2025-09-29

PTC Heater Electronics (Rework Busbar Packs for Use in Non-Busbar Vehicles) (Modify)

Correction code 16014567 FRT 1.02 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.

  • 2025-08-21: Released new procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
Informational PurposesAn informational icon, calling your attention
Note
Newer replacement HV battery packs do not have PTC heater electronics. Follow this procedure to install PTC heater electronics on the replacement pack.
Informational PurposesAn informational icon, calling your attention
Note
This procedure begins with the old HV battery already removed from the vehicle. Use this correction in conjunction with the appropriate HV battery (Remove and Replace) correction.
Informational PurposesAn informational icon, calling your attention
Note
The parts required for this rework will be automatically added to the service activity. However, the heat shrink tubing (3M PN: EPS300-3/4-48"-RED-45 PCS, Digikey PN: 3M161211-ND) must be procured externally (Tesla employees: use the Digikey punchout).
  1. Remove bolts securing ancillary bay cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover, The number of bolts on newer vehicles may vary, Early production vehicles may have 28x bolts, T30, 9 Nm
  2. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  3. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf
  4. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves
  5. Remove ancillary cover from HV battery
  6. Remove battery pyro and shunt insulators
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators, Make sure to wear proper PPE from this step onward until the ancillary cover has been secured
  7. Remove bolts securing pyro disconnect to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 13mm, 9 Nm, Discard after removal
  8. Remove pyro disconnect from ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
  9. Lift HV Controller up to access fuse insulator
    Informational PurposesAn informational icon, calling your attention
    Note
    Setup seatbelt to hold HVC assembly and tray in upward position
  10. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  11. Install insulator for DC input assembly to both fastcharge busbars inlet side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x insulator
  12. Install negative AC inlet terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 3x clips, Use caution as the clips are very easy to damage
  13. Install positive AC inlet terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 3x clips, Use caution as the clips are very easy to damage
  14. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  15. Install pyro disconnect dummy
  16. Use bungee to secure HVC in an upwards position
    Informational PurposesAn informational icon, calling your attention
    Note
    Wrap bungee around RH headrest
  17. Remove the nuts securing the 700VDC 63A compressor fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch nuts, 8mm, 2.5 Nm, Discard after removal
  18. Remove the 700VDC 63A PCS output fuse from AWD bus and dist assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fuse
  19. Remove the nuts securing the 700VDC 63A PCS output fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch nuts, 8mm, 2.5 Nm, Discard after removal
  20. Remove the 700VDC 63A compressor fuse from AWD bus and dist assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fuse
  21. Remove nut securing the HV battery ancillary positive busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 14Nm
  22. Remove the HV battery ancillary positive busbar from AWD bus and dist assembly
  23. Remove nut securing negative AC harness to negative HV battery DC link busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 8mm, 4.5 Nm
  24. Remove nuts securing PTC negative harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nut, 8mm, 4.5 Nm
  25. Disconnect HV carrier connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  26. Remove screw securing HV carrier assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 3 Nm
  27. Remove HV carrier assembly
  28. Install two upside-down M5 nuts on the ancillary tray.
  29. Position the heat shrink sleeve on the new HV carrier wire as illustrated (green rectangle).
  30. Attach the 2 HV carrier terminals together using an M4 nut and bolt (torque 2.5 Nm).
  31. Slide the heat shrink sleeve over the fastened terminals, and then install the sleeve with a heat gun.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use caution and if necessary, PPE such as protective gloves when handling the heat gun.
  32. Install HV carrier assembly
  33. Install screw securing HV carrier assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 3 Nm
  34. Connect HV carrier connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  35. Install nuts securing PTC negative harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nut, 8mm, 4.5 Nm
  36. Install nut securing negative AC harness to negative HV battery DC link busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 8mm, 4.5 Nm
  37. Install the HV battery ancillary positive busbar to AWD bus and dist assembly
  38. Install the nut securing the HV battery ancillary positive busbar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 4.5 Nm
  39. Perform Hioki resistance test at 63A fuse input joint
    Informational PurposesAn informational icon, calling your attention
    Note
    55 μΩ or less, Perform zero adjust to Hioki meter prior to testing
  40. Install 700VDC 63A PCS output fuse to AWD bus and dist assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fuse
  41. Install nuts securing the 700VDC 63A PCS output fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque
  42. Perform Hioki resistance test at 63A fuse input joint
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing
  43. Install the 700VDC 63A compressor fuse to AWD bus and dist assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fuse
  44. Install the nuts securing the 700VDC 63A compressor fuse
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts
  45. Perform Hioki resistance test at 63A fuse out joint
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 145 μΩ or less, Perform zero adjust to Hioki meter prior to testing
  46. Perform Hioki resistance test at 63A fuse in joint
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing
  47. Install fuses access insulator
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips
  48. Remove pyro disconnect dummy
  49. Clean mating surface of pyro
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a non-conductive plastic tool to clean the busbar side, Allow 1 minute for IPA to fully dry, Do not use any other types of cleaner
  50. Set multimeter to "LoZ" (low impedance) mode
  51. Position pyro disconnect to ancillary bay for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
  52. Install bolts securing pyro disconnect to ancillary bay
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 13mm, 9 Nm, Install new patch bolts
  53. Measure resistance from module 2 busbar to pyro disconnect
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing
  54. Measure resistance from pyro disconnect to shunt
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 45μΩ or less
  55. Install battery pyro and shunt insulators
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators
  56. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure no plastisol residue on ancillary bay or HVC, Remove plastisol residue if necessary, Fastener count may vary on new vehicles, Allow 1 minute for IPA to dry
  57. Wipe penthouse with IPA to clean surface
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow to 1 minute dry time
  58. Inspect penthouse walls for damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the penthouse wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
  59. Inspect penthouse cover seal to confirm it has no visual damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Image up close for clarity, Delaminated and torn seals cannot be reused
  60. Remove HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  61. Remove ancillary Service Insulator Kit
  62. Position ancillary cover to HV battery for installation
  63. Install HVC logic cap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cap
  64. Install ancillary cover to HV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    18x bolts, E10 5-Lobe, 8 Nm, new SOP change fastener to captive E10 5-Lobe bolts, use E10 5-Lobe socket without magnet, Follow torque sequence per image, The number of bolts on newer vehicles may vary, Early production vehicles may have 28x bolts, T30, 9 Nm