22/05/2024 18:57:06

HV Harness - HV Battery to Front Drive Unit (Structural Pack) (Remove and Replace)

Correction code 44502112 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.

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.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
  3. Remove the butyl patches (x2) that cover the LH rocker access holes.
    Figure 1. LH front shown; LH rear similar
  4. Install lift pad adapters (x2) into the LH rocker.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use Model Y lift pad adapters (1614078-00-A) only.
    Figure 2. LH front shown; LH rear similar
  5. Repeat step 2 through step 4 for the RH side of the vehicle.
  6. Raise and support the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Verify the jack locations prior to lifting the vehicle. ONLY place on lifting points at the front and rear of rocker panels.
  7. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  8. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  9. Remove the bolts (x2) that attach the HEPA filter assembly to the vehicle, and then remove the assembly from the vehicle.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Pivot the rear edge of the assembly upward to clear the brake reservoir, and then lift the assembly upward to clear the underhood storage unit.
    Tip: Use of the following tool(s) is recommended:
    • 10mm socket
  10. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  11. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Structural Pack).
  12. Remove the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
  13. Remove the bolt that attaches the HV battery to front drive unit HV harness to the front drive unit.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  14. Release the locking tab, rotate the lever up to disengage the connector, and then disconnect the HV battery to front drive unit HV harness connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the release lever up.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the alignment tabs on the FDU header are not damaged.
  15. Remove the bolt that attaches the HV battery to front drive unit HV harness to the HV battery bash plate.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  16. Release the clip that attaches the powertrain coolant hose to the LH side of the front HV battery bash plate.
  17. Release the tabs (x6) that attach the powertrain supply hose to the HV battery to front drive unit HV harness assembly.
    Tip: Use a plastic trim tool to aid as needed.
  18. Remove the bolts that attach the HV battery to front drive unit HV harness brackets to the LH side of the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  19. Remove the bolt that attaches the HV battery to front drive unit HV harness to the rear of the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  20. Release the locking tab, rotate the lever up to disengage the connector, and then disconnect the front drive unit HV cable from the rear of the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not force the release lever up.
  21. Release the HV battery to front drive unit HV harness bracket clips (x6) from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The clips can be seen from in between the HV battery and HV harness.
  22. With assistance, maneuver the HV battery to front drive unit HV harness connections away from the coolant hoses, guide the front portion of the harness out from in between the vehicle body and front bash plate, and then remove the harness from the vehicle.

Install

  1. With assistance, guide the front portion of the HV battery to front drive unit HV harness in between the vehicle body and front bash plate, and then maneuver the connections into position between coolant hoses.
  2. Secure the HV battery to front drive unit HV harness bracket clips (x6) to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    An audible click will be heard.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify clips are fully seated.
  3. Install the bolt that attaches the HV battery to front drive unit HV harness to the rear of the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  4. Verify the HV battery to front drive unit HV harness connector lever is in the upright and open position. Carefully seat the connector to the rear of the HV battery and allow lever to engage. Fully secure the lever and the verify the red tab is locked.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage any pins.
  5. Install the bolts that attach the HV battery to front drive unit HV harness brackets to the LH side of the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  6. Secure the tabs (x6) that attach the powertrain supply hose to the HV battery to front drive unit HV harness assembly.
  7. Install the bolt that attaches the HV battery to front drive unit HV harness to the HV battery bash plate.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  8. Secure the clip that attaches the powertrain coolant hose to the LH side of the front HV battery bash plate.
  9. Install the HV battery to front drive unit HV harness connector onto the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever.
  10. Install the bolt that attaches the HV battery to front drive unit HV harness to the front drive unit.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  11. Install the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
  12. Connect the rear drive unit HV cable to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
  13. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto the mid aero shield bolts.
  14. Lower the vehicle fully.
  15. Remove the vehicle from the lift.
  16. Remove the lift pad adapters (x2) from the LH rocker.
    Figure 3. LH front shown; LH rear similar
  17. Install butyl patches (x2) onto the LH rocker access holes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace with new patch if needed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply pressure along the patch to verify it is fully secured to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    New butyl patches should be approximately 2 in by 2 ½ in.
    Figure 4. LH front shown; LH rear similar
  18. Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
  19. Repeat step 16 through step 18 for the RH side of the vehicle.
  20. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  21. Position the HEPA filter assembly into the vehicle, and then install the bolts (x2) that attach the assembly to the vehicle.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Pivot the front edge of the assembly down past the underhood storage unit, and then carefully move the rear edge past the brake reservoir and into position.
    Tip: Use of the following tool(s) is recommended:
    • 10mm socket
  22. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  23. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  24. Raise the LH front window and close the LH front door.