04/04/2024 04:31:51

Cover - Ancillary Bay (Remove and Replace)

Correction code 16101002 1.08 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.

  • 2024-04-04: Added information on installing and removing acillary bay kit insulators.
  • 2023-11-08: Added/updated HV insulating glove steps.
  • 2023-06-09: Corrected paint pen colors.
  • 2023-05-22: Added caution for correct positive DC cable connection.
  • 1127845-00-A Asy, Service Cover, Penthouse, Model 3
  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076971-02-A Wrench, Torque + Angle, 1/4" Dr
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
Warning IconA warning icon, calling your attention to a possibly risky situation
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: Cover - Ancillary Bay (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the positive 12V output cable to the DCDC passthrough
15 Nm (11.1 lbs-ft)
  • 13 mm 12-point deep socket
  • 3 in extension
  • Ratchet/torque wrench
Replace
Informational PurposesAn informational icon, calling your attention
Note
Mark the fastener with a paint pen after torquing.
Bolt that attaches the ancillary bay cover to the high voltage controller
5 Nm (3.7 lbs-ft) +30 deg
  • External Torx E10
  • 4 in extension
  • Ratchet/torque wrench
  • Torque wrench with angle measurement
Replace
Bolt attaches the ancillary bay cover to the HV battery
8 Nm (5.9 lbs-ft)
  • External Torx E10 5-Lobe
  • 4 in extension
  • Ratchet/torque wrench
Reuse
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
Informational PurposesAn informational icon, calling your attention
Note
Torque these fasteners in the sequence specified in the installation step.
Informational PurposesAn informational icon, calling your attention
Note
These bolts are attached to the ancillary bay cover.

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 possibilty 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. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  2. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  3. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  4. Disconnect the electrical harness from the high voltage controller connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The HV battery positive contactor and negative contactor open with a clunk sound.
  5. Install the logic connector cap onto the high voltage controller connector to prevent mistaken reconnection and protect the connector.
  6. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  7. If the leather over gloves have been removed, inspect the inner edge of the vehicle single-piece rear casting for flashing. If flashing is present, put on cut-resistant gloves.
  8. Release the cover on the positive 12V output cable, at the DCDC passthrough.
  9. Remove and discard the nut that attaches the positive 12V output cable to the DCDC passthrough, and then remove the cable from the passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
  10. Remove and discard the bolts that attach the high voltage controller internally to the ancillary bay cover.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10
    • 4 in extension
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
    Figure 1. 4-Bolt HVC Ancillary Bay Cover
    Figure 2. 3-Bolt HVC Ancillary Bay Cover
  11. Put on HV insulating gloves and leather over gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Continue to wear the gloves until instructed to remove them.
  12. Fully loosen the bolts that attach the ancillary bay cover to the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive to the ancillary bay cover.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    • 4 in extension
    • Ratchet/torque wrench
  13. Remove the logic connector cap from the high voltage controller connector.
  14. Remove the ancillary bay cover from the vehicle.
  15. Reinstall the logic connector cap onto the high voltage controller connector.
  16. Inspect whether HV insulators are present. If not present or partly present, use the Ancillary Bay Insulator kit and install the insulator caps onto the HV battery to cover live HV points. See Insulators - HV Battery (Install and Remove).
  17. Visually inspect the interior of the ancillary bay for any presence of leaked coolant.
    Informational PurposesAn informational icon, calling your attention
    Note
    Areas of interest are the coolant input and output tubes and fittings, and around the perimeter of the ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If any leaked coolant is found, escalate a Toolbox session.
  18. Visually inspect the condition of the ancillary bay cover gasket and the HV battery mating surface for cracks, cuts, gouges, abrasions, or any damage that could affect the seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the damage to the gasket is severe, replace the ancillary bay cover. If there is minor damage (including paint) that might affect the seal, perform an ancillary bay air leak test when instructed to do so.

Install

  1. Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
  2. Use an IPA wipe to clean any residue from the high voltage controller mounting bolt holes and both the inside and outside of the ancillary bay cover at the bolt holes.
  3. If the aluminum tape retrofit patch is damaged, remove it, clean the area with an IPA wipe, apply another patch of aluminum tape, and wet out the patch with a silicone roller to set the adhesive.
    Figure 3. 4-Bolt to 3-Bolt Patch 30mm x 30mm
  4. Inspect the inner edge of the vehicle single-piece rear casting for metal flashing. If flashing is present and the leather over gloves have been removed, put on cut-resistant gloves.
  5. Remove the logic connector cap from the high voltage controller connector.
  6. Remove all insulator kit covers from the HV battery. See Insulators - HV Battery (Install and Remove).
  7. Install the ancillary bay cover on the HV battery, and then hand-tighten the bolts.
  8. Remove HV insulating gloves.
  9. Reinstall the logic connector cap onto the high voltage controller connector.
  10. Torque the ancillary bay cover bolts in the sequence shown, and mark each with an orange paint pen as they are torqued.
    8 Nm (5.9 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    • 4 in extension
    • Ratchet/torque wrench
    Figure 4. 18-Bolt Ancillary Bay Cover Torque Sequence
  11. Hand-tighten new bolts that attach the high voltage controller internally to the ancillary bay cover.
    Figure 5. 4-Bolt HVC Ancillary Bay Cover
    Figure 6. 3-Bolt HVC Ancillary Bay Cover
  12. Torque the high voltage controller to ancillary bay cover bolts in the sequence shown, and mark each bolt with an orange paint pen as they are torqued.
    5 Nm (3.7 lbs-ft) +30 deg
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Insufficient torque of bolts 1 and 2 opens the high voltage interlock loop circuit.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10
    • 4 in extension
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
    Figure 7. 4-Bolt HVC Ancillary Bay Cover
    Figure 8. 3-Bolt HVC Ancillary Bay Cover
  13. Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a pink/violet paint pen after torque.
    15 Nm (11.1 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the rubber boot is not trapped under the cable lug or pinched between the cable lug and nut.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the fastener with a paint pen after torquing.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm 12-point deep socket
    • 3 in extension
    • Ratchet/torque wrench
  14. If removed, replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  15. Remove the logic connector cap from the high voltage controller connector.
  16. Connect the electrical harness to the high voltage controller connector.
  17. If damage was found on the ancillary bay cover gasket or the HV battery mating surface, or if the aluminum tape retrofit patch was replaced, or if another procedure instructed to perform an ancillary bay air leak test, do that now. See Ancillary Bay Air Leak Test.
  18. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  19. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  20. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  21. Connect 12V power. See 12V/LV Power (Disconnect and Connect).