27/02/2024 17:55:54

Controller - High Voltage (Non-Structural Pack) (Remove and Replace)

Correction code 16301602 1.20 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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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: Controller - High Voltage (Non-Structural Pack) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts that attach the HVC to the ancillary bay cover
5 Nm (3.7 lbs-ft) +30 deg
  • External Torx E10
  • 4 in extension
  • Ratchet/torque wrench
Replace
Screws that attach the HVC tray to the ancillary bay
2 Nm (1.5 lbs-ft)
  • Insulated tools:
    • Torx T25 socket
    • 10 in extension
    • Magnetic pick up tool
    • Wiha TorqueVario-S 0.8 Nm - 2.0 Nm screwdriver (installation only)
    • Ratchet/torque wrench
 Reuse Not necessary to remove these fasteners if only removing the HVC
Bolts that attach the HVC tray to the HVC
2 Nm (1.5 lbs-ft)
  • Insulated tools:
    • External Torx E6
    • 2 in extension
    • Ratchet/torque wrench
 Reuse

Remove

  1. If the high voltage controller is being removed as part of another component's replacement procedure, and the same controller will be installed later, go to step 3. Otherwise, continue to the next step.
  2. Perform a backup of the high voltage controller data. See Controller - High Voltage (Backup and Restore).
  3. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  4. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  5. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  6. Perform the vehicle isolation procedure. See Vehicle HV Disablement Procedure
  7. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  8. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  9. Disconnect the ancillary bay harness from the high voltage controller connectors.
  10. Remove the bolts (x2) that attach the high voltage controller to the high voltage controller tray, and then remove the high voltage controller from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • External Torx E6
      • 2 in extension
      • Ratchet/torque wrench

Install

  1. Position the high voltage controller tray on the high voltage controller, and then install the bolts that attach the tray to the controller.
    2 Nm (1.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the correct REV- for the HVC before installation, and make sure the REV- is compatible with the old HVC.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • External Torx E6
      • 2 in extension
      • Ratchet/torque wrench
  2. Connect the ancillary bay harness to the high voltage controller connectors.
  3. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install the ancillary bay cover at this time.
  4. If the high voltage controller was removed and then installed as part of another component's replacement procedure, return to that procedure.
  5. Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
  6. 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.
  7. 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 1. 4-Bolt to 3-Bolt Patch 30mm x 30mm
  8. Set the ancillary bay cover onto the ancillary bay, and install the two bolts on either side of the high voltage controller connector.
    5 Nm (3.7 lbs-ft) +30 deg
  9. Connect the electrical harness to the high voltage controller connector.
  10. Connect the positive 12V output cable to the DCDC passthrough, install a new nut to attach the cable, and mark the nut with a green 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.
    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
  11. If removed, replace the cover on the positive 12V output cable at the DCDC passthrough, and then press down to attach the cover.
  12. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  13. Connect a 12V charger to the 12V battery, or an LV maintainer. See LV Maintainer (Connect and Disconnect).
  14. Perform a restore of the high voltage controller data. See Controller - High Voltage (Backup and Restore).
  15. Disconnect the 12V charger from the 12V battery, or the LV maintainer. See LV Maintainer (Connect and Disconnect).
  16. Install the ancillary bay cover on the HV battery, and then hand-tighten the bolts.
  17. Torque the ancillary bay cover bolts in the sequence shown, and mark each with a green 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 2. 18-Bolt Ancillary Bay Cover Torque Sequence
  18. Hand-tighten new bolts that attach the high voltage controller internally to the ancillary bay cover.
    Figure 3. 4-Bolt HVC Ancillary Bay Cover
    Figure 4. 3-Bolt HVC Ancillary Bay Cover
  19. Torque the high voltage controller to ancillary bay cover bolts in the sequence shown, and mark each bolt with a green 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 5. 4-Bolt HVC Ancillary Bay Cover
    Figure 6. 3-Bolt HVC Ancillary Bay Cover
  20. 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.
  21. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  22. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).