04/06/2024 18:00:40

Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace)

Correction code 16306002 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.

  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).
  3. Remove the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar.
  4. Remove the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar.
  5. Release the clip and disconnect the DCDC harness from the power conversion system.
  6. Remove the bolts that attaches the DCDC ground busbar to the body.
  7. Remove and discard the nut that attaches the DCDC ground busbar to the HV battery, and remove the DCDC ground busbar from the vehicle.
    15 Nm (11.1 lbs-ft)
  8. Remove the bolts that attach the 12V DCDC passthrough to the ancillary bay, and then remove the 12V DCDC passthrough from the ancillary bay..

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Use an IPA wipe to clean the mating surfaces of the DCDC passthrough, and the DCDC harness.
  3. Install the 12V DCDC passthrough into the ancillary bay, install the bolts that attach the 12V DCDC passthrough to the ancillary bay, and then mark the bolts with a paint pen after they are torqued.
    10 Nm (7.4 lbs-ft)
  4. Install the bolt that attaches the DCDC ground busbar to the body, and then mark the bolt with a paint pen after it is torqued.
    20 Nm (14.7 lbs-ft)
  5. Install the DCDC ground busbar to the DCDC passthrough, install a new nut to attach the DCDC ground busbar to the DCDC passthrough, and then mark the nut with a paint pen after it is torqued.
    15 Nm (11.1 lbs-ft)
  6. Connect the DCDC harness to the power conversion system, and then fasten the clip that attaches the DCDC harness to the power conversion system.
  7. Install the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    4.5 Nm (3.3 lbs-ft)
  8. Install the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    4.5 Nm (3.3 lbs-ft)
  9. Use the Hioki resistance meter to measure the resistance between the positive joint of the DCDC harness and the positive terminal of the 12V DCDC passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.100 mΩ (100 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
    Figure 1. Generic Measurement - Actual busbars and fasteners might appear different
  10. Use the Hioki resistance meter to measure the resistance between the negative joint of the DCDC harness and the negative terminal of the 12V DCDC passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.100 mΩ (100 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
    Figure 2. Generic Measurement - Actual busbars and fasteners might appear different
  11. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
  12. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  13. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform an ancillary bay air leak test when instructed to do so.
  14. Connect 12V power. See 12V/LV Power (Disconnect and Connect).