01/08/2024 02:43:30

Cover - Ancillary Bay (Structural Pack) (Remove and Replace)

Correction code 16101042 1.50 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.

  • 2023-11-08: Added/updated HV insulating glove steps.
Warning IconA warning icon, calling your attention to a possibly risky situation
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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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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
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.
Additional part that may be required for this operation (for Europe only):

Remove

  1. Open all the doors and lower all the windows.
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  4. Move the front seats forward.
  5. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  6. Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  7. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  8. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  9. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  10. 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.
  11. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Structural Pack).
  12. Remove HV insulating gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If flashing is present on the vehicle single-piece rear casting, put on cut-resistant gloves.
  13. Lower vehicle until tires are touching the ground.
    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.
  14. 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.
  15. Disconnect power connector to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Pull locking tab upward then release connection.
  16. Disengage LH body harness from rear body and move aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip.
  17. Remove bolt securing busbar cover access door.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  18. Remove bolts (x2) securing charge port busbar kit to HV header.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  19. 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.
  20. Remove NVH insulation from ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move insulation aside.
  21. Remove fasteners (x3) securing ancillary bay cover to high voltage controller.
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10
  22. Release fasteners (x3) securing PCS LVDC header to ancillary bay cover.
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 bit
  23. Release fasteners (x2) securing charge port header to ancillary bay cover and remove doubler.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release charge port header from ancillary bay and remove plastic doubler, Take note of small tabs on shielding.
    Tip: Use of the following tool(s) is recommended:
    • EPL 10 socket
  24. 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.
  25. Release perimeter bolts (x22) securing ancillary bay to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    captured bolts
    Tip: Use of the following tool(s) is recommended:
    • EPL 10 socket
  26. 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 and HV header.

Install

  1. Inspect the inner edge of the vehicle single-piece rear casting for metal flashing. If flashing is present, put on cut-resistant gloves.
  2. 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.
  3. Install ancillary bay cover onto HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recommend assistance, Guide LH side of cover into position clearing HV header, Maneuver cover past body casting and into position with charge port components.
  4. Install perimeter bolts (x22) securing ancillary bay to HV battery.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Thread bolts in evenly and torque.
    Tip: Use of the following tool(s) is recommended:
    • EPL 10 socket
  5. Remove HV insulating gloves.
  6. Secure doubler and install fasteners (x2) securing charge port header to ancillary bay cover .
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure doubler onto header and install bolts, Take note of small tabs on shielding.
    Tip: Use of the following tool(s) is recommended:
    • EPL 10 socket
  7. Install fasteners (x3) securing PCS LVDC header to ancillary bay cover.
    2.5 Nm (1.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 bit
  8. Install fasteners (x3) securing ancillary bay cover to high voltage controller.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10
  9. Install NVH insulation onto ancillary bay cover.
  10. Connect power connector to HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Push red locking tab down to secure connection.
  11. 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.
  12. 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.
  13. 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.
  14. 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.
  15. Position busbar kit connector and lower onto HV header.
  16. Install bolts (x2) securing charge port busbar kit to HV Header.d
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  17. 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.
  18. 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.
  19. Install fastener securing busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  20. Remove HV insulating gloves.
  21. Engage LH body harness onto rear body.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip.
  22. 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.
  23. 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.
  24. Apply Loctite 222 onto mid aero shield bolts (x11) and install mid aero shield.d
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  25. Install push clips at left and right wheel house liner to mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips.
  26. 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.
  27. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  28. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  29. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  30. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  31. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  32. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  33. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  34. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  35. Move the front seats to original positions.
  36. Remove vehicle from lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle.
  37. Raise all four windows.
  38. Close all four doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If 12V is powered up, Unlatch rear doors before closing.