04/06/2024 18:04:07

Fuse - A/C Compressor - HV Battery (Remove and Replace)

Correction code 16304202 5.82 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 bolts (x2) that attach the power conversion system inlet hose to the HV battery front access cover, and then push in on the hose fitting to separate the datum from the cover.
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
  27. Remove the bolts (x2) that attach the power conversion system outlet hose to the HV battery front access cover, and then push in on the hose fitting to separate the datum from the cover.
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
  28. Remove and discard the bolts (x17) that attach the HV battery front access cover to HV battery.
    Tip: Use of the following tool(s) is recommended:
    • 7 mm socket
  29. Use non-conductive plastic chisels to break the seal and separate the HV battery front access cover from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to severely bend or deform the access cover, nor damage the internal components therein.
    Informational PurposesAn informational icon, calling your attention
    Note
    If there is no sealant present, the gasket can be reused and no sealant needs to be applied.
  30. Lift the HV battery front access cover from the HV battery and move it forward, so that the power conversion system inlet and outlet hose fittings move through their respective openings, and then lift the cover away from the HV battery.
  31. Rotate the power conversion system outlet hose aside to gain access to the A/C compressor fuse.
  32. Remove the nuts (x2) that attach the A/C compressor fuse to the mounting studs.
  33. Use the fuse puller to remove the electrical harness terminal from the mounting stud and move aside.
  34. Use the HV insulated pick together with the fuse puller to carefully move the A/C compressor fuse out from under the electrical harness wires, and out of the front bay 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 the fuse puller to carefully install the A/C compressor fuse onto the mounting studs.
  3. Use the fuse puller to install the electrical harness terminal onto the mounting stud.
  4. Install the nuts (x2) that attach the A/C compressor 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 A/C compressor 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 A/C compressor 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 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. Return the power conversion system outlet hose to its original position against the power conversion system.
  8. Use non-conductive plastic chisels or other non-marring tools to remove the sealant from the HV battery and HV battery front access cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    If there is no sealant present, the gasket can be reused and no sealant needs to be applied. Skip to step 6 to proceed with installation.
  9. Use an ESD-safe vacuum to remove debris, wipe the sealing surfaces with an alcohol wipe, and then allow to dry.
  10. Load a cartridge of sealant into the caulking gun and cut the tip of the sealant to make a triangle of X mm by Y mm.
  11. Apply the sealant onto the sealing surface of the HV battery in a continuous smooth bead.
  12. Lower the HV battery front access cover to the HV battery and move it rearward, so that the power conversion system inlet and outlet hose fittings move through their respective openings, and then set the cover onto the HV battery.
  13. Install new bolts (x17) to attach the HV battery front access cover to the HV battery.
    4.5 Nm (3.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 7 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolts in a criss-cross pattern.
  14. Install the power conversion system inlet tube to the HV battery front access cover, and then install the bolts (x2) that attach the tube to the cover.
    3 Nm (2.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
  15. Install the power conversion system outlet tube to the HV battery front access cover, and then install the bolts (x2) that attach the tube to the cover.
    3 Nm (2.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 socket
  16. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  17. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  18. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  19. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  20. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  21. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  22. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  23. Connect LV power. See LV Power (Disconnect and Connect).
  24. Install the trunk side trim bracket. See:
  25. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  26. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  27. 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)
  28. Install the 2nd row rear floor panel. See:
  29. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  30. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  31. Install the 2nd row mid floor panel. See:
  32. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  33. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  34. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  35. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  36. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  37. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.