04/06/2024 18:00:21
Busbar - Fast Charge Contactor to DC Bus - Positive (Remove and Replace)
Correction code 1630010072 FRT 1.62 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.
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
- Open all doors and lower all windows.
- Move both front seats forward.
- Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
-
Fold 2nd row 60 seatback down
NotePull release, Fold down, Protect the seat cushion if necessary
-
Remove LH side bolster
Note1x locator clip, 3x guide tabs, Pull outward then slightly upward to remove
-
Remove bolster plastic bracket from LH
side body
Note2x clips, If necessary, depress the clips from behind, this bracket may come out with bolster. Discard after removal
-
Move 2nd row 60 seatback into vertical
position
-
Release 2nd row seat cushion and
disconnect harness
Note2x clips, 2x connectors, Press tabs backward then pull front edge up
-
Partially release LH front primary
door seal
NoteRelease the lower section of LH front primary door seal
-
Remove LH IP end cap
Note5x clips, 2x guide tabs
-
Remove clip securing LH lower A-pillar
assembly
Note1x push clip
-
Remove LH lower A-pillar
assembly
Note4x clips, 2x guide tabs, Pull rear of lower A-pillar upward to release clip then pull rearward to release front tabs from carpet
-
Remove LH lower B-pillar
assembly
Note7x clips, 4x locator clips, Pull the trim panel outward in the direction of the arrow to release clip from lower B-pillar
-
Remove bolts securing sadface bracket
to vehicle
Note2x bolts, 10mm, 10 Nm
-
Remove sadface bracket from
vehicle
Note1x Positioning clip
-
Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
-
Remove all items from pockets and
ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Remove bolts securing ancillary bay probe
lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
-
Remove ancillary bay probe lid cover from
the ancillary bay cover
-
Verify no high voltage
NoteMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
-
Inspect ancillary bay probe lid cover
gasket then position onto the ancillary bay cover
NoteConfirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time
-
Install bolts securing ancillary bay probe
lid cover to ancillary bay cover
Note2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
-
Remove fastener securing busbar cover
access door
Note1x bolt, 10mm, 9 Nm
-
Remove bolts securing charge port
busbar kit to HV header
Note2x bolts, 10mm, 9 Nm
-
Remove AC chargeport inlet harness
clip
Note1x clip
-
Lift busbar kit connector to remove
from HV header
Note4x guide tabs, Ease removal of aluminum connector housing by shifting rear end of busbar assembly upward
-
Position chargeport busbar connector
for access below
NoteRest on cross-member in front of ancillary bay
-
Remove HV insulating gloves
-
Disconnect HVC logic connector and
install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
-
Remove fasteners securing ancillary bay
cover to high voltage controller (HVC)
Note3x bolts, E10, 5 Nm + 30 degrees
-
Remove bolts securing ancillary bay cover
to HV battery
Note18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
-
Put on HV insulating gloves and
leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
Remove ancillary bay cover from HV
battery
-
Inspect the ancillary bay for any missing
insulators
NoteInstall any missing insulators that are accessible before continuing to next step, The number of bolts on newer vehicles may vary
-
Remove bolts securing pyro disconnect
to ancillary bay
Note2x insulators, patch bolts, 13mm, 9 Nm, Discard after removal
-
Remove pyro disconnect from
ancillary bay
Note1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
-
Install pyro disconnect dummy
-
Remove ancillary bay harness clip around
negative pack contactor area
Note1x clip
-
Disconnect ancillary bay harness
connectors from negative pack contactor
Note2x connectors
-
Remove HV joint insulators from
negative pack contactor
Note2x insulators
-
Remove bolt securing negative pack
contactor to DC link busbar joint
Note1x patch bolt, 13mm, 9 Nm, Discard after removal
-
Remove nut securing negative pack
contactor to HV battery tall silicon terminal
Note1x patch nut, 13mm, 9 Nm, Discard after removal
-
Remove nuts securing the negative pack
contactor to ancillary bay
Note3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
-
Remove the negative pack contactor
from ancillary bay
Note2x guide pins
-
Disconnect LV fastcharge contactor
connector
Note1x connector, Press tabs on both sides by hand and disconnect the connector upwards
-
Disconnect PCS to AC harness
connector
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
-
Remove AC filter harness from FC
contactor cover
Note1x connector, Release locking tab, 1x harness clip
-
Remove harness clips from FC contactor
cover
Note2x clips, Move the wiring harness around the FC cover aside
-
Remove ancillary bay left terminals
cover
Note2x tabs, 1x datum
-
Remove bolt securing negative
fastcharge busbar DC link side
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_007
-
Remove bolt securing positive
fastcharge busbar DC link side
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_006
-
Disconnect megaharness connector from
DC input assembly
Note1x connector
-
Remove insulator for DC input assembly
to both fastcharge busbar inlet side
Note1x insulator
-
Remove bolt securing negative
fastcharge busbar inlet side and negative DC input assembly busbar
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5 Nm + 60 degrees, Discard after removal
-
Remove bolt securing positive
fastcharge busbar inlet side and positive DC input assembly busbar
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5 Nm + 60 degrees, Discard after removal
-
Remove bolts securing busbar DC input
assembly to ancillary bay
Note4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
-
Remove Busbar DC input assembly from
ancillary bay
-
Remove bolts and nut securing FC
assembly to ancillary bay
Note2x bolts, 10mm, 5.5 Nm
-
Remove the FC assembly from
ancillary bay
Note2x guide pins
-
Remove and discard FC insulator cover
from FC assembly
Note8x clips, 1x alignment pin
-
Remove DC link positive busbar from
fastcharge contactor
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Discard after removal, 0300_003
Install
-
Install and torque bolt securing DC
link positive busbar to fastcharge contactor to first value, loosen 180 degrees, and
then torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
-
Install new FC insulator cover to FC
assembly
Note8x clips, 1x alignment pin
-
Position FC assembly to ancillary bay for
installation
Note2x guide pins
-
Install bolts securing FC assembly to
ancillary bay
Note2x bolts, 10mm, 5.5 Nm, Mark after torque
-
Install Busbar DC input assembly to
ancillary bay
NoteEnsure seal is not damaged and seated properly
-
Install bolts securing Busbar DC input
assembly to ancillary bay
Note4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
-
Install and torque bolt securing
negative fastcharge busbar inlet and negative DC input link to first value, loosen 180
degrees, and then torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
-
Install and torque bolt securing
positive fastcharge busbar inlet and positive DC input link to first value, loosen 180
degrees, and then torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
-
Perform Hioki resistance test at both
HV joints of DC input assembly busbar
Note2x HV joints, 60_xD835__xDF07_Ω or less, Test from negative fastcharge busbar to negative DC input busbar and positive fastcharge busbar to positive DC input busbar
-
Install insulator for DC input
assembly to both fastcharge busbars inlet side
Note1x insulator
-
Connect megaharness connector to DC
input assembly
Note1x connector
-
Install and torque bolt securing
positive fastcharge busbar DC link side to first value, loosen 180 degrees, and then
torque to final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
-
Perform Hioki impedance test at the
positive HV joint of the fastcharge busbar DC link side
Note1x HV joint, 25_xD835__xDF07_Ω or less
-
Install and torque bolt negative
fastcharge busbar DC link side to first value, loosen 180 degrees, and then torque to
final value
Note1x patch bolt, 13mm, 15 Nm, Minus 180 degress, 5Nm + 60 degrees, Install new patch bolt, Mark after torque
-
Perform Hioki impedance test at the
negative HV joint of the fastcharge busbar DC link side
Note1x HV joint, 55_xD835__xDF07_Ω or less
-
Install ancillary bay left terminals
cover
Note2x tabs, 1x datum
-
Install harness clips to FC contactor
cover
Note2x clips
-
Connect LV fastcharge connector
Note1x connector
-
Install AC filter harness to FC
contactor cover
Note1x connector, Secure locking tab, 1x harness clip
-
Connect PCS to fastcharge contactor HV
harness connector
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
-
Position negative pack contactor to
ancillary bay for installation
NoteAlign the 2x guide pins
-
Install nuts securing the negative
pack contactor to ancillary bay
Note3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary, Mark after torque
-
Install bolt securing negative pack
contactor to DC link busbar joint
Note1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque
-
Install nut securing negative pack
contactor to HV battery tall terminal
Note1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
-
Perform Hioki impedance test at the HV
joint of the negative pack contactor to negative DC link busbar
Note1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 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 less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
-
Perform Hioki impedance test at the
negative pack contactor to module 1 rear terminal
Note1x HV joint, 110_xD835__xDF07_Ω or less
-
Install HV joint insulators to
negative pack contactor
Note2x insulators
-
Connect ancillary bay harness connectors
to negative pack contactor
Note2x connectors
-
Install ancillary bay harness clip around
negative pack contactor area
Note1x clip
-
Remove pyro disconnect dummy
-
Use IPA cleaning
NoteAllow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect
-
Set the multimeter to the "LoZ" (low
impedance) mode
-
Measure voltage between busbar and
shunt
NoteWhile still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars
-
Position the pyro disconnect to
ancillary bay for installation
Note1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
-
Install bolts securing pyro disconnect
to ancillary bay
Note2x patch bolts, 13mm, 9 Nm
-
Measure resistance from the module 2
busbar to pyro disconnect
Note1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
-
Measure resistance from the pyro
disconnect to shunt
Note1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
-
Remove ancillary bay insulators
-
Inspect ancillary bay walls for
damage
NoteAny dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
-
Inspect ancillary bay cover seal to
confirm it has no visual damage
NoteImage up close for clarity, Delaminated and torn seals cannot be reused
-
Position the ancillary bay cover to HV
battery for installation
NoteEnsure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
-
Clean HV connector contact surface of
residual Penetrox
NoteAllow 1 minute dry time, New busbar comes with penetrox applied to HV connector
-
Clean busbar HV connector contact
surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Apply Penetrox onto HV connector
joints
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
-
Position busbar kit connector and
lower onto HV header
Note4x guide tabs, Shift rear end of busbar assembly upward to help ease installation, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
-
Install AC chargeport inlet harness
clip
Note1x clip
-
Install bolts securing charge port
busbar kit to HV header
Note2x bolts, 10mm, 9 Nm
-
Perform Hioki resistance test at each
HV joint from HV busbar lead to bolt head
Note2x HV joints, 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), Hioki test passed, proceed to next step
-
Install fastener securing busbar cover
access door
Note1x bolt, 10mm, 9 Nm
-
Remove HV insulating gloves
-
Install bolts securing ancillary bay cover
to HV battery
Note18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
-
Install fasteners securing ancillary bay
cover to high voltage controller (HVC)
Note3x bolts, E10, 5 Nm + 30 degrees
- Remove the logic cap and connect the HVC logic connector.
-
Install sadface bracket into
vehicle
Note1x Positioning clip
-
Install bolts securing sadface bracket
to vehicle
Note2x bolts, 10mm, 10 Nm
-
Install LH lower B-pillar
assembly
Note7x clips, 4x locator clips, Align the locator clips to slot, Then push in the direction of the arrow to install the clips after aligning them, Make sure the seal sits overlapping the trim
-
Install LH lower A-pillar
assembly
Note4x clips, 2x guide tabs, Align the 2 front tabs then align the slot with harness bracket and then push rear clip to secure to lower B-pillar, Fully seat seal along trim
-
Install clip securing LH lower
A-pillar assembly
Note1x push clip
-
Install LH IP end cap
Note5x clips, 2x guide tabs
-
Install LH front primary seal
NoteVerify seal is seated properly on all trim panels
-
Connect 2nd row seat harness and
secure cushion
Note2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
-
Fold 2nd row 60 seatback down
NotePull release, Fold down, Protect the seat cushion if necessary
-
Install bolster plastic bracket to LH
side bolster
Note2x tabs, Install new bolster bracket
-
Install LH side bolster
Note1x locator clip, 3x guide tabs, Align the bottom and side tabs then push inward to install
-
Return 2nd row 60 seatback to vertical
position
- Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
-
Move both front seats to original
position.
- Raise all windows and close all doors.