Pyrotechnic Battery Disconnect (Remove and Replace)
Correction code 16300002 0.90 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 proper PPE is worn when performing the below procedure.
- 2024-08-22: Updated PN of the non-conductive socket as mentioned in the notes.
- 2024-01-26: Updated tools and cautions for removing and installing the pyrotechnic battery disconnect.
- 2023-07-25: Added step to record replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
- 1659979-00-A 13 mm Non-Conductive Composite Socket
- 1057602-00-A HV Insulated Ratchet, 1/4" Drive
- 1658675-00-A 13mm HV Ratcheting Wrench- P2 Pyro
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
- Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Disconnect LV power. See LV Power (Disconnect and Connect).
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Use an IPA wipe to clean around the pyrotechnic battery disconnect cover area, and allow 1 minute to dry.
-
Remove and discard the bolts (x8) that
attach the pyrotechnic battery disconnect cover to the HV battery, and then remove the
cover.
WarningThe LH/RH side of the pyrotechnic battery disconnect is always on and "live". Be cautious when working in this area and always wear high voltage protective equipment. Do not remove protective gloves.
-
Visually inspect the pyrotechnic
battery disconnect and cavity for water, dirt, arcing, or any other damage.
NoteIf any issues are detected, contact Service Engineering for assistance before proceeding.
-
Use the special 13 mm non-conducting
isolated socket to remove and discard the bolts (x4) that attach the pyrotechnic battery
disconnect to the HV battery busbars.
WarningUse only 1659979-00-A, which is a 13 mm non-conducting isolated socket, to loosen, remove, install, and tighten the bolts (x4) that attach the pyrotechnic battery disconnect to the HV battery busbars.WarningThe LH/RH side of the pyrotechnic battery disconnect is always on and "live". Use only non-conductive isolated tooling.NoteHold the pyrotechnic battery disconnect while removing the bolts to prevent the disconnect from falling out.
- Move the pyrotechnic battery disconnect straight forward toward the front of the HV battery to separate from the connector, and then tilt down to remove the disconnect from the HV battery.
-
Install the pyrotechnic battery
disconnect flag.
NoteIf the HV battery is installed, the L-shaped side extension is not required.
- If a procedure requested that the pyrotechnic battery disconnect be removed, return to that procedure.
Install
- Record the replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
-
Perform a zero adjust of the Hioki
resistance meter in preparation to measure resistances later in this procedure. See
Resistance Meter (Zero Adjust).
NoteHV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
- Remove the pyrotechnic battery disconnect flag.
- Use an alcohol wipe to clean the high voltage mating surfaces of the pyrotechnic battery disconnect, and allow 1 minute to dry.
-
Use a non-conductive plastic tool to
hold an alcohol wipe to clean the high voltage busbars of the HV battery, and allow 1
minute to dry.
NoteDo not use any other types of cleaner.
- Set the multimeter to the "LoZ" (low impedance) mode.
-
Measure the voltage between the left and right busbars for at least 10 seconds, so as
to balance the voltage across the pyrotechnic battery disconnect mount points.
NoteThe voltage displayed on the multimeter is not as important as balancing the mount points.
- Tilt the pyrotechnic battery disconnect up into the cavity of the HV battery, make horizontal, then move straight back toward the rear of the HV battery to connect to the connector.
- Hold the pyrotechnic battery disconnect in place, and hand-install new bolts (x4) to attach the disconnect to the HV battery busbars.
-
Use the special 13 mm non-conducting
isolated socket to thread and then tighten the boltsWarningUse only 1659979-00-A, which is a 13 mm non-conducting isolated socket, to loosen, remove, install, and tighten the bolts (x4) that attach the pyrotechnic battery disconnect to the HV battery busbars.WarningThe LH/RH side of the pyrotechnic battery disconnect is always on and "live". Use only non-conductive isolated tooling.
-
Use the Hioki resistance meter to
measure the resistance between each lug of the pyrotechnic battery disconnect and the HV
battery busbar behind it.
CAUTIONDo not short the side of the probe tip to the edge of the lugs.NoteResistance values for both lugs must be less than 0.050 mΩ (50 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.
- Use an alcohol wipe to clean the sealing surface of pyrotechnic fuse cover and the HV battery, and allow 1 minute to dry.
-
Install the pyrotechnic battery
disconnect cover to the HV battery, install new bolts (x8) to attach the cover to the HV
battery, and then mark the bolts with a a paint pen after they are
torqued.
- Remove the leather glove protectors and the HV insulating gloves.
- If a procedure requested that the pyrotechnic battery disconnect be installed, return to that procedure. Otherwise continue to the next step.
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Connect LV power. See LV Power (Disconnect and Connect).
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.