2026-09-29

Harness - PCS2 Lite - Ancillary Bay (Remove and Replace)

Correction code 16300502002 FRT 2.22 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Remove

  1. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
    Note
    Do not reconnect the LV power at this time.
  2. Remove the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  3. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Install).
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  4. Install the logic connector cap to the high voltage controller connector.
  5. Inspect the ancillary bay for missing insulators.
    Note
    Install the service insulator kit before proceeding with the following steps.
  6. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  7. Disconnect high voltage controller (HVC) connectors (x7).
  8. Release the clips (x8) that attach the megaharness to the high voltage controller skylite hinge.
  9. Remove the HVC and skylite hinge from the skylite hinge post.
    Note
    2x tabs, 2x location holes
    Note
    Press to release the two tabs, and then pull outward to remove.
  10. Remove the screw that attaches the RH skylite hinge post to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  11. Move the harnesses (x3) outward, and then remove the RH Skylite hinge post from the ancillary bay.
    Note
    3x harness, 2x locating pins
    Note
    Inspect the wire insulation layer. If it is damaged, replace the harness.
  12. Disconnect the PCS2 lite logic connector from the PCS2 lite.
  13. Release the clip that attaches the ancillary bay harness to the positive pack contactor.
  14. Disconnect the ancillary bay harness connectors (x2) from the positive pack contactor.
  15. Disconnect the PCS2 lite LV connector from the PCS2 lite by pulling the locking tab upward.
    Note
    May need a plastic trim tool to help lift the connector upward.
  16. Remove the DCDC pass through. See Passthrough - DCDC - LV (Cable Type) (Remove and Replace).
  17. Remove the RH daisy chain pass through housing from the ancillary bay.
    Note
    If the housing is damaged during removal, replace the PCS2 Lite harness assembly.
    1. Insert the UFO harness removal tool (1475996-00-A) beneath the daisy chain pass through housing.
    2. Insert the tab release tool to release the bottom clips (x2).
    3. Use the trim tool to release the top location pins (x3).
    4. Pull the daisy chain pass through housing upward to remove it.
  18. Remove the ancillary bay harness clips (x3) from the positive DC link.
  19. Remove the ancillary bay harness clips (x2) from the RH base insulator assembly.
    Note
    2x harness clips
  20. Release the locking tab, and then disconnect the X421 connector from the DC connection bus.
  21. Disconnect the AC filter harness connector from the PCS2 Lite.
    1. Fully release the red lock pin.
    2. Press the orange tab inward and lift the connector to remove it from the vehicle.
      Note
      If needed, use a plastic trim tool to assist with removal.
  22. Disconnect the ancillary bay harness connectors (x2) from the negative pack contactor.
  23. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  24. Release the locking tab, and then disconnect the AC filter harness connectors (x2) from the FC contactor cover.
  25. Release harness clips (x3) from the FC contactor cover, and then move the wiring harness aside around the FC contactor cover.
  26. Remove the harness clip from the left terminals cover.
  27. Release the tabs (x2) and datum to remove the LH ancillary bay terminals cover.
  28. Remove and discard the patch bolts (x2) that attach the DC link side to the negative and positive fast charge busbars.
    Tip
    Use of the following tool(s) is recommended:
    • 13 mm socket
    • Torque wrench with angle measurement
    Figure 1. Negative fast charge port busbar bolt
    Figure 2. Positive fast charge port busbar bolt
  29. Remove the bolt that secures the busbar cover access door.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  30. Remove bolts (x2) that secure the charge port busbar kit to the HV header.
    Note
    For 3-phase vehicles, disconnect the AC charging interface.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  31. Lift the busbar kit connector and shift the rear end of the busbar assembly upward to remove the aluminum connector housing from the HV header.
    Note
    4x guide tabs
  32. Remove the bolts (x4) that attach the DC input header seal to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  33. Remover the DC input header seal from the ancillary bay.
    Note
    2x location pins
  34. Remove the bolts (x2) that attach the FC contactor assembly to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm socket
  35. Tilt the FC contactor assembly upward to remove it from the ancillary bay.
    Note
    2x guide pins, 1x clip
  36. Remove the LH daisy chain pass through housing from the ancillary bay.
    Note
    If the housing is damaged during removal, replace the PCS2 Lite harness assembly.
    1. Insert the UFO harness removal tool (1475996-00-A) beneath the daisy chain pass through housing.
    2. Insert the tab release tool to release the bottom clips (x2).
    3. Use the trim tool to release the top location pins (x3).
    4. Release the harness clip and pull the daisy chain pass through housing upward to remove it.
  37. Release the clip, and then remove the X423 connector from the DC link busbar.
    Note
    Release the connector's locking tab.
  38. Remove the pyro disconnect dummy.
  39. Release the clip, and then remove the pyro disconnect logic connector.
  40. Release the clip, and then disconnect shunt assembly connector.
    Note
    Release the connector's locking tab.
  41. Remove the HV joint insulator from the DC link busbar.
    Note
    1x insulator
  42. Release the clip, and then disconnect the X422 connector from the DC link busbar.
    Note
    Release the connector's locking tab.
  43. Remove the ancillary bay harness assembly fixing clips (x5) from the DC link.
  44. Remove the tab from the DC link shell.
    Note
    When removing a tab, ensure it break off along the bottom edge and leaves no sharp corners that could damage the wiring harness.
  45. Route out the PCS2 Lite harness assembly from the inlet outlet pipe, and then remove the harness assembly from the ancillary bay.

Install

  1. Route the PCS2 Lite harness assembly along the inlet outlet pipe, then position it into the ancillary bay for installation.
  2. Install the ancillary bay harness assembly fixing clips (x5) to the DC link.
  3. Install the X422 connector to the DC link busbar, and then secure the clip.
  4. Install the HV joint insulator to the DC link busbar.
  5. Connect the shunt assembly connector and then secure the clip.
  6. Install the pyro disconnect logic connector, and then secure the clip.
  7. Install the pyro disconnect dummy.
  8. Install the X423 connector to the DC link busbar, and then secure the clip.
  9. Align the location pins (x3), secure the bottom clips (x2) and harness clip to install the LH daisy chain pass through housing onto the ancillary bay.
  10. Install the FC contacor assembly to the ancillary bay.
    Note
    2x guide pins, 1x clip
    Note
    Tilt the assembly as needed to align it with the guide pins, then install it.
  11. Install the bolts (x2) that attach the FC contactor assembly to the ancillary bay.
    5.5 Nm (4.1 lbs-ft)
    Note
    Mark the bolts with a paint pen after installation.
    Tip
    Use of the following tool(s) is recommended:
    • Insulated 10 mm deep socket
  12. Install the DC input header seal to the ancillary bay.
    Note
    2x location pins
    Note
    Inspect the sealing ring for damage. If it is damaged, replace the assembly.
  13. Install the bolts that attaches the DC input header seal to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Note
    Mark the bolts with a paint pen after installation.
    Tip
    Use of the following tool(s) is recommended:
    • Insulated External Torx Plus EP10
  14. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    Note
    Allow 1 minute dry time for each surface. The new busbar comes with the penetrox applied to the HV connector. It is necessary to clean the HV connector during the re-use of the busbar.
  15. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads on the HV connector joints, and then spread the liquid evenly until the contact surface is fully covered.
  16. Position the busbar kit connector and lower it onto the HV header.
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbar, they may have been bent. Inspect for damage and replace if necessary.
  17. Install the bolts (x2) that secure the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Note
    For 3-phase vehicles, connect the AC charging interface.
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  18. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    • If the resistance is greater than 0.195 mΩ (195 μΩ), stop the current repair work and escalate a 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), Hioki test passed, proceed to the next step.
  19. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
  20. Install a new patch bolt (1104475-00-F) that attaches the positive fast charge busbar to the DC link side.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  21. Perform a Hioki impedance test on the positive HV joint ensuring it is 25𝜇Ω or less.
  22. Install a new patch bolt (1104475-00-F) that attaches the negative fast charge busbar to the DC link side.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Note
    Mark the bolt after torque.
    Tip
    Use of the following tool(s) is recommended:
    • SKT, 1/4" SQ DR, 13MM, HV INSULATED
  23. Perform a Hioki impedance test on the negative HV joint ensuring it is 40𝜇Ω or less.
  24. Engage the tabs (x2) and datum to install the left ancillary bay terminals cover.
  25. Secure the harness clip to the left terminals cover.
  26. Secure the harness clips (x3) to the fast charge contactor cover.
  27. Connect the AC filter harness connectors (x2) to the fast charge contactor cover.
  28. Connect the LV fast charge contactor connector.
  29. Connect the ancillary bay harness connectors (x2) to the negative pack contactor.
  30. Connect the AC filter harness connector to the PCS2 Lite by pushing it downward, then pushing the locking tab downward to secure it.
    Note
    Ensure the connector is fully seated.
  31. Connect the X421 connector to the DC connection bus.
  32. Install the RH skylite hinge post to the ancillary bay, and then insert the harnesses (x3) into the slot.
    Note
    2x locating pins
  33. Install the screw that attaches the RH skylite hinge post to the ancillary bay.
    2 Nm (1.5 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  34. Install the ancillary bay harness clips (x2) to the RH base insulator assembly.
  35. Install the ancillary bay harness clips (x3) to the positive DC link.
  36. Align the location pins (x3) and secure the bottom clips (x2) to install the RH daisy chain pass through housing onto the ancillary bay.
  37. Install the DCDC pass through. See Passthrough - DCDC - LV (Cable Type) (Remove and Replace).
  38. Connect the PCS2 Lite LV connector to the PCS2 Lite by pushing it downward, then pressing the locking tab down to secure it.
  39. Connect the ancillary bay harness connectors (x2) to the positive pack contactor.
  40. Install the ancillary bay harness clip to the positive pack contactor.
  41. Connect the PCS2 Lite logic connector to the PCS2 Lite.
  42. Install the HVC and skylite hinge to the skylite hinge post.
    Note
    2x tabs, 2x location holes
  43. Install the clips (x8) that attach the megaharness to the HVC skylite hinge.
  44. Connect the HVC connectors (x7).
  45. Measure the voltage across the pyrotechninc battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  46. Remove the service insulator kit.
  47. Remove the logic connector cap from the high voltage controller connector.
  48. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Install).
    Note
    Before installing the ancillary bay cover, inspect the ancillary bay cover seal and confirm there is no visual damage. If the seal is torn and/or delaminated, replace the ancillary bay cover.
  49. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  50. Connect the LV power. See LV Power (Disconnect and Connect) (Modify).