Busbar DC Input to Harness DC Input (Retrofit)
Correction code 163028061.08 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.
- 1076927-00-A Hioki RM 3548 (includes alligator clip leads L2107)
- 1076928-00-A Test Probes - Hioki 9461
- 1127845-00-A Asy, Service Cover, Penthouse, Model 3
- 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
- 1076971-02-A Wrench, Torque + Angle, 1/4" Dr
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
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.
Procedure
- Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the ancillary bay cover from the HV battery. See Cover - Ancillary Bay (Remove and Replace).
- If necessary, install the insulators on the high voltage components within the ancillary bay. See Insulators - HV Battery (Install and Remove).
- Remove the pyrotechnic battery disconnect from the ancillary bay. See Pyrotechnic Battery Disconnect (Remove and Replace).
- Remove the busbar type DC input from the HV battery. See DC Input Assembly - HV Battery (Busbar Type) (Remove and Replace).
- Place a clean shop towel into the opening for the DC input to help capture any debris.
-
Use a dremel tool with wire
disk attachment to remove e-coat from the bosses for the DC input weld nuts
(x4).
NoteMake sure to remove e-coat only from the weld nut bosses.
- Remove the shop towel from the opening for the DC input.
- Use an ESD safe vacuum to clean up any debris from the HV battery and ancillary bay.
- Use an alcohol wipe to clean the exposed surface of the weld nut bosses, and allow to dry.
- Install the harness type DC input into the HV battery. See DC Input Assembly - HV Battery (Harness Type) (Remove and Replace).
-
Perform a Hioki resistance
test between the shield of the DC input header and the threads of the
nearest ancillary bay cover weld nut.
NoteThe acceptable resistance is between 0.30 mΩ and 0.50 mΩ. If the resistance is greater than 0.50 mΩ, stop work and escalate a Toolbox session. If the resistance is lower than 0.30 mΩ, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.30 mΩ, the resistance test has passed.
- Inspect for the presence of the HV battery cabin heater fuse, and if missing, install one. See Fuse - Cabin Heater - HV Battery (Remove and Replace).
- Install the pyrotechnic battery disconnect into the ancillary bay. See Pyrotechnic Battery Disconnect (Remove and Replace).
- Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
- Attach two butyl patches to the underside of the vehicle to cover the bolt holes at the locations shown, and wet-out the patches with a silicone roller.
- Return to the procedure that required the DC input to be retrofitted.