22/08/2024 10:55:13

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
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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. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Disconnect LV power. See LV Power (Disconnect and Connect).
  4. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  5. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  6. Use an IPA wipe to clean around the pyrotechnic battery disconnect cover area, and allow 1 minute to dry.
  7. Remove and discard the bolts (x8) that attach the pyrotechnic battery disconnect cover to the HV battery, and then remove the cover.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The 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.
  8. Visually inspect the pyrotechnic battery disconnect and cavity for water, dirt, arcing, or any other damage.
    Informational PurposesAn informational icon, calling your attention
    Note
    If any issues are detected, contact Service Engineering for assistance before proceeding.
  9. 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The LH/RH side of the pyrotechnic battery disconnect is always on and "live". Use only non-conductive isolated tooling.
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    Note
    Hold the pyrotechnic battery disconnect while removing the bolts to prevent the disconnect from falling out.
  10. 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.
  11. Install the pyrotechnic battery disconnect flag.
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    Note
    If the HV battery is installed, the L-shaped side extension is not required.
  12. If a procedure requested that the pyrotechnic battery disconnect be removed, return to that procedure.

Install

  1. Record the replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
  2. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
    Informational PurposesAn informational icon, calling your attention
    Note
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  3. Remove the pyrotechnic battery disconnect flag.
  4. Use an alcohol wipe to clean the high voltage mating surfaces of the pyrotechnic battery disconnect, and allow 1 minute to dry.
  5. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not use any other types of cleaner.
  6. Set the multimeter to the "LoZ" (low impedance) mode.
    Informational PurposesAn informational icon, calling your attention
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  7. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    The voltage displayed on the multimeter is not as important as balancing the mount points.
  8. 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.
  9. Hold the pyrotechnic battery disconnect in place, and hand-install new bolts (x4) to attach the disconnect to the HV battery busbars.
  10. Use the special 13 mm non-conducting isolated socket to thread and then tighten the bolts
    13 Nm (9.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Use 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The LH/RH side of the pyrotechnic battery disconnect is always on and "live". Use only non-conductive isolated tooling.
  11. Use the Hioki resistance meter to measure the resistance between each lug of the pyrotechnic battery disconnect and the HV battery busbar behind it.
    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 0.050 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.
  12. Use an alcohol wipe to clean the sealing surface of pyrotechnic fuse cover and the HV battery, and allow 1 minute to dry.
  13. 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.
    7.5 Nm (5.5 lbs-ft)
  14. Remove the leather glove protectors and the HV insulating gloves.
  15. If a procedure requested that the pyrotechnic battery disconnect be installed, return to that procedure. Otherwise continue to the next step.
  16. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  17. Connect LV power. See LV Power (Disconnect and Connect).
  18. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.