04/06/2024 18:04:08

Busbar - Fast Charge - Input - Negative (Remove and Replace)

Correction code 1630010042 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 - Input - 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 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 attach the negative inlet fast charge busbar to the fast charge contactor
5 Nm (3.7 lbs-ft) + 60 degrees
15 Nm (11.1 lbs-ft)
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Paint Pen
  • Torque wrench with angle measurement
 Replace
Patch bolts that secure the negative and the positive fast charge busbar DC link sides
5 Nm (3.7 lbs-ft) + 60 degrees
15 Nm (11.1 lbs-ft)
  • Insulated tools:
    • 4 in extension
    • Ratchet/torque wrench
    • 13 mm socket
  • Electrical Protective Gloves
  • Paint Pen
  • Torque wrench with angle measurement
 Replace
Patch bolts that attach the negative and positive fast charge busbar inlet side to the negative and positive DC input assembly busbar
5 Nm (3.7 lbs-ft) + 60 degrees
15 Nm (11.1 lbs-ft)
  • 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 that secure the busbar DC input 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 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
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Open all doors and lower all windows.
  2. Move the front seats forward.
  3. Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  4. Remove the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  5. Verify the operation of the multimeter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set the multimeter to DC voltage. Confirm the multimeter is properly measuring voltage by testing the 16v battery.
  6. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  7. 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
  8. Remove the bolts (x2) that attach 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
  9. Remove the A/C charge port inlet harness clip.
  10. 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.
  11. Position the charge port busbar connector on the cross-member in front of the ancillary bay for access.
  12. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
  13. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  14. Install the pyrotechnic disconnect dummy.
  15. Remove the HV battery negative contactor. See HV Pack Contactor (Remove and Replace).
  16. Press the tabs on both sides by hand, and lift the connector upwards to disconnect the LV fast charge contactor connector.
  17. Disconnect the connector that attaches the power conversion system to the A/C harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. Use plastic trim tool to help lift the connector upward as needed.
  18. Release the locking tab to remove the A/C filter harness from the fast charge contactor cover.
  19. Remove the harness clips (x2) from the fast charge contactor cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the wiring harness around the fast charge cover aside.
  20. Remove the ancillary bay left terminals cover.
  21. Remove and discard the patch bolts (x2) that secure the negative and the positive fast charge busbar DC link sides.
    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
  22. Disconnect the megaharness connector from the DC input assembly.
  23. Remove the insulator for the DC input assembly to both fast charge busbar inlet sides.
  24. Remove and discard the patch bolts (x2) that attach the negative and positive fast charge busbar inlet side to the negative and 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
  25. Remove and discard the bolts (x4) that secure the busbar DC input assembly to the 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
  26. Remove the busbar DC input assembly from the ancillary bay.
  27. Remove the bolts (x2) that attach the fast charge assembly to the 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
  28. Remove the guide pins (x2) to remove the fast charge assembly from the ancillary bay.
  29. Release the clips (x8) and the alignment pin to remove and discard the fast charge insulator cover from the fast charge assembly.
  30. Remove the patch bolt that attach the negative inlet fast charge busbar to the fast charge contactor, and then remove and discard the negative inlet 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

Install

  1. Install and torque the patch bolt that attach the negative inlet fast charge busbar to the fast charge contactor to the first value, then loosen 180 degrees, and then torque to the final value.
    5 Nm (3.7 lbs-ft) + 60 degrees
    15 Nm (11.1 lbs-ft)
    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 the clips (x8) and the alignment pin to install the new fast charge insulator cover to the fast charge assembly.
  3. Position the fast charge assembly to the ancillary bay, and then secure the guide pins (x2).
  4. Install the bolts (x2) that attach the fast charge assembly to the ancillary bay.
    5.5 Nm (4.1 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
      • 10 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  5. Install the busbar DC input assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the seal is not damaged and is seated properly.
  6. Install the new bolts (x4) that secure the busbar DC input assembly to the 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 and torque the new patch bolts (x2) that attach the negative and positive fast charge busbar inlet side to the negative and positive DC input assembly busbar to the first value, then loosen 180 degrees, and then torque to the final value.
    5 Nm (3.7 lbs-ft) + 60 degrees
    15 Nm (11.1 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
      • 13 mm socket - 1057606-00-A
    • Electrical Protective Gloves
    • Paint Pen
    • Ratchet/torque wrench
    • Torque wrench with angle measurement
  8. Perform 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.
  9. Install the insulator for the DC input assembly to both fast charge busbar inlet sides.
  10. Connect the megaharness connector to the DC input assembly.
  11. Install the new patch bolts (x2) that secure the negative and the positive fast charge busbar DC link sides to the first value, then loosen 180 degrees, and then torque to the final value.
    5 Nm (3.7 lbs-ft) + 60 degrees
    15 Nm (11.1 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
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
    • Torque wrench with angle measurement
  12. Perform Hioki impedance test at the positive and the negative HV joints of the fast charge busbar DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance of the positive HV joint should be 25𝜇Ω or less, and the resistance of the negative HV joint should be 55𝜇Ω or less.
  13. Install the ancillary bay left terminals cover.
  14. Install the harness clips (x2) to the fast charge contactor cover.
  15. Connect the LV fast charge connector.
  16. Secure the locking tab to install the A/C filter harness to the fast charge contactor cover.
  17. Connect the connector that attaches the power conversion system to the A/C harness.
    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.
  18. Install the HV battery negative contactor. See HV Pack Contactor (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install the ancillary bay cover at this time.
  19. Position the ancillary bay cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure all accessible insulators are present.
  20. 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.
  21. 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.
  22. 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.
  23. Install the A/C charge port inlet harness clip.
  24. 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:
    • 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
  25. Perform 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.
  26. 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
  27. 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.
  28. Install the 2nd row seat cushion bracket. See Bracket - Edge Support - Seat Cushion - 2nd Row - LH (Remove and Replace).
  29. Connect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  30. Move the front seats back to the original position.
  31. Raise all windows and close all doors.