Tesla Model S: HV Harness - Front Drive Unit to HVJB
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
minimum rating of class 00 (500V) must be worn any time a high
voltage cable is handled. Refer to Tech Note TN-15-92-003, "High
Voltage Awareness Care Points" for additional safety information.
Special tools required for this procedure:
Supplier
|
Part Number
|
Description
|
Tesla |
1051629-00-A |
Cap, Connection, Rosenberger,
H4Z001-000/52 |
Tesla |
10794924-00-A |
Nylon Fish Tape, 25 ft. |
Removal
- Perform the vehicle electrical isolation procedure (refer
to procedure).
- Remove the high voltage junction box (HVJB) cover (refer to
procedure).
Warning: Use a multimeter to check voltages across the HV
cables and to ground before continuing this procedure.
- Remove the front LH wheel arch liner (refer to procedure).
- Remove the bolt that secures the HV harness to the bracket in
the front left wheel arch (torque 4 Nm). Release the HV harness from
the bracket.
- Remove and discard the screws (x4) that secure the B+ and B- HV
cables to the front drive unit (torque 7 Nm).
- Release any push clips that secure the HV harness to studs on
the bulkhead.
- Install protective caps over both HV cables to protect the
terminals and seals.
- Secure the HV cables to the nylon fish tape tool using string or
fishing line.
Note: The nylon fish tape tool is used to
pull and route the new harness through the channel
during installation.
Note: Secure both HV cables
together and slightly staggered to reduce the
likelihood of one of them getting caught in the
channel.
Note: The following image shows the HV
cables without the protective caps installed.
- Lower the vehicle.
- Release the front of the LH C-pillar lower trim panel near the
base of the B-pillar.
Caution: Take care not to damage component(s).
- Fold the carpet inboard to expose the entrance to the channel
that runs along the left rocker panel.
- Gently pull the HV harness towards the rear of the vehicle and
through the channel.
Caution: Ensure that the string or fishing
line is not accidently released from the HV cables
while pulling the nylon fish tape tool through the
channel.
- Once the HV harness is all the way through the channel, release
the string or fishing line, but do not pull the nylon fish tape tool
back through the channel or remove it from the vehicle.
- Disconnect the 12V connector from the HVIL switch.
- Remove the bolts (x3) that secure the fuse bracket (torque 9
Nm).
- Remove the bolt that secures the HV fuse ground to the body
(torque 5.5 Nm).
- Remove the nuts that secure the B+ and B- HV cables to the HVJB
(torque 9 Nm).
Note: It is not necessary to replace the
fastener(s) after it is removed. The threaded area
has a reusable dry sealant, which looks similar to
adhesive patch material.
- Pull the front of the harness through the grommet between the
seat base and 2nd row cabin.
- Remove the HV harness and fuse assembly from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the
following:
Caution: Replace all Patchbolt(s).
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Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
Note: This procedure describes how to remove and replace
the 40A Wall Connector handle and cable assembly. For instructions
on how to remove and replace the 80A Wall Connector handle and cable
SEE MORE:
Removal
Position vehicle with clear access to door assembly.
Remove sill panel trim (refer to procedure)
Disconnect door harness connectors (x3) from dash wiring
harness.
Support door on stand.
Caution: Take care not to damage component(s).
Installation
Installation procedure is the reverse of removal,
except for the following:
Warning: Only use
cleaning agents and solvents in a well-ventilated area.
Caution: Replace all
nylon-insert locknuts.
Caution: Ensure that