15/12/2023 01:30:14

Harness - Ancillary Bay - HV Battery (Structural Pack) (Remove and Replace)

Correction code 16305012 2.58 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.

  • 2023-12-07: Rearranged steps to improve procedure.
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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.

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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.

Remove

  1. Open all doors and lower the windows.
  2. Put the vehicle in Service Mode. See Service Mode.
  3. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  4. Remove the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  5. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  6. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  7. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  8. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure (Structural Pack).
  9. Lower the vehicle until the tires are touching the floor.
  10. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  11. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  12. Disconnect the shunt assembly connector.
  13. Release the clip that attaches the shunt harness branch to the tray.
  14. Disconnect the fast charge contactor connector.
  15. Disconnect the ancillary bay harness from the HV connector harness.
  16. Release the clip that attaches the HV connector harness branch to the tray.
  17. Disconnect the negative contactor connectors (x2)
  18. Release the ancillary bay harness clip for access.
  19. Disconnect the HV drive unit isolator header connector.
  20. Disconnect the rear battery passthrough connectors (x2).
  21. Release the clips (x2) that attach the ancillary bay harness to the tray below the PCS hoses.
  22. Remove the 63A fuse cover.
  23. Disconnect the HVIL connector from the HV heat pump harness.
  24. Remove the nut and washer that attach the ancillary bay harness to the coil pack.
  25. Remove and discard the nuts that attach the inner 63A fuse to the ancillary bay.
  26. Remove the ancillary bay harness from the plastic bobbin stud.
  27. Disconnect HVIL connector from the drive unit HV header.
  28. Disconnect the positive contactor connectors (x2).
  29. Release the clip that attaches the ancillary bay harness to the tray.
  30. Disconnect the HV controller connectors (x7).
  31. Release the harness clips (x3) that attach the harness to the HVC hinge tray and route the harness away.
  32. Release the HVC hinge tray from the hinge clips (x2) and remove it from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the two hinge clips. As an alternative the hinge tray bolts can also be removed.
  33. Disconnect the PCS LV connector from the PCS.
  34. Disconnect the PCS logic connector from the PCS.
  35. Disconnect the PCS to DC bus HV connector.
  36. Disconnect the AC filter harness.
  37. Remove the bolts (x6) that attach the PCS to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that ONLY the 8mm bolts are removed. Do not remove the T30 fasteners.
  38. Remove and discard the nut that attaches the ancillary bay harness to the negative DC link.
  39. Release the clip that attaches the ancillary bay harness to the tray between the PCS and bobbin.
  40. Feed the RH side of the harness to the left of the HV battery and maneuver it below the coolant hose and the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance is recommended. Carefully tilt the PCS upward, enough to clear the FC contactor connector below the RH side.
  41. Remove the ancillary bay harness from the ancillary bay.

Install

  1. Position the ancillary bay harness into the ancillary bay for installation.
  2. Feed the RH side of harness to the RH side of the HV battery and maneuver it below the coolant hose and PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance is recommended. Carefully tilt the PCS upward, sufficiently to clear the FC contactor connector below the RH side.
  3. Install the clip that attaches the ancillary bay harness to the tray between the PCS and bobbin.
  4. Install a new nut that attaches the ancillary bay harness to the negative DC link (torque 1.5 Nm).
  5. Install the bolts (x6) that attach the PCS to the HV battery (torque 6 Nm).
  6. Connect the FC contactor HV harness connector to the PCS.
  7. Connect the DC bus HV connector to the PCS.
  8. Connect the PCS logic connector to the PCS.
  9. Connect the PCS LV connector to the PCS.
  10. Install the HVC hinge tray onto the hinge clips (x2) and install the assembly into the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the way the harness will route over the hinge. Carefully attach the hinge tray onto the hinge clips. Make sure the tray is fully seated.
  11. Install the harness clips (x3) onto the HVC hinge tray and route the harness.
  12. Connect the HV controller connectors (x7).
  13. Install the ancillary bay harness clip near the PCS return hose.
  14. Connect the positive contactor connectors (x2).
  15. Connect the HVIL to the drive unit HV header.
  16. Install the ancillary bay harness to the plastic bobbin stud.
  17. Install new nuts (x2) that attach the inner 63A fuse to the ancillary bay (torque 2.5 Nm).
  18. Install the washer and nut that attach the ancillary bay harness to the coil pack (torque 1.5 Nm).
  19. Connect the HVIL connector to the HV heat pump harness.
  20. Install the 63A fuse cover.
  21. Connect the rear battery passthrough connectors (x2).
  22. Install the clips (x2) that attach the ancillary bay harness to the tray below the PCS coolant hoses.
  23. Connect the HV drive unit isolator header connector.
  24. Install the clip that attaches the ancillary bay harness onto the tray.
  25. Connect the negative contactor connectors (x2).
  26. Install the clip that attaches the HV connector harness branch onto the tray.
  27. Connect the ancillary bay harness connector to the HV connector harness.
  28. Connect the fast charge contactor connector.
  29. Install the clip that attaches the shunt harness branch onto the tray.
  30. Connect the shunt assembly connector.
  31. 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).
  32. Inspect the ancillary bay phantom seal and make sure that no damage is present.
    Informational PurposesAn informational icon, calling your attention
    Note
    If damage is found, replace the ancillary bay phantom seal.
  33. Install the ancillary bay cover onto the HV battery. See Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  34. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  35. Fully lower the vehicle.
  36. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  37. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  38. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  39. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  40. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  41. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  42. Exit Service Mode. See Service Mode.