22/05/2024 15:05:30

Shunt - HV Battery (Remove and Replace)

Correction code 16303602 1.26 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
  • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
  • 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
  • 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.

  • 2023-07-06: Added a video in step 7 of Install part.

Remove

  1. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  2. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  3. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  4. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  5. Disconnect the electrical harness from the shunt connector.
  6. Unhook the electrical harness from the shunt insulator, and then remove the shunt insulator, if installed.
  7. Remove and discard the bolt that attaches the shunt to the busbar.
  8. Remove the shunt 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. 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".
  3. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
  4. Install the shunt to the busbar, and then install and hand-tighten a new bolt to attach the shunt to the busbar.
  5. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  6. Tighten the bolt that attaches the shunt to the busbar, and then mark the bolt with a paint pen after it is torqued.
    9 Nm (6.6 lbs-ft)
  7. 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). If the resistance is above this value, escalate a Toolbox session, as appropriate.
    Figure 1. Generic Measurement - Actual busbars and fasteners might appear different
  8. Install the shunt insulator, if previously removed.
  9. Connect the electrical harness to the shunt connector, and then hook the electrical harness to the shunt insulator, if installed.
  10. Install the pyrotechnic battery disconnect shunt insulator(s).
    Figure 2. 1st Generation
    Figure 3. 2nd Generation
  11. Remove the logic connector cap from the high voltage controller connector.
  12. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  13. Use a paint pen to write the 5-digit new shunt resistance value from step 2 and the date onto the ancillary bay cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    For example, "Shunt res 25819, 05/25/2021".
  14. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  15. Attach the laptop with Toolbox 3 to the vehicle.
  16. In Toolbox, select the Actions/Autodiag tab, type "contactors" into the search field, click Ensure Power Off, and then click RUN.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    After the contactors open, steps 17 and 18 must be completed within 60 seconds.
  17. Select the Actions/Autodiag tab, type "shunt ohm" into the search field, and then click HVP write shunt ohm, and then click Run Network.
  18. In the window that opens, click on the line above “Submit”, type the 5-digit shunt resistance value from step 2, click Submit, and then wait for the routine to successfully complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the routine fails, repeat from step 16.
  19. Disconnect the laptop from the vehicle.