2025-10-15

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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. See Ergonomic Precautions for safe and healthy working practices.

  • 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
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

Informational PurposesAn informational icon, calling your attention
Note
This procedure supplements replacement of the HV battery for the situation where the DC input of the replacement battery is of the busbar type, yet the vehicle is configured with a charge port harness and not charge port busbars. After completing this procedure, return to the procedure that is installing the replacement HV battery.
Informational PurposesAn informational icon, calling your attention
Note
This is not a standalone procedure, it conditionally supplements an HV battery replacement.
Informational PurposesAn informational icon, calling your attention
Note
Perform this procedure with the replacement HV battery on the battery table, before installation into the vehicle.
  • 2025-10-15: Removed redundant steps, as these were nested within other steps.

Procedure

  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. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  3. Remove the ancillary bay cover from the HV battery. See Cover - Ancillary Bay (Remove and Replace).
  4. If necessary, install the insulators on the high voltage components within the ancillary bay. See Insulators - HV Battery (Install and Remove).
  5. Remove the busbar type DC input from the HV battery. See DC Input Assembly - HV Battery (Busbar Type) (Remove and Replace).
  6. Place a clean shop towel into the opening for the DC input to help capture any debris.
  7. Use a dremel tool with wire disk attachment to remove e-coat from the bosses for the DC input weld nuts (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to remove e-coat only from the weld nut bosses.
  8. Remove the shop towel from the opening for the DC input.
  9. Use an ESD safe vacuum to clean up any debris from the HV battery and ancillary bay.
  10. Use an alcohol wipe to clean the exposed surface of the weld nut bosses, and allow to dry.
  11. Install the harness type DC input into the HV battery. See DC Input Assembly - HV Battery (Harness Type) (Remove and Replace).
  12. Perform a Hioki resistance test between the shield of the DC input header and the threads of the nearest ancillary bay cover weld nut.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  13. Inspect for the presence of the HV battery cabin heater fuse, and if missing, install one. See Fuse - Cabin Heater - HV Battery (Battery On Table) (Install).
  14. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  15. 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.
  16. Return to the procedure that required the DC input to be retrofitted.