04/06/2024 18:02:12

Shunt - Ancillary Bay (Remove and Replace)

Correction code 1630010032 FRT 0.96 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.

  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 1131071-00-A Dummy Disconnect, Pyro, Safety
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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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.
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Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. 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.

Torque Specifications

Table 1. Torque Specifications: Shunt - Ancillary Bay (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the HV battery shunt to the busbar
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 13 mm socket
    • Ratchet/torque wrench
 Replace

Remove

  1. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
  2. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  3. Remove the HV battery shunt isolator. See Insulator - Access - Shunt (Remove and Replace).
  4. Remove and discard the bolt that attaches the HV battery shunt to the busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  5. Remove the pyrotechnic battery disconnect dummy.
  6. Remove the HV battery shunt.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.
  2. Record the 5-digit shunt resistance as printed at the bottom of the part number label of the new shunt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance is in the range of 20000 to 30000 nano Ohms. For example, "R:25819nΩ” is a resistance of 25819 nano Ohms, so record "25819".
    Informational PurposesAn informational icon, calling your attention
    Note
    Convert the recorded resistance value from decimal to hexadecimal format.
  3. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  4. Position the HV battery shunt to the busbar, and then hand-tighten a new bolt that attaches the HV battery shunt to the busbar.
  5. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  6. Set the multimeter to the "LoZ" (low impedance) mode.
    Informational PurposesAn informational icon, calling your attention
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  7. Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points.
    Informational PurposesAn informational icon, calling your attention
    Note
    The voltage displayed on the multimeter is not as important as balancing the mount points.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
  8. While 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.
  9. Continue to measure the voltage for another 10 seconds after the pyrotechic battery disconnect has been set onto the busbars.
  10. Install the new bolts (x2) that attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  11. Tighten a new bolt that attaches the HV battery shunt to the busbar.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  12. Use the Hioki resistance meter to measure the resistance at the HV joint between the pyrotechnic battery disconnect and the LH busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.048 mΩ (48 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
  13. Use the Hioki resistance meter to measure the resistance at the HV joint between the pyrotechnic battery disconnect and the shunt.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.033 mΩ (33 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
  14. Use the Hioki resistance meter to measure the resistance of the HV joint between the shunt and the adjacent busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.045 mΩ (45 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
  15. Install the HV battery shunt isolator. See Insulator - Access - Shunt (Remove and Replace).
  16. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  17. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  18. In Toolbox, click the Actions/Autodiag tab, type "HVP write shunt ohm" in the search field, click on HVP write shunt ohm, and then type the "previous hexadecimal value" recorded in step 2, and then click Run Network and wait for the routine to complete.
  19. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).