2025-03-12

DC INPUT HEADER -2P - 600V (Remove and Replace)

Correction code 1630010802 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.

Torque Specifications

Table 1. Torque Specifications: DC INPUT HEADER -2P - 600V (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that secures the negative fast charge busbar inlet side and negative DC input assembly busbarBolt that secures the positive fast charge busbar inlet side and positive DC input assembly busbar
15 Nm (11.1 lbs-ft) - 180 degrees
5 Nm (3.7 lbs-ft) + 60 degrees
  • Insulated tools:
    • 13 mm socket
    • Ratchet/torque wrench
 Replace
Bolt that secures busbar cover access door
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm socket
    • Ratchet/torque wrench
 Reuse
Bolts (X2) that secure charge port busbar kit to HV header
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
 Reuse
Bolts (X4) that secure busbar DC input assembly to ancillary bay
10 Nm (7.4 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
 Reuse

Remove

  1. Remove the pyro disconnect from ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Install pyro disconnect dummy.
  3. Disconnect mega harness connector from DC input assembly.
  4. Remove insulator for DC input assembly from both fast charge busbar inlet side.
  5. Remove and discard bolt securing negative fast charge busbar inlet side and negative DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 13 mm socket
      • Ratchet/torque wrench
  6. Remove and discard bolt securing positive fast charge busbar inlet side and positive DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 13 mm socket
  7. Remove fastener securing busbar cover access door.
  8. Remove bolts securing charge port busbar kit to HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 13 mm socket
    Informational PurposesAn informational icon, calling your attention
    TIp
  9. Release LH body harness from rear body and move aside.
  10. Partially remove LH B-pillar lower trim.
  11. Partially pull out LH rear body harness.
  12. Lift busbar kit connector to remove it from HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use inflatable air bag to suspend busbar away from HV header during removal and installation, hold busbar firmly as there is tension on, and avoid damaging the harness bracket.
  13. Remove and discard bolts securing busbar DC input assembly to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
  14. Remove busbar DC input assembly from ancillary bay.

Install

  1. Install busbar DC input assembly to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the seal is not damaged and seated properly.
  2. Install the bolts (x4) securing busbar DC input assembly to ancillary bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
  3. Install and torque bolt securing negative fast charge busbar inlet and negative DC input link to first value, loosen 180 degrees, and then torque to final value.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 13 mm socket
  4. Install and torque bolt securing positive fast charge busbar inlet and positive DC input link to first value, loosen 180 degrees, and then torque to final value.
    15 Nm (11.1 lbs-ft) - 180 degrees
    5 Nm (3.7 lbs-ft) + 60 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 4 in extension
    • 13 mm socket
  5. Perform Hioki resistance test at both HV joints of DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.060 mΩ (60 μΩ).Test from negative fastcharge busbar to negative DC input busbar and positive fastcharge busbar to positive DC input busbar.
  6. Install insulator for DC input assembly to both fast charge busbars inlet side.
  7. Connect mega harness connector to DC input assembly.
  8. Clean HV connector contact surface of residual Penetrox.
  9. Clean busbar HV connector contact surface of residual Penetrox.
  10. Apply Penetrox onto HV connector joints.
  11. Remove Inflatable Air Bag from under HV header.
  12. Position busbar kit connector and lower onto HV header.
  13. Install bolts securing charge port busbar kit to HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
  14. Perform Hioki resistance test at both HV joints of DC input assembly busbar.
  15. Install fastener securing busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm socket
      • Ratchet/torque wrench
  16. Remove pyro disconnect dummy.
  17. Install the pyro disconnect from ancillary bay. See Pyro Disconnect - HV Battery (Remove and Replace).