Tesla Model S: HV Junction Box - Cover - 2nd Generation (Remove and Replace) - Removal

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

1. Disconnect 12V and HV power:
   • Rear wheel drive (RWD): Refer to procedure.
   • Dual Motor: Refer to procedure.
2. Remove the 2nd row seat frame:
   • Standard seats: Refer to procedure.
   • Executive seats: Refer to procedure.
3. Remove the HVIL bolt from the HVJB cover. Do not remove the remaining fasteners at this time.
   • North America, Japan (torque 4 Nm)

     Note: In North American and Japanese vehicles, the HVIL bolt is one-time use only. Install a new bolt during reinstallation.

     

   • Europe, APAC (torque 5 Nm)

     Note: In European and APAC vehicles, the HVIL bolt can be reused during reinstallation.

     

Warning: Ensure that the multimeter and leads are capable of handling at least 500V.

4. Remove the remaining fasteners that secure the HVJB cover.
   • North America, Japan (torque 8 Nm)

     Note: In North American and Japanese vehicles, there are 5 additional fasteners.

     

   • Europe, APAC (torque 8 Nm)

     Note: In European and APAC vehicles, there are 6 additional fasteners.

     

5. Use a multimeter to check voltages across the HV cables and to ground:

   Warning: 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.

   Warning: Never use a fastener or an e-coated surface as a path to ground. In this procedure, ensure that the ground strap from the HVJB is secure to the body and use the lug as a path to ground.

   • The 4 HV cables to the HV battery and rear drive unit
   • The 2 HV cables to the forward junction box
   • The 2 HV cables to the charge port
   • Dual Motor vehicles only: The 2 HV cables to the front drive unit

   

   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+ DCDC converter
   6	B- DCDC converter
   7	B- charge port
   8	B+ charge port

   Note: Vehicles with 3-phase charging have 4 harnesses to the charge port:

   

   1	B+ N charge port
   2	B- L1 charge port
   3	B+ L3 charge port
   4	B- L2 charge port

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