2026-02-12

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. NOTE: See Ergonomic Precautions for safe and healthy working practices.

2025-08-21: Released new procedure.

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.

Note

Newer replacement HV battery packs do not have PTC heater electronics. Follow this procedure to install PTC heater electronics on the replacement pack.

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.

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).

Remove the pyrotechnic disconnect and install the dummy disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace)
Lift HV Controller up to access fuse insulator

Note
Setup seatbelt to hold HVC assembly and tray in upward position
Install HVC logic cap

Note
1x cap
Install insulator for DC input assembly to both fastcharge busbars inlet side

Note
1x insulator
Install negative AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Install positive AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Use bungee to secure HVC in an upwards position

Note
Wrap bungee around RH headrest
Remove the nuts securing the 700VDC 63A compressor fuse

Note
2x patch nuts, 8mm, 2.5 Nm, Discard after removal
Remove the 700VDC 63A PCS output fuse from AWD bus and dist assembly

Note
1x fuse
Remove the nuts securing the 700VDC 63A PCS output fuse

Note
2x patch nuts, 8mm, 2.5 Nm, Discard after removal
Remove the 700VDC 63A compressor fuse from AWD bus and dist assembly

Note
1x fuse
Remove the nut that secures the HV battery ancillary positive busbar

Note
1x nut, 10mm, 4.5 Nm
Remove the HV battery ancillary positive busbar from AWD bus and dist assembly
Remove nut securing negative AC harness to negative HV battery DC link busbar

Note
1x nut, 8mm, 4.5 Nm
Remove nuts securing PTC negative harness

Note
2x nut, 8mm, 4.5 Nm
Disconnect HV carrier connector

Note
1x connector
Remove screw securing HV carrier assembly

Note
1x screw, T20, 3 Nm
Remove HV carrier assembly
Position the heat shrink sleeve on the new HV carrier wire as illustrated (green rectangle).
Attach the 2 HV carrier terminals together using an M4 nut and bolt.
TIp
Use of the following tool(s) is recommended:

Torx T20 bit
2.5 Nm (1.8 lbs-ft)
Slide the heat shrink sleeve over the fastened terminals, and then install the sleeve with a heat gun.

Warning
Use caution and if necessary, PPE such as protective gloves when handling the heat gun.
Remove the bolt that secures the HV carrier assembly.
TIp
Use of the following tool(s) is recommended:

Torx T20 bit
Route the harness through the HV carrier assembly
Install screw securing HV carrier assembly

Note
1x screw, T20, 3 Nm
Connect HV carrier connector

Note
1x connector
Install nut securing negative AC harness to negative HV battery DC link busbar

Note
1x nut, 8mm, 4.5 Nm
Install two upside-down M5 nuts on the ancillary tray.
Install the HV battery ancillary positive busbar to AWD bus and dist assembly
Install the nut securing the HV battery ancillary positive busbar

Note
1x nut, 10mm, 4.5 Nm
Perform Hioki resistance test at 63A fuse input joint

Note
55 μΩ or less, Perform zero adjust to Hioki meter prior to testing
Install 700VDC 63A PCS output fuse to AWD bus and dist assembly

Note
1x fuse
Install nuts securing the 700VDC 63A PCS output fuse

Note
2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts, Mark after torque
Perform Hioki resistance test at 63A fuse input joint

Note
1x HV joint, 145μΩ or less, Perform zero adjust to Hioki meter prior to testing
Install the 700VDC 63A compressor fuse to AWD bus and dist assembly

Note
1x fuse
Install the nuts securing the 700VDC 63A compressor fuse

Note
2x patch nuts, 8mm, 4.5 Nm, Install new patch nuts
Perform Hioki resistance test at 63A fuse out joint

Note
1x HV joint, 145 μΩ or less, Perform zero adjust to Hioki meter prior to testing
Perform Hioki resistance test at 63A fuse in joint

Note
1x HV joint, 105μΩ or less, Perform zero adjust to Hioki meter prior to testing
Install fuses access insulator

Note
3x clips
Remove pyro disconnect dummy
Clean mating surface of pyro

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
Set multimeter to "LoZ" (low impedance) mode
Position pyro disconnect to ancillary bay for installation

Note
1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
Install bolts securing pyro disconnect to ancillary bay

Note
2x patch bolts, 13mm, 9 Nm, Install new patch bolts
Measure resistance from module 2 busbar to pyro disconnect

Note
1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing
Measure resistance from pyro disconnect to shunt

Note
1x HV joint, 45μΩ or less
Install battery pyro and shunt insulators

Note
2x insulators
Clean HVC studs and ancillary bay cover underside with isopropyl alcohol

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
Wipe penthouse with IPA to clean surface

Note
Allow to 1 minute dry time
Inspect penthouse walls for damage

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
Inspect penthouse cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Remove HVC logic cap

Note
1x cap
Remove ancillary Service Insulator Kit
Remove the ancillary cover. See Cover - Ancillary Bay (Remove and Replace)

2017–2023 Model 3 Service Manual

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

Figure 1

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Figure 3