2025-10-23

Busbar Fast Charge - Input - Positive - PN Prefixed with 2xx (Remove and Replace)

Correction code 1630021602 FRT 1.50 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Torque Specifications

Remove

  1. Remove the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  2. Disconnect the AC filter harness connector from the PCS2 Lite by pulling the locking tab upward.
  3. Disconnect the LV fast charge contactor connector by pressing the tabs on both sides with your hands and pulling the connector upwards.
  4. Disconnect the AC filter harness connectors (x2) from the fast charge contactor cover by releasing the locking tabs and pulling them off.
  5. Remove the harness clips (x3) from the fast charge contactor cover and move the wiring harness aside.
  6. Remove the harness clip from the left terminals cover.
  7. Release the tabs (x2) and datum to remove the left terminals cover.
  8. Remove and discard the patch bolt that attaches the negative fast charge busbar to the DC link side.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  9. Remove and discard the patch bolt that attaches the positive fast charge busbar to the DC link side.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  10. Remove the input header seal. See Seal - HV Input Header (Remove and Replace).
  11. Remove the bolts (x2) that attach the fast charge contactor assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  12. Remove the fast charge contactor assembly from the ancillary bay by releasing the clip, disengaging the guide pins (x2), and tilting it upwards.
  13. Remove the HV insulating gloves and leather over gloves.
  14. Remove the fast charge access insulator from the fast charge contactor assembly by releasing the clips (x7), disengaging the alignment pin, and tilting the harness clip upwards to remove it.
  15. Remove the fast charge HV carrier from the fast charge contactor assembly by releasing the tabs (x6).
  16. Release the location pins (x3) and tabs (x2), then remove and discard the patch bolt that attaches the positive input fast charge busbar to the fast charge contactor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:

Install

  1. Secure the location pins (x3) and tabs (x2), then install a new patch bolt that attaches the positive input fast charge busbar to the fast charge contactor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolt after torque.
  2. Install the fast charge HV carrier to the fast charge contactor assembly, ensuring all the tabs (x6) are secured.
  3. Install the fast charge access insulator to the fast charge contactor assembly by aligning the alignment pin, securing the clips (x7) and the harness clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that all clips are installed in place.
  4. Put on the HV insulating gloves and leather over gloves.
  5. Install the fast charge contactor assembly to the ancillary bay by tilting it at a certain angle, aligning the guide pins (x2), and securing the clip.
  6. Install the bolts (x2) that attach the fast charge contactor assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  7. Install the input header seal. See Seal - HV Input Header (Remove and Replace).
  8. Install a new patch bolt that attaches the positive fast charge busbar to the DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolt after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  9. Perform a Hioki impedance test on the positive HV joint ensuring it is 25𝜇Ω or less.
  10. Install a new patch bolt that attaches the negative fast charge busbar to the DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolt after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  11. Perform a Hioki impedance test on the negative HV joint ensuring it is 40𝜇Ω or less.
  12. Align the tabs (x2) and datum, then install the left terminals cover.
  13. Install the harness clip to the left terminals cover.
  14. Secure the harness clips (x3) to the fast charge contactor cover.
  15. Connect the AC filter harness connectors (x2) to the fast charge contactor cover
  16. Connect the LV fast charge contactor connector.
  17. Connect the AC filter harness connector to the PCS2 Lite by pushing it downward, then pushing the locking tab downward to secure it.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the connector is fully seated.
  18. Install the pyro disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).