04/06/2024 18:03:07

Contactor - Negative - HV Battery (Remove and Replace)

Correction code 16302002 6.40 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).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install and hand-tighten one of the pyrotechnic battery disconnect mounting bolts to the LH busbar to aid in a later step.
  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 negative contactor connections (x2), and then move the electrical harness aside.
  28. Release the edge clip that attaches the electrical harness to the HV battery negative contactor.
  29. Remove and discard the bolt that attaches the HV battery negative contactor to the negative HV spine busbar.
  30. Remove and discard the bolt that attaches the HV battery negative contactor to the pyrotechnic battery disconnect busbar.
  31. Remove the nuts (x2) that attach the HV battery negative contactor to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnetic pickup tool as necessary to retrieve the nuts.
  32. Remove the HV battery negative contactor from the mounting studs (x2) and guide pins (x2), and out of the HV battery.

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 an alcohol wipe to clean the high voltage mating surfaces of the HV battery negative contactor and the busbars, and allow 1 minute to dry.
  3. Install the HV battery negative contactor into the HV battery, and onto the mounting studs (x2) and guide pins (x2).
  4. Install the nuts (x2) that attach the HV battery negative contactor to the HV battery.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnetic pickup tool as necessary to thread the nuts onto the studs.
  5. Install a new bolt to attach the HV battery negative contactor to the pyrotechnic battery disconnect busbar, and mark the bolt with a paint pen after tightening.
    14.5 Nm (10.7 lbs-ft)
  6. Install a new bolt to attach the HV battery negative contactor to the negative HV spine busbar, and mark the bolt with a paint pen after tightening.
    14.5 Nm (10.7 lbs-ft)
  7. Use the Hioki resistance meter to measure the resistance at the HV joint of the HV battery negative contactor and the 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 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.
  8. Use the Hioki resistance meter to measure the resistance at the HV joint of the HV battery negative contactor and the negative HV spine 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.
  9. Return the electrical harness to the HV battery negative contactor, and then connect the electrical harness to the HV battery negative contactor connections (x2).
  10. Fasten the edge clip that attaches the electrical harness to the HV battery negative contactor.
  11. 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.
  12. Install the power conversion system. See Power Conversion System (Remove and Replace).
  13. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  14. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  15. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  16. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  17. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  18. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  19. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  20. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  21. Connect LV power. See LV Power (Disconnect and Connect).
  22. Install the trunk side trim bracket. See:
  23. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  24. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  25. 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)
  26. Install the 2nd row rear floor panel. See:
  27. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  28. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  29. Install the 2nd row mid floor panel. See:
  30. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  31. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  32. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  33. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  34. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  35. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.