09/09/2024 04:27:23

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

Correction code 16305002 4.08 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.

    • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
    • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
    • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
    • 1057607-00-A Magnet, Flexible, HV Insulated, 18"
    • 1111868-00-B Connector Removal, Coolant, PCS, M3
    • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
    • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
    • 1475996-00-A UFO Connector Removal Tool
    • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.

    Remove

    1. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
    2. Drain the coolant from the power conversion system. See Ancillary Bay Coolant (Drain and Refill).
    3. Remove the penthouse cover. See Cover - Ancillary Bay (Remove and Replace).
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
    4. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    5. Remove the high voltage controller. See Controller - High Voltage (Non-Structural Pack) (Remove and Replace).
    6. Release the clips (x5) that attach the HV battery ancillary bay harness to the hinge tray.
      Informational PurposesAn informational icon, calling your attention
      Note
      Pull and unhook to release the flat rectangular clips.
    7. Raise the hinge tray vertically, pull up on the tray at each hinge, and then remove the tray from the vehicle.
    8. Remove the power conversion system. See Power Conversion System (Non-Structural Pack) (Remove and Replace).
    9. Remove the HV battery negative contactor. See Contactor - Negative - HV Battery (Non-Structural Pack) (Remove and Replace).
    10. Remove the insulator for the DC input assembly.
    11. Remove and discard the bolts that attach the DC input busbars to the fast charge contactor busbars.
    12. Disconnect the electrical harness from the DC input assembly connector.
    13. Remove the bolts that attach the DC input assembly to the ancillary bay, and then remove the DC input assembly from the vehicle.
    14. Remove the HV battery fast charge contactor from the ancillary bay. See Contactor - Fast Charge - HV Battery (Remove and Replace).
      Informational PurposesAn informational icon, calling your attention
      Note
      Do not disassemble the HV battery fast charge contactor assembly after removal.
    15. Remove the clip that confines the LH Hall-effect sensor to the LH flood port cover above the LH flood port.
      Informational PurposesAn informational icon, calling your attention
      Note
      A newer version of the ancillary bay harness is not equipped with a Hall-effect sensor. Skip this step and the next step if no Hall-effect sensor is present.
    16. Release the tab that holds the LH Hall-effect sensor to the LH flood port cover, and then separate the sensor from under the tab.
    17. Remove the 12V DC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace).
    18. Remove the HV battery positive contactor. See Contactor - Positive - HV Battery (Non-Structural Pack) (Remove and Replace).
    19. Remove the insulator cap from the nut that joins the positive DC link to the positive busbar.
    20. Remove and discard the nut that joins the positive DC link to the positive busbar.
    21. Remove the nuts (x2) that attach the positive DC link to the ancillary bay floor, lift the link off of the studs and posts, and then move the link inboard to access the HV battery ancillary bay harness clips.
    22. Release the clips that attach the HV battery ancillary bay harness to the positive DC link insulator, and remove the DC link from the ancillary bay.
      Informational PurposesAn informational icon, calling your attention
      Note
      The rear most clip is behind the positive DC link insulator.
    23. Use the UFO connector removal tool to disconnect the RH passthrough connector from the HV battery module 4 BMS connector.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not try to remove the RH passthrough in this step, as it will be damaged. Only disconnect the connector.
      Tip: Access the ancillary bay from the RH rear door area for this step.
      Figure 1. View From RH Rear Door
    24. Use a pry tool to release the RH passthrough clips (x3) that attach the RH passthrough to the posts of the ancillary bay floor, and then separate the passthrough from the ancillary bay floor.
    25. Remove the clip that confines the RH Hall-effect sensor to the RH flood port cover above the RH flood port.
    26. Release the tab that holds the RH Hall-effect sensor to the RH flood port cover, and then separate the sensor from under the tab.
    27. Remove the cable ties that attach the HV battery ancillary bay harness to the power conversion system DC bus HV harness on either side of the RH Hall-effect sensor.
    28. Release the clips that attach the fuse access insulator to the RH ancillary bay bus cover, and remove the insulator.
    29. If installed, release the clips that attach the shunt access insulator over the shunt, and remove the insulator.
    30. Release the clips (x4) that attach the HV battery ancillary bay harness along the busbar insulator.
    31. Release the HV battery ancillary bay harness from under the respective tabs, and disconnect the harness from the A/C compressor and PTC heater high voltage interlock loop connector , the rear drive unit high voltage interlock loop connector, and the shunt connector.
    32. Release the clips that attach the pyrotechnic battery disconnect connector to the ancillary bay floor, and separate the connector from the floor.
    33. If the vehicle is configured with dual motors, release the HV battery ancillary bay harness from under the tab, and disconnect the harness from the front drive unit high voltage interlock loop connector.
    34. Release the clip that attaches the HV battery ancillary bay harness to the post near the LH UFO.
      Informational PurposesAn informational icon, calling your attention
      Note
      Pull and unhook to release the flat rectangular clip.
    35. Use the UFO connector removal tool to disconnect the LH passthrough connector from the HV battery module 1 BMS connector.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not try to remove the LH passthrough in this step, as it will be damaged. Only disconnect the connector.
      Tip: Access the ancillary bay from the LH rear door area for this step.
    36. Use a pry tool to release the LH passthrough clips (x3) that attach the LH passthrough to the posts of the ancillary bay floor, remove the passthrough, and then remove the HV battery ancillary bay harness from the vehicle.

    Install

    1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
    2. Lay the HV battery ancillary bay harness down inside of the ancillary bay.
      Informational PurposesAn informational icon, calling your attention
      Note
      The large fast charge contactor connector goes on the LH side near the LH passthrough to the HV battery.
    3. Install the LH passthrough onto the posts at the LH ancillary bay floor, and then press the passthrough down to fasten the passthrough clips (x3).
    4. Press the center of the LH passthrough to connect the passthrough connector to the HV battery module 1 BMS connector.
    5. Fasten the clip that attaches the HV battery ancillary bay harness to the post near the LH UFO.
    6. If the vehicle is configured with dual motors, connect the HV battery ancillary bay harness to the front drive unit high voltage interlock loop connector, and then fasten the harness under the tab.
    7. Install the pyrotechnic battery disconnect connector into the ancillary bay floor, and then fasten the clips that attach the connector to the floor.
    8. Connect the HV battery ancillary bay harness to the shunt connector, the rear drive unit high voltage interlock loop connector, the A/C compressor and PTC heater high voltage interlock loop connector, and then fasten the harness under the respective tabs.
    9. Fasten the clips (x4) that attach the HV battery ancillary bay harness along the busbar insulator.
    10. If removed, install the shunt access insulator over the shunt, and then fasten the clips that attach the insulator to the shunt.
    11. Install the fuse access insulator to the RH ancillary bay bus cover, and then fasten the clips that attach the insulator to the cover.
    12. Fasten the RH Hall-effect sensor under the tab of the RH flood port cover.
      Informational PurposesAn informational icon, calling your attention
      Note
      A newer version of the ancillary bay harness is not equipped with a Hall-effect sensor. Skip this step and the next step if no Hall-effect sensor is present.
    13. Install the clip that confines the RH Hall-effect sensor to the RH flood port cover above the RH flood port.
    14. Install new cable ties on either side of the RH Hall-effect sensor to attach the HV battery ancillary bay harness to the power conversion system DC bus HV harness.
    15. Install the RH passthrough onto the posts at the RH ancillary bay floor, and then press the passthrough down to fasten the passthrough clips (x3).
    16. Press the center of the RH passthrough to connect the passthrough connector to the HV battery module 4 BMS connector.
    17. Bring the positive DC link to the ancillary bay, and then fasten the clips that attach the HV battery ancillary bay harness to the positive DC link insulator.
    18. Use an IPA wipe to clean the HV mating surfaces of the positive DC link and the positive busbar.
    19. Install the positive DC link onto the studs and posts of the ancillary bay floor, and then install the nuts (x2) that attach the link to the floor.
      6 Nm (4.4 lbs-ft)
    20. Install a new nut to join the positive DC link to the positive busbar.
      9 Nm (6.6 lbs-ft)
    21. Use the Hioki resistance meter to measure the resistance at the joint between the positive DC link and the positive busbar.
      Informational PurposesAn informational icon, calling your attention
      Note
      The maximum acceptable resistance is 0.060 mΩ (60 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
      Figure 2. Generic Measurement - Actual busbars and fasteners might appear different
    22. Install the insulator cap onto the nut that joins the positive DC link to the positive busbar.
    23. Install the HV battery positive contactor. See Contactor - Positive - HV Battery (Non-Structural Pack) (Remove and Replace).
    24. Install the 12V DC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace).
    25. Fasten the LH Hall-effect sensor under the tab of the LH flood port cover.
    26. Install the clip that confines the LH Hall-effect sensor to the LH flood port cover above the LH flood port.
    27. Install the HV battery fast charge contactor into the ancillary bay. See Contactor - Fast Charge - HV Battery (Remove and Replace).
    28. Install the DC input assembly to the ancillary bay, install the bolts (x4) that attach the DC input assembly to the ancillary bay, and then mark the bolts with a paint pen after they are torqued..
      6 Nm (4.4 lbs-ft)
    29. Install new bolts (x2) to attach the DC input busbars to the fast charge contactor busbars.
    30. Precondition the bolts by torquing to 15 Nm, then back off one half turn, retorque to 5 Nm +60 deg, and then mark the bolts with a paint pen.
      15 Nm (11.1 lbs-ft) -180 deg
      5 Nm (3.7 lbs-ft) +60 deg
    31. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive DC input busbar and the positive (LH) fast charge contactor busbar.
      Informational PurposesAn informational icon, calling your attention
      Note
      The maximum acceptable resistance is 0.060 mΩ (60 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
      Figure 3. Generic Measurement - Actual busbars and fasteners might appear different
    32. Use the Hioki resistance meter to measure the resistance at the HV joint between the negative DC input busbar and the negative (RH) fast charge contactor busbar.
      Informational PurposesAn informational icon, calling your attention
      Note
      The maximum acceptable resistance is 0.060 mΩ (60 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
      Figure 4. Generic Measurement - Actual busbars and fasteners might appear different
    33. Install the insulator for the DC input assembly.
    34. Connect the electrical harness to the DC input assembly connector.
    35. Install the HV battery negative contactor. See Contactor - Negative - HV Battery (Non-Structural Pack) (Remove and Replace).
    36. Install the power conversion system, perform an ancillary bay coolant leak test, and refill the coolant. See Power Conversion System (Non-Structural Pack) (Remove and Replace).
    37. Install the hinge tray vertically onto the hinges, press down on the tray at each hinge so that the tray attaches to the hinges, and then lower the tray.
    38. Fasten the clips (x5) that attach the HV battery ancillary bay harness to the hinge tray.
    39. Install the high voltage controller. See Controller - High Voltage (Non-Structural Pack) (Remove and Replace).
    40. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    41. Install the ancillary bay cover and connect 12V power. See Cover - Ancillary Bay (Remove and Replace).