Main Wiring Harness

FRT No: 16030603

    Remove


  1. Remove sheet 1. (Refer to procedure)

  2. Remove remaining 10 sheets.

  3. Using assistance, release locks and carefully rotate rotisserie through 180 degrees to invert the battery to position the APS on the LH side and the BSM on the RH side.

  4. Before commencing the harness removal, carefully observe the position of the harness. Take photographs for personal reference if necessary.


  5. Remove screws (x2) securing harness terminals to 2 pole fuse holder and release ring terminals (x3) (torque - 2.3 Nm / 20 in-lbs).

    6. NOTE: When installing, apply Loctite® 242™ thread locking compound to bolt/screw threads.


  6. Remove nut securing harness clip to enclosure and release clip (torque - 0.6 Nm / 5 in-lbs).

  7. Disconnect connector between harness and adapter block.


  8. Remove screws (x2) securing PEM connector to enclosure and release connector (torque - 3.4 Nm / 30 in-lbs).


  9. Disconnect connector between harness and contactor.

  10. Remove nut securing harness clip to enclosure, release clip and main harness and contactor harness (torque - 0.6 Nm / 5 in-lbs).


  11. Disconnect connectors (x2) from APS.


  12. Disconnect connector between harness and service disconnect receptacle.

  13. Note fitted position and remove screws (x2) securing harness terminals to shunt, release terminals and collect washers (torque - 1.9 Nm / 17 in-lbs).


  14. Remove screws (x4) securing harness to 3 pole fuse holder and release terminals (x5) (torque - 2.3 Nm / 20 in-lbs).

    15. NOTE: When installing, apply Loctite® 242™ thread locking compound to bolt/screw threads.


  15. Disconnect connector between harness and pre-charge resistor.


  16. Disconnect connector between harness and pre-charge relay.


  17. Disconnect connector between harness and logic connector.


  18. Disconnect connectors (x3) between harness and BSM.


  19. Remove cable ties (x2) and disconnect connector between harness and immersion sensor. BSM shown removed for demonstration only. BSM removal not required.


  20. Remove and discard cable ties (x10) securing BMB section of harness to enclosure.

    21. NOTE: Remove the cable ties from the harness and not the enclosure.


  21. Remove and discard remaining cable ties (x3) securing side BMB section of harness to enclosure.

  22. Remove and discard remaining cable ties (x9) securing harness to enclosure and remove harness.

    Installation


  1. Installation procedure is the reverse of removal except for the following:

  2. Beginning at the RH side of the enclosure, attach the BMB section of the wiring harness to the cable ties (x10) loosely. Do not tighten cable ties at this stage.

  3. Ensure that each BMB connector (x22) passes through the enclosure cut-outs.

  4. Loosely install cable ties (x3) securing the side BMB section of the harness to the enclosure. Do not tighten cable ties at this stage.

  5. Loosely install side cable tie securing harness to immersion sensor connector. Do not tighten cable tie at this stage.

  6. Lay the harness across the back of the enclosure and loosely install cable ties (x9) Do not tighten cable ties at this stage.

  7. Ensure all connectors are connected, except for the APS multiplugs and the top BSM connector.

  8. Working from the RH side, pull harness rearwards and begin to tighten cable ties in a counter-clockwise order.
    9. CAUTION: Do not over tighten cable ties, allow for slight harness movement when tightening. Ensure that the cable tie is trimmed so that no sharp edges remain.
     


  9. Gently pull harness to the left and continue to tighten the cable ties in a counter-clockwise order.

  10. Connect connectors (x2) to APS.

  11. Install sheet 1 first, followed by sheet 11 then install remaining sheets in a left to right order.

  12. Ensure that the correct sheet is being installed. Fused sheets (labelled 'F') and unfused sheets (labelled 'U') are positioned alternately in the enclosure.

  13. The position of the harness is critical. Ensure harness is positioned so that it will not be crushed or pinched by sheets upon removal.

(c) 2008 TESLA MOTORS, INC.

All right reserved. This material may not be reproduced or copied, in whole or in part, without written permission of Tesla Motors, Inc.