25/06/2024 02:48:49

Cover - Pyrotechnic Fuse - HV Battery 1.0/1.5 (Remove and Replace)

Correction code 16100502 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 to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See to make sure wearing proper PPE when performing the below procedure.

  • 2024-06-25: Added alternative sealants to replace Threebond 1216E due to non availability of Threebond in certain markets.
  • 2024-01-19: Added Tesla-approved sealants to steps.

Sealant required for this procedure:

  • Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A) or Dowsil 7091 (1962594-00-A)
Warning IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
Warning
Proper personal protective equipment (PPE) is required to perform this procedure:
  • High voltage insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
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Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.

Remove

  1. Remove the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install).
  2. Remove all items from pockets and make sure not to wear any metal items.
  3. 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.
  4. Put on the HV insulating gloves and the leather over gloves.
  5. Put on the HV-safe static control wrist strap. Clip the strap's ground connection to a threaded hole on the edge of the HV battery enclosure.
  6. Vacuum the area around the fuse cover to remove all dust and debris.
  7. Clean the area around the fuse cover with alcohol wipes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not set the fasteners on top of the HV battery. Place each fastener in an appropriate receptacle to reduce the chances of omitting fasteners during reinstallation or leaving fasteners inside the HV battery.
  8. Remove the bolts (x9) that attach the fuse cover to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    One or more of the bolts might be covered or partially covered by sealant. If necessary, scrape off the sealant to expose the bolt head.
  9. Use an insulated blade to score the sealant around the edge of the fuse cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage the red gasket or metal carrier.
  10. Use a non-conductive tool to lift the fuse cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    If necessary, use a hammer or mallet to tap the tool so that it penetrates the sealant.
  11. Once partially separated, remove and discard the fuse cover.

Install

  1. Use an IPA wipe to clean the sealing surface and gasket of the fuse cavity, the sealing surface of the new fuse cover, the top surface of the new fuse cover, and allow at least 1 minute to dry.
  2. Install a new warning label onto the top of the fuse cover.
  3. Apply sealant to the gasket around the fuse cavity.
  4. Install the fuse cover to the HV battery, install the bolts (x9) that attach the fuse cover to the HV battery, and then mark the bolts with a paint pen after tightening.
    2.2 Nm (1.6 lbs-ft)
  5. Remove the leather glove protectors and the HV insulating gloves.
  6. Put on disposable nitrile gloves.
  7. Apply sealant around the perimeter of the fuse cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply additional sealant to where the spacer interferes with the cover.
  8. Wet a nitrile gloved finger with isopropyl alcohol and then spread out the sealant, creating a fillet.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use the HV insulating gloves or leather glove protectors for this step.
  9. Remove the nitrile gloves, and put on the HV insulating gloves and leather glove protectors.
  10. Install the HV battery assembly. See HV Battery (RWD/AWD) (Remove and Install).
  11. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.