04/06/2024 18:01:16

DC Input Assembly - HV Battery (Harness Type) (Remove and Replace)

Correction code 16302302 1.38 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
  • 1057607-00-A Magnet, Flexible, HV Insulated, 18"
  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
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. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Remove the insulator for the DC input assembly.
  3. Remove and discard the bolts that attach the DC input busbars to the fast charge contactor busbars.
  4. Disconnect the electrical harness from the DC input assembly connector.
  5. Remove the bolts that attach the DC input assembly to the ancillary bay, and then remove the DC input assembly from the vehicle.

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. Install the DC input assembly to the ancillary bay, install the bolts (x4) that attach the DC input assembly to the ancillary bay, and then mark the bolts with a paint pen after they are torqued..
    6 Nm (4.4 lbs-ft)
  3. Install new bolts (x2) to attach the DC input busbars to the fast charge contactor busbars.
  4. Precondition the bolts by torquing to 15 Nm, then back off one half turn, retorque to 5 Nm +60 deg, and then mark the bolts with a paint pen.
    15 Nm (11.1 lbs-ft) -180 deg
    5 Nm (3.7 lbs-ft) +60 deg
  5. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive DC input busbar and the positive (LH) fast charge contactor busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 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
    Figure 1. Generic Measurement - Actual busbars and fasteners might appear different
  6. Use the Hioki resistance meter to measure the resistance at the HV joint between the negative DC input busbar and the negative (RH) fast charge contactor busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 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
    Figure 2. Generic Measurement - Actual busbars and fasteners might appear different
  7. Install the insulator for the DC input assembly.
  8. Connect the electrical harness to the DC input assembly connector.
  9. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  10. 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.
  11. Connect 12V power. See 12V/LV Power (Disconnect and Connect).