Tesla Model S: Forward Junction Box (Dual Motor) (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
- Disconnect 12V and HV power (refer to procedure).
- Remove the wiper motor (refer to procedure).
- Remove the LH and RH shock tower to bulkhead struts (refer to
procedure).
- Release the 2 bolts that secure each fuse box to the front
crossmember (torque 5 Nm).
- If the vehicle is equipped with air suspension, release the
bolts (x2) that secure the air reservoir (torque 2.5 Nm). Carefully
set the reservoir in the RH side of the underhood area.
Note: It is not necessary to disconnect the
air lines.
- Release the bolts (x6) that secure the forward junction box
cover (FJB) (torque 6.5 Nm). Remove the cover.
Warning: Before continuing, put on high voltage gloves.
- Use a small, insulated screwdriver or similar tool to pry open
the cover on the front upper left of the FJB.
Warning: Do not use a metallic tool to open the
cover.
- Use a multimeter to check voltages between:
- B+ to ground
- B- to ground
- B+ and B-
Warning: If any voltage reading is more than 10V,
the contactors are not fully opened. Discontinue this
procedure immediately. Contact a Field Service Engineer
before performing any further work.
- Release the bolts (x2) that secure the HV cables to the busbars
inside the FJB (torque 4 Nm).
- Release the 4 harnesses from the top of the FJB.
1
|
HV Battery heater
harness |
2
|
DC-DC converter
harness |
3
|
Compressor harness |
4
|
PTC heater harness |
- Release the 12V harness from the RH side of the FJB.
- Release the clips (x2) that secure the HV cables.
Note: The O-rings on the HV cables might create
suction, which makes the cables difficult to remove. It
might require greater than normal force to release the
cables.
- Release the bolts (x3) that secure the FJB to the body (torque
10 Nm). Carefully remove the FJB.
Installation
Installation procedure is the reverse of removal, except for the
following:
If necessary, adjust the wipers (refer to procedure).
READ NEXT:
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
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
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
SEE MORE:
Removal
Ensure that the wipers are in the off position by rotating the
end of the left-hand steering column lever towards the rear of the
vehicle.
Open the hood to the service position.
Remove both wiper arms (refer to procedure).
Remove the bolts (x2) that secure the LH
Warning: To avoid personal injury, eye protection must
be worn when performing this operation.Warning: To avoid personal injury, safety-toe shoes and
cut-resistant gloves are recommended when performing this
operation.
Note: A demonstration video for removing and replac