22/05/2024 15:07:17

Guide - Probing - HV Battery (Retrofit)

Correction code 16303806 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.

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Note

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.

Retrofit

  1. Perform this retrofit when a service procedure instructs to remove the HV battery probing guide, yet the guide is of the older design which has an extension that passes under the power conversion system coolant output tube and attaches adjacent to the pyrotechnic battery disconnect.
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    Note
    This procedure can also be performed proactively if the ancillary bay cover has been removed as part of another service operation.
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    Note
    It is not necessary to perform this procedure for the newer design HV battery probing guide. The newer guide does not have the extension.
  2. If a service procedure has requested that the HV battery probing guide be removed, go to step 7. Otherwise, continue to the next step.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  4. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  5. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  6. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  7. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  8. Verify that the HV battery probing cover is of the older design.
    Figure 1. Older Design
    Figure 2. Newer Design
  9. Disconnect the electrical harness from the HV battery fast charge contactor connector.
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    Note
    Squeeze the tabs on either side of the harness connector, to release the tabs from the contactor connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not pry the connectors apart, as this action breaks the tabs and connectors, and necessitates harness replacement.
  10. Disconnect the electrical harness from the HV battery negative contactor connectors.
  11. Release the clip that attaches the HV battery ancillary bay harness from the HV battery fast charge contactor, and then move the harness to the left and away from the HV battery probing cover.
  12. While holding down on the HV battery probing cover extension with one hand, pull up on the probing cover with the other hand and fold it over the extension.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure to wear PPE including goggles when performing this step.
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    Note
    The folding motion should break the cover.
  13. With the cover in two or more pieces, carefully remove the pieces from the ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to stress or damage the power cover system coolant output tube.
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    Note
    It may be necessary to make a second break so that the larger pieces can be removed.
  14. Use an ESD-safe vacuum to remove any smaller pieces and debris from the ancillary bay.
  15. If the fast charge contactor busbars have a blue choke coil, perform these additional steps:
    1. Use a dremel tool with cutting wheel to cut out the internal divider of the newer design HV battery probing cover.
      Tip: Make multiple cuts to form strips which can be cut off individually.
    2. Use the dremel tool with the grinding stone to further trim the divider to be less than 1 mm high.
    3. Use a pocket screwdriver to deburr the divider, and then clean the divider with an IPA wipe.
  16. Install the newer design HV battery probing cover and verify the fit.
  17. Use diagonal cutters to remove the lip from the underside of a bolt head insulator.
  18. Install the insulator over the exposed bolt of the front drive unit positive HV joint .
  19. If a service procedure has requested that the HV battery probing guide be removed, remove the cover and return to that procedure. Otherwise, leave the cover in place and continue to the next step.
  20. Move the HV battery ancillary bay harness to the HV battery fast charge contactor, and then fasten the clip that attaches the harness to the contactor.
  21. Connect the electrical harness to the HV battery negative contactor connectors.
  22. Connect the electrical harness to the HV battery fast charge contactor connector.
  23. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  24. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  25. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  26. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).