2025-03-12

HARNESS - CHARGER OUTPUT TO DC (Remove and Replace)

Correction code 1630011102 FRT 0.00 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 wearing proper PPE when performing the below procedure.

  • 1076921-00-A FLUKE DIGITAL MULTIMETER 1587
  • 1130480-02-A Slim Test Probes
  • 1076927-00-A Hioki RM 3548
  • 1076928-00-A Test Probes - Hioki 9461
Warning IconA warning icon, calling your attention to a possibly risky situation
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 safety information.

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

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

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

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

Make sure that the HV gloves are not expired. HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12-month period.

Torque Specifications

Table 1. Torque Specifications: HARNESS - CHARGER OUTPUT TO DC (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut securing negative output to DC bus charger harness to negative HV battery DC link busbar
4.5 Nm (3.3 lbs-ft)
  • Electrical Protective Gloves
  • 4 in extension
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
 Replace
Bolt securing RH ancillary bay bus cover
3 Nm (2.2 lbs-ft)
  • Electrical Protective Gloves
  • Flex head ratchet/flex head torque wrench
  • Torx T25 socket
 Reuse
Nut securing HV battery ancillary positive busbar to RH ancillary bay bus cover
4.5 Nm (3.3 lbs-ft)
  • Electrical Protective Gloves
  • 4 in extension
  • Flex head ratchet/flex head torque wrench
  • 8 mm socket
 Replace
Nuts (X2) securing 700V DC 63A compressor fuse to RH ancillary bay bus coverNuts securing 700V DC 63A PCS output fuse to RH ancillary bay bus cover
4.5 Nm (3.3 lbs-ft)
  • 8 mm socket
  • Electrical Protective Gloves
  • Flex head ratchet/flex head torque wrench
 Replace

Remove

  1. Remove the positive DC link from ancillary bay. See HV Battery System - HV Battery Electrical Components - Ancillary Bay - DC Link - Positive (Remove and Replace).
  2. Cut cable ties securing mega harness to charger output to DC bus harness.
  3. Remove insulators for fuses.
  4. Remove 700V DC 63A PCS output fuse.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Electrical Protective Gloves
    • Flex head ratchet/flex head torque wrench
  5. Remove 700V DC 63A compressor fuse.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Electrical Protective Gloves
    • Flex head ratchet/flex head torque wrench
  6. Remove the nut that secure HV battery ancillary positive busbar bracket, and then remove the bracket.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  7. Remove nut securing negative output to DC bus charger harness to negative HV battery DC link busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  8. Remove bolt securing RH ancillary bay bus cover.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  9. Lift busbar DC link cover up.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to damage cover when lifting, It is recommended to assist.
  10. Remove charger output to DC Harness from busbar DC link.

Install

  1. Install charger output to DC Harness to Busbar DC link.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not allowed to damage the insulation layer of the harness, if necessary use a 90 degree hook to assist, ensure that harness is not pinched.
  2. Install nut securing negative output to DC bus charger harness to negative HV battery DC link busba.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  3. Perform Hioki resistance test at charger output to DC bus.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 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, as appropriate.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  4. Install the busbar DC link cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to damage cover when lifting, It is recommended to assist.
  5. Install bolt securing RH ancillary bay bus cover.
    3 Nm (2.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  6. Install HV battery ancillary positive busbar to RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • 4 in extension
    • Flex head ratchet/flex head torque wrench
    • 8 mm socket
  7. Install 700V DC 63A PCS output fuse to RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Electrical Protective Gloves
    • Flex head ratchet/flex head torque wrench
  8. Install nuts securing 700V DC 63A compressor fuse to RH ancillary bay bus cover.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Electrical Protective Gloves
    • Flex head ratchet/flex head torque wrench
  9. Perform Hioki resistance tests (X4) at both 63A fuse input joint and 63A fuse output joint.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 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, as appropriate.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  10. Install insulators for fuse and bolts.
  11. Install new cable ties securing mega harness to charger output to DC bus harness.
  12. Install the positive DC link from ancillary bay. See HV Battery System - HV Battery Electrical Components - Ancillary Bay - DC Link - Positive (Remove and Replace).
  13. Move the LH and RH front seats back to their original position.
  14. Raise all the windows and close all the doors.
  15. Close the trunk.