2024-06-04

Contactor - Positive - HV Battery (Remove and Replace)

Correction code 16302102 4.02 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 proper PPE is worn when performing the below procedure.

  • 2023-06-01: Added steps and notes to accommodate mica insulators and tape.
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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.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning

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 glove and safety information.

Remove

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  4. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  5. Position the 2 post lift pads for HV battery removal.
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Remove the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  11. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  12. Remove all items from pockets and make sure not to wear any metal items.
  13. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  14. Put on the HV insulating gloves and then leather over gloves.
  15. Remove the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
  16. Press in the connector side tabs (x2), and then disconnect the electrical harness from the HV battery fastcharge contactor connector.
  17. Vehicles built before September 19, 2022 only - Go to step 20.
  18. Remove and discard the bolt that attaches the AC filter branch of the AC harness to the negative inlet fast charge busbar.
  19. Use a HV insulated pick to lift the AC filter branch terminal from the negative inlet fast charge busbar, and then release the AC filter branch from the HV battery fast charge contactor insulator.
  20. Release the tabs (x3), and then remove the HV battery fast charge contactor insulator cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - A mica insulator might obstruct removal of the insulator cover. Bend or cut the mica insulator as necessary to aid removal of the cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease removal of the insulator.
  21. Disconnect the electrical harness from the HV battery positive contactor connectors (x2).
  22. Release the edge clip that attaches the electrical harness to the HV battery positive contactor, and then move the electrical harness aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Release the additional clips (x2) located under the enclosure.
  23. Vehicles built September 19, 2022 and later only - Remove the positive contactor rear terminal HV insulator.
  24. Remove and discard the bolt that attaches the HV battery positive pack contactor to the 2 button contactor rear terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - If there is mica tape covering the bolt, remove and retain the tape for installation.
  25. Remove and discard the bolt that attaches the HV battery positive contactor to the positive DC link rear busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - If there is mica tape covering the bolt, remove and retain the tape for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease removal of the bolt.
  26. Remove the nuts (x3) that attach the HV battery positive contactor to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnetic pickup tool as necessary to retrieve the nuts.
  27. Remove the HV battery positive contactor from the mounting studs (x2) and guide pins (x2), and out of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Use a plastic trim tool to hold the blue gasket to the side and ease removal of the contactor.

Install

  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. Use an alcohol wipe to clean the high voltage mating surfaces of the HV battery positive contactor and the busbars, and allow 1 minute to dry.
  3. Install the HV battery positive contactor into the HV battery, and onto the mounting studs (x2) and guide pins (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Use a plastic trim tool to hold the blue gasket to the side and ease installation of the contactor.
  4. Install the nuts (x3) that attach the HV battery positive contactor to the HV battery.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnetic pickup tool as necessary to thread the nuts onto the studs.
  5. Install a new bolt to attach the HV battery positive contactor to the positive DC link rear busbar, and mark the bolt with a paint pen after tightening.
    14.5 Nm (10.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease installation of the bolt.
  6. Install a new bolt to attach the HV battery positive contactor to the 2 button contactor rear terminal, and mark the bolt with a paint pen after tightening.
    14.5 Nm (10.7 lbs-ft)
  7. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the positive DC link rear busbar.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not short the side of the probe tip to the edge of the busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance must be less than 0.045 mΩ (45 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
  8. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the 2 button contactor rear terminal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not short the side of the probe tip to the edge of the busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance must be less than 0.045 mΩ (45 μΩ). There is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
  9. Vehicles built before September 19, 2022 only - If removed previously, apply the mica tape to the HV battery positive contactor bolt heads.
  10. Vehicles built September 19, 2022 and later only - Install the positive contactor rear terminal HV insulator.
  11. Return the electrical harness to the HV battery positive contactor, fasten the edge clip that attaches the electrical harness to the HV battery positive contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Fasten the additional clips (x2) located under the enclosure.
  12. Connect the electrical harness to the HV battery positive contactor connections (x2).
  13. Install the HV battery fast charge contactor insulator cover, and then fasten the tabs (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease installation of the insulator.
  14. Vehicles built before September 19, 2022 only - Go to step 17.
  15. Fasten the AC filter branch to the HV battery fast charge contactor insulator, and then use a HV insulated pick to set the AC filter branch terminal onto the negative inlet fast charge busbar.
  16. Install a new bolt to attach the AC filter branch of the AC harness to the negative inlet fast charge busbar.
    15 Nm (11.1 lbs-ft)
    5 Nm (3.7 lbs-ft) +60 deg
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Torque the bolt first to 15 Nm, then loosen the bolt 180 degrees, finally tighten the bolt to 5 Nm +60 degrees.
  17. Connect the electrical harness to the HV battery fastcharge contactor connector, and press down until it clicks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the connector does not contact the insulator when seating.
  18. Install the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
  19. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  20. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  21. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  22. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  23. Connect LV power. See LV Power (Disconnect and Connect).
  24. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  25. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  26. Install the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  27. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.