04/06/2024 18:00:25

Fuse - Power Conversion System - HV Battery (Remove and Replace)

Correction code 16304402 6.30 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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

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. Release the clip that attaches the power conversion system outlet hose to the HV battery.
  24. Release the clip that attaches the power conversion system outlet hose to the to the HV battery fitting, and then disconnect the hose from the HV battery.
  25. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain) (On Table).
  26. Remove the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  27. Remove the power conversion system. See Power Conversion System (Remove and Replace).
  28. 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.
  29. Remove the nuts (x2) that attach the power conversion system fuse to the mounting studs.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 8mm, 2.5 Nm
  30. Remove the electrical harness terminal from the mounting stud and move aside.
  31. Use the fuse puller to remove the power conversion system fuse from the mounting studs.

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. Use the fuse puller to install the power conversion system fuse onro the mounting studs.
  3. Install the electrical harness terminal onto the mounting stud.
  4. Install the nuts (x2) that attach the power conversion fuse to the mounting studs.
    2.5 Nm (1.8 lbs-ft)
  5. Use the Hioki resistance meter to measure the resistance at the HV joint of the power conversion system fuse and the positive DC 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 fuse lug.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance must be less than 0.145 mΩ (145 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.
  6. Use the Hioki resistance meter to measure the resistance at the HV joint of the power conversion system fuse and the electrical harness terminal.
    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 electrical harness terminal or the nut's captive washer.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance must be less than 0.145 mΩ (145 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.
  7. 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.
  8. Install the power conversion system. See Power Conversion System (Remove and Replace).
  9. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  10. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  11. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  12. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  13. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  14. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  15. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  16. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  17. Connect LV power. See LV Power (Disconnect and Connect).
  18. Install the trunk side trim bracket. See:
  19. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  20. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  21. 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)
  22. Install the 2nd row rear floor panel. See:
  23. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  24. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  25. Install the 2nd row mid floor panel. See:
  26. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  27. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  28. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  29. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  30. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  31. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.