04/06/2024 18:00:09

Shunt - HV Battery (Remove and Replace)

16303602 6.45 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.

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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 moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  4. Position the 2 post lift pads for HV battery removal.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  7. Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  8. Remove the 2nd row mid floor panel. See:
  9. Remove the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  10. Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  11. Remove the 2nd row rear floor panel. See:
  12. Remove the bolts (x2) that attach the busbar duct to the body, and then remove the busbar duct from the vehicle.
  13. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the trunk side trim bracket. See:
  16. Disconnect LV power. See LV Power (Disconnect and Connect).
  17. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  18. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  19. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  20. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  21. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  22. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  23. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain).
  24. Remove the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  25. Remove the power conversion system. See Power Conversion System (Remove and Replace).
  26. Remove the bolts (x6) that attach the power conversion system mounting tray to the HV battery, and then remove the tray from the HV battery.
  27. Disconnect the electrical harness from the HV battery shunt connector.
  28. Remove and discard the bolts (x2) that attach the HV battery shunt to the busbars.
  29. Pivot the HV battery shunt counterclockwise about the guide pin until the shunt moves out from under the busbar, and then lift the shunt straight off of the guide pin.

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. Record the new HV battery shunt resistance as displayed on the HV battery shunt part label, exactly as seen. For example, "R:14737nΩ".
    Informational PurposesAn informational icon, calling your attention
    Note
    The shunt resistance is programmed into the high voltage controller in step 24.
  3. Use an alcohol wipe to clean the high voltage contact surfaces of the HV battery shunt and the busbars, and allow at least 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the underside of the upper busbar.
  4. Install the HV battery shunt onto the guide pin, and then pivot the shut clockwise and under the busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to help guide the shunt under the busbar.
  5. Install new bolts (x2) to attach the HV battery shunt to the busbars, and then mark the bolts with a paint pen after tightening.
    14.5 Nm (10.7 lbs-ft)
  6. Connect the electrical harness to the HV battery shunt connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a Push-Pull-Push check of the connector.
  7. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery shunt and the front 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 lugs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Resistance values for both lugs 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 shunt and the shunt-pyrotechnic battery disconnect 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 lugs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Resistance values for both lugs 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. Install the power conversion system mounting tray into the HV battery, and then install the bolts (x6) that attach the tray to the HV battery.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that no wires are pinched beneath the tray.
  10. Install the power conversion system. See Power Conversion System (Remove and Replace).
  11. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  12. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  13. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  14. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  15. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  16. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  17. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  18. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  19. Connect LV power. See LV Power (Disconnect and Connect).
  20. Place a 12V power supply into the underhood storage unit, connect the positive lead of the 12V power supply to the jump post, and then connect the negative lead of the 12V power supply to chassis ground.
  21. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  22. In Toolbox 3, click the Actions/Autodiag tab, type "contactors" in the search field, click on Ensure Power Off, and then click Run.
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    Note
    After the contactors open, step 23 and step 24 must be completed within 60 seconds.
  23. Click the Actions/Autodiag tab, type "HVP write" in the search field, click on HVP write shunt ohm, and then click Run Network.
  24. In the window that opens, type the 5 digits of the resistance recorded earlier in step 2, click Submit, and allow the routine to complete. For example, "14737".
    Informational PurposesAn informational icon, calling your attention
    Note
    If the routine fails, repeat from step 22.
  25. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  26. Disconnect the negative lead of the 12V power supply from chassis ground, disconnect the positive lead of the 12V power supply from the jump post, and then remove the 12V power supply from the underhood storage unit.
  27. Install the trunk side trim bracket. See:
  28. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  29. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  30. Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
    2.5 Nm (1.8 lbs-ft)
  31. Install the 2nd row rear floor panel. See:
  32. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  33. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  34. Install the 2nd row mid floor panel. See:
  35. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  36. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  37. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  38. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  39. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  40. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.