2024-06-25: Added alternative part number for silicone lubricant.
2024-06-05: Added warning to measure the
specified order of locations for high voltage.
Warning
This procedure verifies
that high voltage power is no longer available to high voltage components (PTC heater,
A/C compressor, inverters, etc). Perform this procedure before servicing high voltage
components.
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.
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.
Warning
Always wear High Voltage (HV) gloves and safety glasses when handling
any high voltage component, including test equipment. Before each use, test gloves using
an authorized glove tester and verify that the testing date on the gloves has not
expired.
Warning
All repair and operating instructions should be reviewed and
understood before working on Tesla vehicles, associated components, or associated repair
equipment.
Warning
Assume that high voltage is present at all times when working on a
Tesla vehicle, associated high voltage components, or associated high voltage test
equipment until proven otherwise. Be aware that energy states can change during testing,
so err on the side of caution.
Warning
Always have an electrical safety hook in the area when working with HV
components. Electrical safety hooks are used to remove an injured person from a live
high voltage circuit without risking additional injury.
Warning
Use a high voltage digital multimeter to check for the presence of
high voltage on both sides of the connector every time a high voltage connector is
disconnected.
Warning
Make sure that the
insulation meter and leads are capable of handling at least 500V DC.
Warning
Obey all instructions
when using test equipment or servicing a Tesla vehicle or associated high voltage
components. If repair instructions are not clear or if there are any questions about how
to use the test equipment, send feedback to ServiceManualFeedback@tesla.com.
Warning
If any test equipment fails to operate as expected, do not attempt to
diagnose or repair the vehicle. Follow the appropriate lock out – tag out procedure for
the equipment, notify your manager.
Warning
When using test equipment, make sure that all cables are connected
before turning equipment on or otherwise initiating use.
Warning
High voltage is present on battery recovery chargers whenever the HV
LEDs are lit. However, indicators and LEDs can fail. Do not assume that if an LED is not
lit no high voltage is present. Assume high voltage is present at all times until proven
otherwise by use of a multimeter.
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 any time a high voltage cable is handled. Refer to
Tech Note TN-15-92-003, "High Voltage Awareness Care Points"
for additional safety information.
Warning
If the 12V power
supply is disconnected, do not attempt to open any doors with door glass in
closed position. Failure to follow this instruction could result in door glass
shatter.
Note
Before
disconnecting the 12V power supply, ensure that the driver’s door window is
fully open. Failure to follow this instruction could result in vehicle
lockout.
Proper
personal protective equipment (PPE) and insulating HV gloves with a minimum
rating of class 00 (500V) must be worn while performing the remainder of this
procedure.
Warning
Ensure that
the multimeter and leads are capable of handling at least 500V.
Disconnect the low voltage harness, then release the bolt and remove the orange
drive inverter cover (torque 3 Nm).
Remove both O-rings from the drive inverter cover and discard.
Use the drive inverter case as a
chassis ground. Measure the following voltages in the order
specified:
Warning
In order to limit potential exposure to high voltage, measure for
high voltage in the order specified below.
B+ to ground
B- to ground
B+ to B-
Warning
If any voltage reading is more
than 10V, the high voltage contactors are not fully opened. Due to the risk of
electrocution, contact Service Engineering before performing any further
work.
CAUTION
To prevent future
water ingress, install new O-rings (1003784-00-A or later) on the drive inverter
cover and apply Silicone Lubricant (1010251-00-A or 1083744-01-A) on both before
installing the cover. Insert the cover at an angle to prevent damage to the O-rings.
Once the left (B+) O-ring is seated, rotate the cover into position.
Checking for High Voltage at the High Voltage Junction Box (HVJB)
Perform all of the voltage checks listed in the HVJB cover
procedure. If any voltage reading is more than 10V, the high voltage contactors
are not fully opened. Due to the risk of electrocution, contact Service
Engineering before performing any further work.
Checking for High Voltage at the 3rd Generation Charger
Note
This procedure can only be
performed on vehicles with a 3rd generation charger (all vehicles built after April
10, 2016).
Remove the NVH padding that covers the 2nd row seat frame.
Remove the bolts (x8) that secure the seat frame to the body (torque 26
Nm).
Tip: If the seat frame
is being removed for access, it might not be necessary to remove it from the
vehicle. Instead, lift up on the frame and temporarily secure it to the 2nd row
seat backrest.
Remove all clips that secure cables to the 2nd row seat frame. Ensure that all
cables are reattached to the seat frame upon reinstallation.
CAUTION
Do not damage
any cables.
Lift up the bottom of the seat frame and support it to provide access to the
charger.
Remove and discard the warranty label from the charger access panel.
Note
Components have been removed
in this graphic to aid clarity.
Release and discard the fasteners (x11) that secure the charger cover (torque 2
Nm).
CAUTION
Replace all patchbolt(s).
Carefully remove the front access cover to expose the fasteners that secure the
HV cables to the HV Battery.
Use the charger casing as a chassis ground. Measure the following
voltages:
Warning
Ensure that
the multimeter and leads are capable of handling at least 500V.
Warning
Do not use a
probe with an exposed tip length that is greater than 3 mm.
Warning
In order to limit potential exposure to high voltage, measure for
high voltage in the order specified below.
B+ to ground
B- to ground
B+ to B-
Warning
If any voltage reading is more than 10V, the High Voltage (HV) contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work.
Reinstall components that were removed for access.
Note
Clean the adhesive residue on
the charger and charger access panel with an alcohol wipe before installing a
new warranty label.
WarningIf any voltage reading is more than 10V, the high voltage contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before performing any further work.
Tip: If the seat frame is being removed for access, it might not be necessary to remove it from the vehicle. Instead, lift up on the frame and temporarily secure it to the 2nd row seat backrest.
