Contactors - HV Battery - Pair (7-Seat) (Remove and Replace)
Code de correction
TBD
FRT
1.62
REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire indiqués ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire.
REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création.
NOTE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lorsque vous effectuez la procédure ci-dessous.
REMARQUE : Voir Précautions ergonomiques pour consulter les pratiques de travail sécuritaires et saines.
- 2026-02-04: Released new procedure.
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Open all four doors
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Lower all four windows
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Move LH front seat forward
RemarqueAdjust seat back if needed to avoid contacting headliner
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Move RH front seat forward
RemarqueAdjust seatback if needed to avoid contacting headliner
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Move 60 seat to easy entry position
RemarquePress shoulder switch then push seat forward
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Partially remove lower portion of LH rear door seal
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Remove LH 7s lower C-pillar trim
Remarque8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips
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Move 60 seat to original position
RemarquePress shoulder switch then pull seat backward
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Fold 2nd row 60 seatback down
RemarqueVia seat switch or manual tether, Protect seat back upholstery if necessary
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Disconnect 2nd row 60 seat connector
Remarque1x connector,
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Move 60 seat forward using towel bar
RemarqueWith one hand on towel bar pull up and slide the seat forward with your other hand
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Remove 60 seat rear outboard track fastener
Remarque1x patch bolt, 11mm, 37 Nm, Discard after removal
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Remove 60 seat rear inboard track fasteners
Remarque2x patch bolts, 11mm, 37 Nm, Discard after removal
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Move 60 seat fully rearward using towel bar
Remarquepull up bar, slide seat forward
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Remove 60 seat outboard track cover
Remarque1x clip, Slide covers forward to release from 60 seat tracks
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Remove center track cover from 2nd row seats
Remarque2x clips, Slide covers forward to release from 2nd row seat tracks
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Release cabin carpet from 60 seat
RemarquePull cabin carpet towards front of vehicle
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Remove 60 seat front inboard track fasteners
Remarque1x bolts, 11mm, 37 Nm, Discard after removal
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Remove 2nd row 60 seat frame front outboard track fasteners
Remarque1x bolts, 11mm, 37 Nm, Discard after removal
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Remove 2nd row 60 seat assembly from vehicle
RemarqueRecommend assistance, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement
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Move RH front seat forward
RemarqueAdjust seatback if needed to avoid contacting headliner
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Move 60 seat to easy entry position
RemarquePress shoulder switch then push seat forward
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Partially remove RH rear door seal
RemarquePillar and sill trim have tabs seated underneath seal
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Remove RH C-pillar lower trim
Remarque5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ by vehicle build location, and the number of clips may also varyt, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall
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Move 40 seat to original position
RemarquePress shoulder switch then pull seat backward
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Fold 2nd row 40 seatback down
RemarqueVia seat switch or manual tether, Protect seat back upholstery if necessary
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Remove 40 seat outboard track cover
Remarque1x clip, Slide cover forward to release from 40 seat track
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Remove bolts securing 40 seat podium to vehicle
Remarque2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
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Move 40 seat forward using towel bar
RemarqueWith one hand on towel bar pull up and slide the seat forward with your other hand
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Remove bolts securing 40 seat inner and outer tracks to vehicle
Remarque2x patch bolts, 11mm, 37 Nm, Discard bolts after removal
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Move 40 seat fully rearward using towel bar
Remarquepull bar, slide seat forward
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Disconnect 2nd row 40 seat connector
Remarque1x connector, Newer models may have red locking tab
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Remove 40 seat from vehicle
RemarqueRecommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement
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Remove 3rd row seat cushion
Remarque2x clips, 1x connector, 2x circular hooks, Press tabs backward then pull front edge up, Press rear seat cushion and lift the front seat cushion
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Remove 3rd row LH seat cushion bolster
Remarque1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster towards front of vehicle to remove
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Remove 3rd row RH seat cushion bolster
Remarque1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster towards front of vehicle to remove
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Release LH side of 3rd row rear carpet
Remarque2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet
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Release RH side of 3rd row rear carpet
Remarque2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet
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Remove 3rd row rear cabin carpet
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Open hood
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Power off vehicle from center display
RemarqueVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Remove rear apron
Remarque16x trim clips, 3x datums, 2x clips
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Remove HEPA filter assembly
Remarque2x bolts, 10mm, 10 Nm, Pivot rear edge up past brake reservoir then lift up to clear frunk assembly
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Disconnect LV battery and first responder loop
Remarque2x connectors, Ensure that one minute has passed after window movement before performing the power-off, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
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Verify operation of multimeter
RemarqueSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
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Remove 3rd row NVH insulator
Remarque1x connector, Disconnect connector then remove insulator
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Install HVC logic cap
Remarque1x logic cap
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
RemarqueCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
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Put on HV insulating gloves and leather over gloves
RemarqueUse HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.
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Release positive LV output cover from PCS cable
Remarque1x cover
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Remove PCS cable from LV passthrough output
Remarque1x nut, 13mm, 9 Nm, Discard nut after removal
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Remove bolts securing ancillary bay probe lid cover
Remarque2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
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Remove ancillary bay probe lid cover
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Verify no high voltage
RemarqueMake sure to wear PPE (HV gloves, Safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
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Wipe ancillary bay cover with IPA to clean surface
RemarqueAllow to 1 minute dry time
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Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover
RemarqueConfirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time
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Install bolts securing ancillary bay probe lid cover to ancillary bay cover
Remarque2x bolts, EP10 5-Lobe, 6 Nm, Install new bolts
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Remove bolts securing ancillary bay cover to HVC
Remarque3x bolts, E10, 5 Nm + 30 degrees
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Remove bolts securing ancillary bay cover to HV battery
Remarque18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
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Remove HVC logic cap
Remarque1x logic cap
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Remove ancillary bay cover from HV battery
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Install HVC logic cap
Remarque1x logic cap
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Inspect ancillary bay for any missing insulators
RemarqueInstall service insulator kit before continuing to next step
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Remove bolts securing pyro disconnect to ancillary bay
Remarque1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal
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Remove pyro disconnect from ancillary bay
Remarque1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay
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Install pyro disconnect dummy
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Lift HV Controller up
RemarqueHold HVC assembly and tray in upward positition with rubber bungee
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Disconnect PCS to DC bus HV connector
Remarque1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS logic connector from PCS
Remarque1x connector
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Disconnect PCS LV connector from PCS
Remarque1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Remove nut securing DCDC ground busbar to HV battery
Remarque1x nut, 13mm, 9 Nm, Discard nut after removal
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Gently lift the DCDC ground busbar upwards
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Remove bolts securing DCDC pass through to ancillary bay
Remarque2x bolts, E10 5-Lobe, 10 Nm
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Remove DCDC pass through from ancillary bay
RemarqueAttention: To avoid metal damage to the cable insulation layer
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Disconnect ancillary bay harness connectors from positive pack contactor
Remarque2x connectors
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Remove HV PCS to DC Bus harness clip from positive pack contactor
Remarque1x clip
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Remove HV joint insulators from positive HV switch
Remarque2x insulators
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Remove bolt securing positive pack contactor to positive busbar
Remarque1x patch bolt, 13mm, 9 Nm, Discard after removal
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Remove nut securing positive pack contactor to module 4 rear terminal
Remarque1x patch nut, 13mm, 9 Nm, Discard after removal
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Remove nuts securing positive pack contactor to ancillary bay
Remarque3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
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Remove positive pack contactor from ancillary bay
Remarque2x guide pins
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Position positive pack contactor to ancillary bay for installation
Remarque2x guide pins
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Install nuts securing positive pack contactor to ancillary bay
Remarque3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary
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Install bolt securing positive pack contactor to positive busbar
Remarque1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque
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Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal
Remarque1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
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Measure resistance from HV joint between HV battery positive contactor and center of HV battery positive terminal
Remarque1x HV joint, 110μΩ or less
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Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar
Remarque1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
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Install HV joint insulators onto positive pack contactor
Remarque2x insulators
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Install ancillary bay harness clip to positive pack contactor
Remarque1x clip
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Connect ancillary bay harness connectors to positive pack contactor
Remarque2x connectors
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Position DCDC pass through to ancillary bay for installation
RemarqueAttention: To avoid metal damage to the cable insulation layer
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Install bolts securing DCDC pass through to ancillary bay
Remarque2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque
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Install DCDC ground busbar to HV battery
RemarqueGently press down
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Install nut securing DCDC ground busbar to HV battery
Remarque1x nut, 13mm, 9 Nm, Install new nut
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Connect PCS LV connector to PCS
Remarque1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Connect PCS logic connector to PCS
Remarque1x connector
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Connect PCS to DC bus HV connector
Remarque1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Lower HV Controller back into place
RemarqueRemove bungee and slowly lower controller
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Disconnect ancillary bay harness connectors from negative pack contactor
Remarque2x connectors
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Remove HV joint insulators from negative pack contactor
Remarque2x insulators
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Remove bolt securing negative pack contactor to DC link busbar joint
Remarque1x patch bolt, 13mm, 9 Nm, Discard after removal
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Remove nut securing negative pack contactor to HV battery tall silicon terminal
Remarque1x patch nut, 13mm, 9 Nm, Discard after removal
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Remove nuts securing negative pack contactor to ancillary bay
Remarque3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary
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Remove negative pack contactor from ancillary bay
Remarque2x guide pins
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Position negative pack contactor to ancillary bay for installation
Remarque2x guide pins
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Install nuts securing negative pack contactor to ancillary bay
Remarque3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs
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Install nut securing negative pack contactor to HV battery tall terminal
Remarque1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque
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Install bolt securing negative pack contactor to DC link busbar joint
Remarque1x patch bolt, 13mm, 9 Nm, Install new patch bolt, Mark after torque
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Perform Hioki impedance test at HV joint of negative pack contactor to negative DC link busbar
Remarque1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
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Perform Hioki impedance test at negative pack contactor to module 1 rear terminal
Remarque1x HV joint, 110μΩ or less
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Install HV joint insulators to negative pack contactor
Remarque2x insulators
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Connect ancillary bay harness connectors to negative pack contactor
Remarque2x connectors
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Remove pyro disconnect dummy
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Clean mating surface of pyro
RemarqueAllow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, Busbar, And the pyrotechnic battery disconnect
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Set multimeter to "LoZ" (low impedance) mode
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Measure voltage between busbar and shunt
RemarqueMeasure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points
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Position pyro disconnect to ancillary bay for installation
Remarque1x connector, While still measuring the voltage, Have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, And then press the pyrotechnic battery disconnect down onto the busbars, The pyro disconnect can only be installed one way
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Install bolts securing pyro disconnect to ancillary bay
Remarque2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen
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Measure resistance from module 2 busbar to pyro disconnect
Remarque1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing
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Measure resistance from pyro disconnect to shunt
Remarque1x HV joint, 45μΩ or less, Perform zero adjust to Hioki meter prior to testing
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Remove service insulator kit
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Remove HVC logic cap
Remarque1x logic cap
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Inspect ancillary bay walls for damage
RemarqueAny dent or depression in the sealing surface that causes it to not be flat will result in a leak, Any paint that comes off the ancillary bay wall, Whether or not it sticks to the seal, Will require enclosure leak test when reassembled, It can still be reused
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Inspect ancillary bay cover seal to confirm it has no visual damage
RemarqueImage up close for clarity, Delaminated and torn seals cannot be reused
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Wipe ancillary bay cover with IPA to clean surface
RemarqueAllow to 1 minute dry time
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Position ancillary bay cover to HV battery for installation
RemarqueEnsure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered.
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Remove leather over gloves and HV insulating gloves
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Install bolts securing ancillary bay cover to HV battery
Remarque18x bolts, EP10 5-Lobe, 8 Nm, Fasteners are captive, Follow torque sequence per image
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Install bolts securing ancillary bay cover to HVC
Remarque3x bolts, E10, 5 Nm + 30 degrees
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Install positive LV output from PCS cable and torque nut securing it
Remarque1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque
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Install positive LV output cover to PCS cable
Remarque1x cover
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Remove HVC logic cap
Remarque1x logic cap
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Install 3rd row NVH insulator
Remarque1x connector, Install insulator then connect connector
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Position 3rd row rear cabin carpet
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Secure RH side of 3rd row rear carpet
Remarque2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt
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Secure LH side of 3rd row rear carpet
Remarque2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt
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Install 3rd row LH seat cushion bolster
Remarque1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster into seat frame complete
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Install 3rd row RH seat cushion bolster
Remarque1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster into seat frame complete
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Install 3rd row seat cushion and connect harness
Remarque1x connector, Secure 3rd row seat cushion into RH and LH latches
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Connect first responder loop and LV battery
Remarque2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
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Install HEPA filter assembly
Remarque2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct, Do not pinch washer hose inbetween HEPA filter assembly and body
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Install rear apron
Remarque16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron
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Close hood
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Install 40 seat into vehicle
RemarqueRecommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium
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Connect 2nd row 40 seat connector
Remarque1x connector,
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Install bolts securing 40 seat podium to vehicle hand tight
Remarque2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step
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Move 40 seat forward using towel bar
Remarquepull up bar, slide seat forward
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Install bolts securing 40 seat inner and outer tracks to vehicle
Remarque2x patch bolts, 11mm, 37 Nm, Install new bolts
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Move 40 seat to original position
RemarquePress shoulder switch then pull seat backward
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Install cabin carpet to 40 seat
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Torque bolts securing 40 seat podium to vehicle
Remarque2x patch bolts, 11mm, 37 Nm
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Install center track cover to 2nd row seats
Remarque2x clip, Slide cover straight on to clip to 2nd row seat tracks
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Install 40 seat outboard track cover
Remarque1x clip
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Position 40 seat into easy entry mode
RemarquePress shoulder switch and push 40 seat forward
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Install RH rear sill trim
Remarque4x tabs, 3x clips, 5x location pins, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips
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Reseat RH rear door seal
RemarqueSeat pillar and sill trim tabs underneath seal
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Move 40 seat to original position
RemarquePress shoulder switch then pull seat backward
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Move RH front seat to original position
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Install 2nd row 60 seat assembly
RemarqueRecommend assistance
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Connect 2nd row 60 seat connector
Remarque1x connector,
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Install fasteners securing 60 seat frame to body
Remarque5x patch bolts, 11mm, 37 Nm, Install new patch bolts, bottom seat bolts located in rear
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Secure cabin carpet to 60 seat
RemarqueStrap velcro on
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Return 2nd row 60 seatback to vertical position
RemarqueVia trunk seat switch, Remove seatback protection if necessary
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Install 60 seat outboard track cover
Remarque1x clip
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Position 60 seat into easy entry mode
RemarquePress shoulder switch and push 60 seat forward to position into easy entry mode
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Install LH 7s lower C-pillar trim
Remarque8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips
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Reseat LH rear door seal
RemarqueSeat pillar and sill trim tabs underneath seal
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Move 60 seat to original position
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Move RH front seat to original position
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Move LH front seat to original position
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Raise all four windows
RemarqueVia LH front door switch
- Exécutez la routine ODIN PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)
- Unlock the vehicle gateway. See Passerelle (déverrouiller).
- Exécutez la routine ODIN PROC_VCLEFT_X_2R-SEAT-RECLINE-CALIBRATIONvia Service Mode:Low Voltage ➜ Second Row Seats ➜ Calibratevia Toolbox:(link)
- Exécutez la routine ODIN PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)
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Close all four doors
RemarqueIf LV is powered up then unlatch rear doors before closing