Tesla Model S: HV Junction Box - 2nd Generation (Remove and Replace)
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.
Removal
- Remove the high voltage junction box (HVJB) cover (refer to
procedure).
Warning: Perform all of the voltage checks listed in the
procedure. If any voltage reading is more than 10V, the high voltage
contactors are not fully opened. Due to the risk of electrocution,
contact Service Engineering before performing any further work.
- Release the 2 HVJB harness connections from the master charger
by pressing on the tab on each connector. If the vehicle is equipped
with dual chargers, repeat this step for the harness connections to
the slave charger.
- Dual motor vehicles only: Mark the rear HV cable that leads to
the front drive unit as B-, and the forward HV that leads to the
front drive unit as B+.
Table 1: HV Cable fasteners inside HVJB
1 |
B+ Front Drive
Unit (if equipped) |
2 |
B- Front Drive
Unit (if equipped) |
3 |
B+ battery/drive
inverter |
4 |
B- battery/drive
inverter |
5 |
B+ forward
junction box |
6 |
B- forward
junction box |
7 |
B- charge port |
8 |
B+ charge port |
- Release the 2 nuts that secure the HV cables that lead to the
front drive unit (torque 9 Nm).
Note: Refer to Table 1.
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.
- Mark the rear HV cables that lead to the battery and drive
inverter as B‒, and the forward HV cables that lead to the battery
and drive inverter as B+.
Note: Refer to Table 1.
- Release the 2 nuts that secure the HV cables that lead to the
battery and drive inverter (torque 9 Nm).
Note: Refer to Table 1.
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.
- Mark the rear HV cable that leads to the forward junction box as
B+ and the forward HV cable that leads to the forward junction box
as B-.
Note: Refer to Table 1.
- Release the 2 bolts that secure the HV cables that lead to the
forward junction box (torque 4 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.
- Mark the HV cables that lead to the charge port.
- Single-phase charging: Mark the forward
cable as B- and the rear cable as B+.
- 3-phase charging: Starting from the front
and working toward the rear of the vehicle, mark the 4 HV cables
that lead to the charge port from front to rear as L2, L3, L1,
and N.
Note: Vehicles equipped with 3-phase charging have
4 charge port cables instead of 2.
Table 2: 3-Phase charge port cables
1 |
B+ N charge port |
2 |
B- L1 charge port |
3 |
B+ L3 charge port |
4 |
B- L2 charge port |
- Release the bolts that secure the HV cables that lead to the
charge port.
- North America, Japan: 2 bolts (torque 9
Nm).
- Europe, APAC: 4 bolts (torque 4 Nm).
Note: Refer to Table 1.
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.
- Release the bolt that secures the ground strap to the rear of
the HVJB (torque 6 Nm).
Note: Leave the ground strap secured to the
vehicle.
- Disconnect the low voltage harness connection on the rear LH
side of the HVJB .
- Release the 4 bolts that secure the HVJB to the body (torque 5
Nm). Remove the HVJB from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the
following:
- Before reinstalling the ground strap, clean the ground tab,
then apply a small amount of Penetrox A-13 electrical joint
compound to the ground tab.
- For the proper torque sequence of the bolts that secure the
HVJB cover, refer to HV Junction Box - Cover - 2nd Generation
(Remove and Install).
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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
Insert the HVIL bolt into the shield collar clamp by 2 threads.
1
Install HVIL bolt 2
threads
SEE MORE:
Removal
Remove door handle for access (refer to procedure)
Position handle assembly on a soft working surface.
Remove door handle rear seal.
Release motor harness connector.
Remove cable ties securing door pressure sensor and motor
wiring.
Release motor wiring connec
Recover refrigerant from the vehicle (refer to procedure), see section "Recover
Refrigerant and Verify Charge").
Remove the underhood storage unit(refer to procedure).
Release the bolt that secures the HVAC compressor discharge line (torque
10 Nm).