – 2. Sitzreihe – RH (Ausbauen und Ersetzen).
- Install the RH lower c-pillar trim. See Verkleidung – C-Säule – Unten – LH (Ausbauen und Ersetzen).
- Install the LH 2nd row seat back. See Rückenlehne – 2. Sitzreihe – LH (Ausbauen und Ersetzen).
- Install the LH lower c-pillar trim. See Verkleidung – C-Säule – Unten – LH (Ausbauen und Ersetzen).
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Install clips securing rear main cabin carpet to vehicle
Anmerkung3x push clips
- Install the 2nd row lower seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen).
- Move LH front seat to original position
- Move RH front seat to original position
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Exit Service Mode through UI
AnmerkungControls > Service Mode > Exit Service Mode
- Raise LH front window
- Close LH front door
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Remove lift pad adapters from RH rocker
Anmerkung2x lift pad adapters
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Install butyl patches onto RH rocker access holes
Anmerkung2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the RH rocker panel carrier. See Träger – Trittbrett – LH (Strukturpack) (Ausbauen und Ersetzen).
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Remove lift pad adapters from LH rocker
Anmerkung2x lift pad adapters
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Install butyl patches onto LH rocker access holes
Anmerkung2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the LH rocker panel carrier. See Träger – Trittbrett – LH (Strukturpack) (Ausbauen und Ersetzen).