04/06/2024 18:00:12

High Voltage Battery Assembly - HV Connector Header, DC FC, Doubler (Remove and Install)

Correction code 1601070051 FRT 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Remove the tonneau slats.
  2. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  3. Clean all debris from the ancillary cover.
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    Note
    During removal of the ancillary cover any debris on top of the cover may be deposited into the ancillary bay.
  4. Open the powered frunk.
  5. Open the charge port door through the touchscreen.
  6. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  7. Disconnect MV power. See Disconnect MV Power.
  8. Verify operation of the multimeter.
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    Note
    Set multimeter to DC voltage. Confirm multimeter is properly measuring voltage by testing MV battery. Touch lightly and do not damage terminals.
  9. Remove all items from pockets and ensure not wearing metal items.
  10. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  11. Put on the HV insulating gloves and leather over gloves.
  12. Verify there is no high voltage present at the charge port.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Measure B+ to B-, and B+ to Ground. If voltage is greater than 10V, pack contactors are not open or welded. Stop work and reach out to Service Engineering.
  13. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  14. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  15. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
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    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  16. Support the HV busbar assembly.
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    Note
    Suspend assembly to maintain clearance.
  17. Remove the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  18. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Install the bolts (x2) that attach the fast charger header doubler.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E10 5-Lobe
  2. If grease was found inside the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
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    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  3. Clean the HV connector contact surface of residual Penetrox.
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    Note
    Allow 1 minute dry time after removing the Penetrox.
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    Note
    New busbar comes with Penetrox applied to HV connector
  4. Clean the busbar HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
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    Note
    It is necessary to clean the HV connector during reuse of the busbar.
  5. Apply Penetrox onto the HV connector joints.
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    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  6. Position the busbar electrical connector and lower onto the HV header.
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    Note
    Release the support.
  7. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  8. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  9. Put on the HV insulating gloves and leather over gloves.
  10. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
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    Note
    x2 HV joints.
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    Note
    When using the Hioki tester, verify the meter has been properly adjusted and set prior to usage.
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    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. 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), the hioki test passed, proceed to next step.
  11. Remove the leather over gloves and the HV insulating gloves.
  12. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  13. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  14. Reconnect MV power. See Disconnect MV Power
  15. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  16. Close the powered frunk.
  17. Install the tonneau slats.