04/06/2024 18:02:39

Contactor - Fast Charge - HV Battery (Remove and Replace)

Correction code 16302602 5.94 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.
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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. Remove all items from pockets and make sure not to wear any metal items.
  24. 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.
  25. Put on the HV insulating gloves and then leather over gloves.
  26. Remove the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
  27. Press in the connector side tabs (x2), and then disconnect the electrical harness from the HV battery fastcharge contactor connector.
  28. Vehicles built before September 19, 2022 only - Go to step 31.
  29. Remove and discard the bolt that attaches the AC filter branch of the AC harness to the negative inlet fast charge busbar.
  30. 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.
  31. Release the tabs (x3), and then remove the HV battery fast charge contactor insulator cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - A mica insulator might obstruct removal of the insulator cover. Bend or cut the mica insulator as necessary to aid removal of the cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease removal of the insulator.
  32. Vehicles built before September 19, 2022 only - If there is mica tape covering the bolts that attach the busbars to the HV battery fast charge contactor, take a cell phone photo, and then remove and retain the tape for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    The photo will help with placement during installation.
  33. Remove and discard the bolts (x2) that attach the DC link negative busbar to the HV battery fast charge contactor, and then remove the busbar from the contactor.
  34. Remove and discard the bolts (x2) that attach the negative linlet fast charge busbar to the HV battery fast charge contactor, and then remove the busbar from the contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - The AC filter branch of the AC harness is removed from the negative linlet fast charge busbar in this step.
  35. Remove and discard the bolts (x2) that attach the DC link positive busbar to the HV battery fast charge contactor, and then remove the busbar from the contactor.
  36. Remove and discard the bolts (x2) that attach the positive linlet fast charge busbar to the HV battery fast charge contactor, and then remove the busbar from the contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 or later only - Use the HV insulated pick to release the clips (x2) that attach the AC filter branch terminal to the positive inlet fast charge busbar.
  37. Remove the bolts (x3) that attach the HV battery fast charge contactor to the fast charge insulator, and then slide the contactor off the guide pins and out of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnetic pickup tool as necessary to retrieve the bolts.
  38. Remove the HV battery fast charge contactor off the guide pins (x2) and out of the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease removal of the contactor.

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. Install the HV battery fast charge contactor into the HV battery, and onto the guide pins (x2) of the fast charge insulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease installation of the contactor.
  3. Install the bolts (x3) that attach the HV battery fast charge contactor to the HV battery, and then mark the bolts with a paint pen after tightening.
    5.5 Nm (4.1 lbs-ft)
  4. Use an alcohol wipe to clean the high voltage mating surfaces of the HV battery fast charge contactor and the busbars, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean both sides of the DC link and inlet fast charge busbars (x4).
  5. Install the positive inlet fast charge busbar onto the HV battery fast charge contactor, and then install and hand-tighten new bolts (x2) to attach the busbar to the contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the AC filter branch terminal underneath the outer bolt, and for vehicles built September 19, 2022 and later, make sure to fasten the clips that attach the terminal to the positive inlet fast charge busbar.
  6. Install the DC link positive busbar onto the HV battery fast charge contactor, and then install and hand-tighten new bolts (x2) to attach the busbar to the contactor.
  7. Install the negative inlet fast charge busbar onto the HV battery fast charge contactor, and then install and hand-tighten new bolts (x2) to attach the busbar to the contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built before September 19, 2022 only - Install the AC filter branch terminal underneath the outer bolt and at an angle so not to interfere with the HV battery fast charge contactor insulator cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Temporarilly install a discarded bolt in the location for the outer bolt for the negative inlet fast charge busbar.
  8. Install the DC link negative busbar onto the HV battery fast charge contactor, and then install and hand-tighten new bolts (x2) to attach the busbar to the contactor.
  9. Tighten the inner bolts (x4) that attach the DC link and inlet fast charge busbars (x4) to the HV battery fast charge contactor, and then mark the bolts with a paint pen after tightening.
    9 Nm (6.6 lbs-ft)
  10. Tighten the outer bolts (x4) that attach the DC link and inlet fast charge busbars (x4) to their respective busbars, and then mark the bolts with a paint pen after tightening.
    15 Nm (11.1 lbs-ft)
    5 Nm (3.7 lbs-ft) +60 deg
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Torque the bolts first to 15 Nm, then loosen the bolts 180 degrees, finally tighten the bolts to 5 Nm + 60 degrees.
  11. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive inlet fast charge busbar and the feeder 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 busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  12. Use the Hioki resistance meter to measure the resistance at the HV joint between the DC link positive busbar and the feeder 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 busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  13. Use the Hioki resistance meter to measure the resistance at the HV joint between the negative inlet fast charge busbar and the feeder 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 busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  14. Use the Hioki resistance meter to measure the resistance at the HV joint between the DC link negative busbar and the feeder 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 busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
  15. Vehicles built before September 19, 2022 only - If removed previously, apply the mica tape to the bolts that attach the busbars to the HV battery fast charge contactor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to the cell phone photo.
  16. Vehicles built September 19, 2022 and later only - Remove and discard the bolt that attaches the negative inlet fast charge busbar to the negative DC input busbar.
  17. Install the HV battery fast charge contactor insulator cover, and then fasten the tabs (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicles built September 19, 2022 and later only - Move the blue gasket aside to ease installation of the insulator.
  18. Vehicles built before September 19, 2022 only - Go to step 21.
  19. 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.
  20. Install a new bolt to attach the AC filter branch of the AC harness to the negative inlet fast charge busbar.
    15 Nm (11.1 lbs-ft)
    5 Nm (3.7 lbs-ft) +60 deg
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Torque the bolt first to 15 Nm, then loosen the bolt 180 degrees, finally tighten the bolt to 5 Nm +60 degrees.
  21. Connect the electrical harness to the HV battery fastcharge contactor connector, and press down until it clicks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the connector does not contact the insulator when seating.
  22. Install the HV battery rear access cover. See Cover - Rear Access - HV Battery (Remove and Replace).
  23. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  24. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  25. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  26. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  27. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  28. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  29. Connect LV power. See LV Power (Disconnect and Connect).
  30. Install the trunk side trim bracket. See:
  31. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  32. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  33. 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)
  34. Install the 2nd row rear floor panel. See:
  35. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  36. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  37. Install the 2nd row mid floor panel. See:
  38. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  39. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  40. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  41. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  42. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  43. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.