04/06/2024 18:01:34

HV Harness - Heat Pump - HV Battery (Structural Pack) (Remove and Replace)

Correction code 16301102 2.04 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
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.
  1. Open all four doors
  2. Lower all four windows
  3. Place vehicle in service mode with touchscreen
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold Tesla T icon at top of center display for four seconds and then type "service" into dialog box
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove bolt securing frunk to washer fluid reservoir neck
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  6. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  7. Move LH front seat forward
  8. Move RH front seat forward
  9. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  10. Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  11. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  12. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  13. Power off vehicle from center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
  14. Disconnect LV battery connector and First Responder Loop
    Informational PurposesAn informational icon, calling your attention
    Note
    2x 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
  15. 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
  16. Raise and support vehicle
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    Note
    Ensure vehicle is not charging before lifting it off the ground
  17. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  18. Remove push clips at left and right wheel house liner to mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  19. Remove mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
  20. Remove all items from pockets and ensure not wearing metal items
  21. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check 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
  22. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  23. Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify 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.
  24. Release RDU HV harness from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  25. Verify no high voltage at RDU HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Make 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
  26. Release compressor HV harness connection from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up
  27. Remove bolts securing HV header connector to HV battery
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    Note
    2x bolts, 8mm, 6 Nm
  28. Lower vehicle until tires are touching the ground
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  29. Disconnect HVC logic connector and install logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
  30. Disconnect power connector to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pull locking tab upward then release connection
  31. Remove bolt securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  32. Remove bolts securing charge port busbar kit to HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  33. Disengage LH body harness from rear body and move aside
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  34. Lift busbar kit connector to remove from HV header
    Informational PurposesAn informational icon, calling your attention
    Note
    Use inflatable air bag to suspend busbar away from HV header during removal and installation
  35. Remove NVH insulation from ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    Move insulation aside
  36. Remove fasteners securing ancillary bay cover to high voltage controller
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E10, 10 Nm
  37. Release fasteners securing PCS LVDC header to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, T20, 2.5 Nm
  38. Release fasteners securing charge port header to ancillary bay cover and remove doubler
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10 EPL, 10 Nm, Release charge port header from ancillary bay and remove plastic doubler, Take note of small tabs on shielding
  39. Release perimeter bolts securing ancillary bay to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    22x captured bolts, EPL 10, 5 Nm
  40. Remove ancillary bay cover from HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Lift up on the RH side and pivot the cover, Maneuver away from body casting and charge port components
  41. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  42. Remove 63A fuse cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x securing tabs
  43. Remove 63A fuse from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 8mm, 2.5 Nm, Discard after removal
  44. Remove 63A fuse from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 8mm, 2.5 Nm, Discard after removal
  45. Remove HV battery heat pump HV harness from tray stud
  46. Remove HV battery heat pump HV harness from plastic bobbin stud
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 7mm, 1.5 Nm, 1x washer
  47. Disconnect HVIL connector from HV heatpump harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  48. Release HVIL assembly connector from tray
    Informational PurposesAn informational icon, calling your attention
    Note
    1x tab, Slide connector upward to release from tray
  49. Remove heat pump internal HV harness from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    4x securing tabs, Gently release tabs and raise upward to remove
  50. Secure heat pump internal HV harness
    Informational PurposesAn informational icon, calling your attention
    Note
    4x securing tabs, Push down to engage locking tabs
  51. Secure HVIL connector onto tray
    Informational PurposesAn informational icon, calling your attention
    Note
    1x tab, Slide connector downward
  52. Connect HVIL connector onto tray
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  53. Install HV battery heat pump HV harness onto plastic bobbin stud
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 7mm, 1.5 Nm, 1x washer
  54. Position HV battery heat pump HV harness onto tray stud
  55. Install 63A fuse into ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 8mm, 2.5 Nm, Install new nuts
  56. Install 63A fuse into ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 8mm, 2.5 Nm, Install new nuts
  57. Install 63A fuse cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x securing tabs
  58. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  59. Inspect ancillary bay phantom seal to verify no damage is present
    Informational PurposesAn informational icon, calling your attention
    Note
    If damage is present, Replace ancillary bay phantom seal
  60. Install ancillary bay cover onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Guide LH side in, Maneuver cover past body casting and into position with charge port components
  61. Install perimeter bolts securing ancillary bay to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    22x captured bolts, EPL 10, 5 Nm, Thread bolts in evenly and torque
  62. Secure doubler and install fasteners securing charge port header to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10 EPL, 10 Nm, Secure doubler onto header and install bolts, Take note of small tabs on shielding
  63. Install fasteners securing PCS LVDC header to ancillary bay cover
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, T20, 2.5 Nm
  64. Install fasteners securing ancillary bay cover to high voltage controller
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, E10, 10 Nm
  65. Install NVH insulation onto ancillary bay cover
  66. Connect power connector to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push red locking tab down to secure connection
  67. Connect HVC logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
  68. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  69. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  70. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 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
  71. Position busbar kit connector and lower onto HV header
  72. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  73. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Note
    2x 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
  74. Install fastener securing busbar cover access door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 9 Nm
  75. Remove HV insulating gloves
  76. Engage LH body harness onto rear body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  77. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  78. Install bolts securing HV header connector to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 8mm, 6 Nm
  79. Secure HV compressor connection to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking 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
  80. Secure RDU HV harness onto HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x 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
  81. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
  82. Install push clips at left and right wheel house liner to mid aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  83. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  84. Connect first responder loop and LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  85. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  86. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  87. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  88. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  89. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  90. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  91. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  92. Move LH front seat to original position
  93. Move RH front seat to original position
  94. Exit Service Mode through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Service Mode > Exit Service Mode
  95. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle
  96. Raise all four windows
  97. Close all four doors
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing