15/12/2023 01:29:57

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

Correction code 16301632 1.74 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.

  • 2023-11-10: Added links for 3-phase structural pack ancillary bay cover procedure.
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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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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.

Remove

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. 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 4. Otherwise, continue to the next step.
  3. Perform a backup of the high voltage controller data. See Controller - High Voltage (Backup and Restore).
  4. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace) or Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  5. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  6. Disconnect the ancillary bay harness from the high voltage controller connectors.
  7. 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.

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.
  2. Connect the ancillary bay harness to the high voltage controller connectors.
  3. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  4. If the high voltage controller was removed and then installed as part of another component's replacement procedure, return to that procedure.
  5. Inspect the inner edge of the vehicle single-piece rear casting for metal flashing. If flashing is present, put on cut-resistant gloves.
  6. Inspect the ancillary bay phantom seal and verify that no damage is present. Otherwise, replace the seal.
  7. With the help of an assistant, position the LH side of the ancillary bay cover over the DC input HV header, pivot the cover to under the body casting, position the RH side of the cover over the high voltage controller connector and DC output connector, and then lower the cover onto the ancillary bay.
  8. Install the two bolts on either side of the high voltage controller connector.
    10 Nm (7.4 lbs-ft)
  9. Connect the electrical harness to the high voltage controller connector.
  10. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  11. Connect an LV maintainer. See LV Maintainer (Connect and Disconnect).
  12. Perform a restore of the high voltage controller data. See Controller - High Voltage (Backup and Restore).
  13. Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  14. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace) or Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  15. Disable Service Mode from the touchscreen. See Service Mode.
  16. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.