Contactor - Positive - HV Battery (Remove and Replace)
Correction code 16302102 5.88 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.
- 2023-06-01: Added steps and notes to accommodate mica insulators and tape.
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.
- Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
- Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
- Position the 2 post lift pads for HV battery removal.
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
- Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
- Remove the 2nd row mid floor panel. See:
- Remove the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
- Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Remove the 2nd row rear floor panel. See:
- Remove the bolts (x2) that attach the busbar duct to the body, and then remove the busbar duct from the vehicle.
- Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
- Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
- Remove the trunk side trim bracket. See:
- Disconnect LV power. See LV Power (Disconnect and Connect).
- Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
- Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
- Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
- Remove all items from pockets and make sure not to wear any metal items.
-
Inspect the HV insulating
gloves.
NoteRefer to service document TN-15-92-003, for information on inspecting HV gloves.
- Put on the HV insulating gloves and then leather over gloves.
- Remove the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
- Press in the connector side tabs (x2), and then disconnect the electrical harness from the HV battery fastcharge contactor connector.
- Vehicles built before September 19, 2022 only - Go to step 31.
- Remove and discard the bolt that attaches the AC filter branch of the AC harness to the negative inlet fast charge busbar.
- 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.
-
Release the tabs (x3), and then remove
the HV battery fast charge contactor insulator cover.
- Disconnect the electrical harness from the HV battery positive contactor connectors (x2).
- Release the edge clip that attaches the electrical harness to the HV battery positive contactor, and then move the electrical harness aside.
- Vehicles built September 19, 2022 and later only - Remove the positive contactor rear terminal HV insulator.
-
Remove and discard the bolt that
attaches the HV battery positive pack contactor to the 2 button contactor rear
terminal.
NoteVehicles built before September 19, 2022 only - If there is mica tape covering the bolt, remove and retain the tape for installation.
-
Remove and discard the bolt that
attaches the HV battery positive contactor to the positive DC link rear
busbar.
NoteVehicles built before September 19, 2022 only - If there is mica tape covering the bolt, remove and retain the tape for installation.
-
Remove the nuts (x3) that attach the
HV battery positive contactor to the HV battery.
NoteUse an insulated magnetic pickup tool as necessary to retrieve the nuts.
- Remove the HV battery positive contactor from the mounting studs (x2) and guide pins (x2), and out of the HV battery.
Install
- Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
- 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.
- Install the HV battery positive contactor into the HV battery, and onto the mounting studs (x2) and guide pins (x2).
-
Install the nuts (x3) that attach the
HV battery positive contactor to the HV battery.NoteUse an insulated magnetic pickup tool as necessary to thread the nuts onto the studs.
-
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.
-
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.
-
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.
CAUTIONDo not short the side of the probe tip to the edge of the busbar.NoteThe 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.
-
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.
CAUTIONDo not short the side of the probe tip to the edge of the busbar.NoteThe 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.
- Vehicles built before September 19, 2022 only - If removed previously, apply the mica tape to the HV battery positive contactor bolt heads.
- Vehicles built September 19, 2022 and later only - Install the positive contactor rear terminal HV insulator.
- 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.
- Connect the electrical harness to the HV battery positive contactor connections (x2).
- Install the HV battery fast charge contactor insulator cover, and then fasten the tabs (x3).
- Vehicles built before September 19, 2022 only - Go to step 17.
- 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.
-
Install a new bolt to attach the AC
filter branch of the AC harness to the negative inlet fast charge busbar.CAUTIONTorque the bolt first to 15 Nm, then loosen the bolt 180 degrees, finally tighten the bolt to 5 Nm +60 degrees.
-
Connect the electrical harness to the
HV battery fastcharge contactor connector, and press down until it clicks.
NoteMake sure that the connector does not contact the insulator when seating.
- Install the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
- Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
- Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
- Install the HV Battery. See HV Battery (AWD) (Remove and Install).
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
- Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
- Connect LV power. See LV Power (Disconnect and Connect).
- Install the trunk side trim bracket. See:
- Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
- Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
-
Install the busbar duct to the body,
and then install the bolts (x2) that attach the busbar duct to the body.
- Install the 2nd row rear floor panel. See:
- Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
- Install the 2nd row mid floor panel. See:
- Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
- Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
- Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.