04/06/2024 18:00:24

Busbar - Fast Charge Contactor to DC Bus - Negative (Remove and Replace)

Correction code 1630010062 FRT 1.56 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.

Table 1. Torque Specifications: Busbar - Fast Charge Contactor to DC Bus - Negative (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that secures the busbar cover access door
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench - 1057602-00-A
    • 10 mm 12-point deep socket - 1133768-00-C
    • Extension 1/4 Dr. Wobble 10.5"
  • Electrical Protective Gloves
  • Ratchet/torque wrench
 Reuse
Bolts (x2) that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench - 1057602-00-A
    • 10 mm 12-point deep socket - 1133768-00-C
  • Electrical Protective Gloves
  • Ratchet/torque wrench
 Reuse
Patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Paint Pen
  • Torque wrench with angle measurement
 Replace
Patch bolt that attaches the DC link side positive fast charge busbar to the fast charge contactor
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Paint Pen
  • Torque wrench with angle measurement
 Replace
Patch bolt that attaches the inlet side negative fast charge busbar and the negative DC input assembly busbar
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Electrical Protective Gloves
  • Paint Pen
  • Torque wrench with angle measurement
 Replace
Patch bolt that attaches the inlet side positive fast charge busbar to the positive DC input assembly busbar
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket - 1057606-00-A
  • Electrical Protective Gloves
  • Paint Pen
  • Ratchet/torque wrench
  • Torque wrench with angle measurement
 Replace
Bolts (x4) that secure the DC input busbar assembly to the Ancillary Bay
10 Nm (7.4 lbs-ft)
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
  • Electrical Protective Gloves
  • Ratchet/torque wrench
  • External Torx E10 5-Lobe - 1059330-00-B
  • Paint Pen
  • ¼ in to 3/8 in adapter
 Replace
Bolts (x2) that attach the fast charge assembly to the Ancillary Bay
5.5 Nm (4.1 lbs-ft)
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 10 mm socket
  • Electrical Protective Gloves
  • Paint Pen
 Reuse
Patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Paint Pen
  • Torque wrench with angle measurement
 Replace

Remove

  1. Open all the doors and lower all the windows.
  2. Disconnect the LV power. See LV Battery - Li-lon (Disconnect and Connect).
  3. Remove the LH 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  4. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  5. Remove the bolt that secures the busbar cover access door.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench - 1057602-00-A
      • 10 mm 12-point deep socket - 1133768-00-C
      • Extension 1/4 Dr. Wobble 10.5"
    • Electrical Protective Gloves
    • Ratchet/torque wrench
  6. Remove bolts (x2) that secure the charge port busbar kit to the HV header.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench - 1057602-00-A
      • 10 mm 12-point deep socket - 1133768-00-C
    • Electrical Protective Gloves
    • Ratchet/torque wrench
  7. Release the AC charge port inlet harness clip.
  8. 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.
  9. Position the charge port busbar connector on the cross-member in front of the ancillary bay for access.
  10. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  11. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  12. Remove the HV battery negative contactor. See HV Pack Contactor (Remove and Replace).
  13. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  14. Disconnect the PCS to AC harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the locking tab upward to release. Use a plastic trim tool to help lift the connector upward as necessary.
  15. Release the locking tab, and then disconnect the AC filter harness from the FC contactor cover.
  16. Release harness clips (x2) from the FC contactor cover, and then move the wiring harness aside around the FC contactor cover.
  17. Remove the LH Ancillary Bay terminal cover.
  18. Remove and discard the patch bolt that secures the DC link side negative fast charge busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement
  19. Remove and discard the patch bolt that secures the DC link side positive fast charge busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement
  20. Disconnect the megaharness connector from the DC input assembly.
  21. Remove the insulator for DC input assembly to both inlet side fast charge busbars.
  22. Remove and discard the patch bolt that secures the inlet side negative fast charge busbar and the negative DC input assembly busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
    • Torque wrench with angle measurement
  23. Remove and discard the patch bolt that secures the inlet side positive fast charge busbar and the positive DC input assembly busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket - 1057606-00-A
    • Electrical Protective Gloves
    • Paint Pen
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
  24. Remove and discard the bolts (x4) that secure the DC input busbar assembly to Ancillary Bay, and then remove the DC input busbar assembly from Ancillary Bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
    • Electrical Protective Gloves
    • Ratchet/torque wrench
    • External Torx E10 5-Lobe - 1059330-00-B
    • Paint Pen
    • ¼ in to 3/8 in adapter
  25. Remove the bolts (x2) that secure the fast charge assembly to Ancillary Bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 10 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  26. Remove the fast charge assembly from Ancillary Bay.
  27. Remove and discard the fast charge insulator cover from the fast charge assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the insulator cover upward to release it from the clips (x8) and alignment pin.
  28. Remove and discard the patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor, and then remove the DC link side negative fast charge busbar from the fast charge contactor.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement

Install

  1. Install a new patch bolt that attaches the DC link side negative fast charge busbar to the fast charge contactor.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement
  2. Install new fast charge insulator cover to the fast charge assembly.
  3. Position the fast charge assembly to Ancillary Bay for installation.
  4. Install the bolts (x2) that secure the fast charge assembly to Ancillary Bay.
    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 10 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  5. Install the DC input busbar assembly to Ancillary Bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the seal is not damaged and seated properly.
  6. Install new bolts (x4) that secure the DC input busbar assembly to Ancillary Bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
    • Electrical Protective Gloves
    • Ratchet/torque wrench
    • External Torx E10 5-Lobe - 1059330-00-B
    • Paint Pen
    • ¼ in to 3/8 in adapter
  7. Install a new patch bolt that secures the inlet side negative fast charge busbar and the negative DC input assembly busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
    • Torque wrench with angle measurement
  8. Install a new patch bolt that secures the inlet side positive fast charge busbar and the positive DC input assembly busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket - 1057606-00-A
    • Electrical Protective Gloves
    • Paint Pen
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
  9. Perform a Hioki resistance test at both HV joints of the DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 60𝜇Ω or less. Test from the negative fast charge busbar to the negative DC input busbar, and from the positive fast charge busbar to the positive DC input busbar.
  10. Install the insulator for DC input assembly to both inlet side fast charge busbars.
  11. Connect the megaharness connector to the DC input assembly.
  12. Install a new patch bolt that secures the DC link side positive fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement
  13. Perform a Hioki resistance test at the positive HV joint of the DC link side fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 25𝜇Ω or less.
  14. Install a new patch bolt that secures the DC link side negative fast charge busbar.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 4 in extension
      • Ratchet/torque wrench
      • 13 mm socket
    • Paint Pen
    • Torque wrench with angle measurement
  15. Perform a Hioki resistance test at the negative HV joint of the DC link side fast charge busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 55𝜇Ω or less.
  16. Install the LH Ancillary Bay terminal cover.
  17. Install the harness clips (x2) to the FC contactor cover.
  18. Connect the LV fast charge connector.
  19. Secure the locking tab to install the AC filter harness to the FC contactor cover.
  20. Connect the PCS to AC harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the connector downward, and then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  21. Install the HV battery negative contactor. See HV Pack Contactor (Remove and Replace).
  22. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  23. Position the Ancillary Bay cover to HV battery for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure all accessible insulators are present.
  24. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    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.
  25. 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.
  26. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    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.
  27. Install the AC charge port inlet harness clip.
  28. Install the bolts (x2) that secure the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • Extension 1/4 Dr. Wobble 10.5"
      • Ratchet/torque wrench - 1057602-00-A
      • 10 mm 12-point deep socket - 1133768-00-C
    • Electrical Protective Gloves
    • Ratchet/torque wrench
  29. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    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), Hioki test passed, proceed to the next step.
  30. 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:
    • Insulated tools:
      • Ratchet/torque wrench - 1057602-00-A
      • 10 mm 12-point deep socket - 1133768-00-C
      • Extension 1/4 Dr. Wobble 10.5"
    • Electrical Protective Gloves
    • Ratchet/torque wrench
  31. Install the Ancillary Bay cover. See Ancillary Bay Cover (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    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.
  32. Install the LH 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  33. Connect the LV power. See LV Battery - Li-lon (Disconnect and Connect).
  34. Raise all the windows and close all the doors.