10/04/2024 17:37:25

Harness - Ancillary Bay (Remove and Replace)

Correction code 1710118011 1710118012 FRT 2.82 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.

  • 2024-04-10: Updated steps to disconnect and connect the PCS MV connector.
  • 2024-04-10: Added step to install Ancillary Access Bench (2035746-00-A)
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. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
  3. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  4. Remove the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.
  5. Remove the RH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release rearward, and then slide over the LH side NVH cover before removing upward.
  6. Remove the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  7. Remove the LH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
  8. Remove the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
  9. Clean all debris from the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    During the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
  10. Release the pressurize pack air line from the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 connector
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
  11. Remove the VOSS fitting from the Pressurize Pack air line to the ancillary.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  12. Disconnect the electrical connector, and then remove the bolt that attaches the pressurize pack valve block to the air suspension reservoir.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
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    Note
    Release the lock before disengaging the connector.
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    Note
    Cut the zip tie at the reservoir/ancillary air line bundle.
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    Note
    Release the harness clip at the bracket.
  13. Release the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
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    Note
    Rotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.
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    Note
    Leave all air lines and connections secured, and then set the assembly aside.
  14. Remove the nuts (x2) that attach the air suspension reservoir to the body.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  15. Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise and swing the air suspension reservoir to the side of the bed.
  16. Open the powered frunk.
  17. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  18. Disconnect MV power. See Disconnect MV Power.
  19. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  20. Disconnect the pressurized pack lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
  21. Remove the VOSS fitting from pressurized pack air lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
  22. Secure the RDU header connector to the ancillary.
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    Note
    x1 connector
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    Note
    Verify the lever is in the upright and open position. Carefully seat connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage any pins.
  23. Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
  24. Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  25. Lower the vehicle until the tires are touching the ground.
  26. Disconnect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking: Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Wait 1 second between locking tab release to discharge and prevent arcing.
  27. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  28. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  29. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  30. Support the HV busbar assembly to maintain clearance with a bungee cord.
  31. Remove the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  32. Remove the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  33. Release fasteners securing ancillary cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    22x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the penthouse cover, Follow fastening order
  34. Remove the ancillary cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a suction cup and maneuver around the busbar and the tonneau cage.
  35. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  36. Put on the HV insulating gloves and leather over gloves.
  37. While supporting the harness end of the PCS MV connector, press the release, and then slide the red lock plate away from the black handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not slide the red lock plate without supporting the PCS MV connector.
  38. Continue to support the harness end of the PCS MV connector, raise the black handle to its vertical position to release, and then pull straight up on the black handle to disconnect the PCS MV connector from the MV header of the PCS.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
  39. Remove the bolt that attaches the PCS MV harness.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip
  40. Release the edge clip and fir tree clip that attaches the MV header to the HV battery, and then release the header from the vehicle.Release the MV header.
  41. Release the clips (x2) and disconnect the HVC connectors (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the connector locks. Press the levers and pull at connector. Do not pull from harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    If RTV is present at 2 connectors, using a ceramic knife (1076856-00-A) cut through and remove RTV until connector can be disconnected.
  42. Disconnect the BMB passthrough electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the connector locks. Press levers and pull at connector. Do not pull from harness.
  43. Disconnect the ACJB LV connector and ACJB to device cluster HV electrical connector, and then release the harness (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the connector locks. Press levers and pull at connectors. Do not pull at harness.
  44. Remove the ancillary harness.
  45. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Position the ancillary harness.
  2. Connect the ACJB LV and HV electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the connector locks.
  3. Connect the BMB passthrough electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the connector locks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Connectors are poke yoked. Do not force engagement. Ensure locking tabs are facing the front of vehicle when connecting.
  4. Connect the HVC electrical connectors (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 clips
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Release the connector locks. Press levers and pull at connector. Do not pull from harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply sealant to connectors at device cluster if it was present during disassembly (1080593-00-A, 1682237-00-G).
  5. Secure the MV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    x4 datums, x1 edge clip, x1 fir tree clip
  6. Install the bolt that attaches the PCS MV harness.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip
  7. Raise the black handle of the PCS MV connector so that it is at 90 degrees to the body of the connector.
  8. Position the PCS MV connector over the MV header so that the red positive lead of the connector is closest to the edge of the PCS and over the text "LV+" scribed on the PCS cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    The MV header is symmetrical, and it is possible to connect the PCS MV connector backwards.
  9. Holding only the electrical harness and the black handle, connect the PCS MV connector to the MV header.
  10. Use two fingers centered directly over the pins of the MV header (under the arch of the black handle) to press and hold the PCS MV connector to the MV header, and then carefully lower the black handle until it is flat.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
  11. While supporting the harness end of the PCS MV connector, slide the red lock plate to the black handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not slide the red lock plate without supporting the PCS MV connector.
  12. Inspect the PCS MV connector that it is not tilted, but is parallel to the top surface of the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the PCS MV connector is tilted, there may be damage to the MV header inside the PCS. This damage may cause the PCS to go MIA, or deassert the DCDC enable line. Check for respective alerts and faults.
  13. Install the ancillary cover.
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    Note
    Use a suction cup.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver around the busbar and tonneau cage.
  14. Remove the leather over gloves and HV insulating gloves.
  15. Install the bolts (x22) that attach the ancillary cover to the HV battery.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use E10 5-Lobe socket without magnet.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
  16. Install the bolts (x2) that attach the low voltage header.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  17. Install the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  18. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  19. Clean the HV connector contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
  20. Clean the busbar HV connector contact surface of residual Penetrox with IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during re-use of the busbar.
  21. Apply Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  22. Position the busbar connector, and then lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the bungee cord.
  23. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket (insulated)
  24. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  25. Put on the HV insulating gloves and leather over gloves.
  26. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 HV joints
    Informational PurposesAn informational icon, calling your attention
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), stop work and escalate the Toolbox session.
    • 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), the Hioki test passed. proceed to the next step.
  27. Remove the leather over gloves and HV insulating gloves.
  28. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  29. Connect the ancillary bay MV electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Double locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
  30. Install the screws (x8) that attach the tonneau coverbox cross supports.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Supports install in the same direction of the fasteners.
  31. Install the LH tonneau NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the busbar clearance during installation to avoid damage to the NVH material.
  32. Install the bolts (x5) that attach the LH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  33. Install the RH tonneau NVH cover.
  34. Install the bolts (x6) that attach the RH tonneau NVH cover.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  35. Remove the Ancillary Access Bench, and then put the air suspension reservoir into position for installation.
  36. Install the nuts (x2) that attach the air suspension reservoir.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 fir tree clips
  37. Secure the air suspension valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 rubber grommets
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position air lines and connections into place for installation.
  38. Install a new VOSS air fitting to the pressurize pack valve block at the ANC circuit.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 VOSS fitting
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurize pack line install.
  39. Secure the pressurize pack air line from the ancillary to the valve block.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 line
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  40. Install the bolt that attaches the pressurize pack valve block to the air suspension reservoir, and then connect the electrical connector.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 clip, x1 zip tie
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the reservoir and ancillary air lines at the white marked sections.
  41. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  42. Fully raise the vehicle.
  43. Remove all items from pockets and ensure not wearing metal items.
  44. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
  45. Put on the HV insulating gloves and leather over gloves.
  46. Clean the mating surface of the pyro.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use any other types of cleaner.
  47. Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
  48. Remove the leather over gloves and HV insulating gloves.
  49. Install new VOSS fittings and nut to the pyro cover.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm 12-point deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the VOSS plastic plug until the pressurized pack line installation.
  50. Install the bolts (x4) that attach the pyro fuse access cover.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the seal is fully seated and undamaged.
  51. Install the pressurized pack lines (x2).
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm 6 point flare nut wrench
    • 12 mm flare nut crowfoot socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 VOSS fittings
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
  52. Install the mid aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    x6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply Loctite 222 onto mid aero shield bolts and install the fasteners.
  53. Lower the vehicle until the tires are touching the ground.
  54. Connect MV power. See Disconnect MV Power.
  55. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  56. Close the powered frunk.
  57. Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
  58. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.