2023-12-15

Busbar - Inlet - Negative - Fast Charge - HV Battery (Structural Pack) (Remove and Replace)

Correction code 16307402 1.92 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. See Ergonomic Precautions for safe and healthy working practices.

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.

Remove

  1. Open all the doors and lower all the windows.
  2. Place the vehicle into Service Mode. See Service Mode.
  3. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  4. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  5. Release the clip that attaches the DC fast charge HVIL connector to the tray.
  6. Release the connector lock, and then disconnect the ancillary bay harness from the HV connector harness.
  7. Slide the DC fast charge HV connector straight up to remove it from the assembly.
  8. Disconnect the shunt assembly connector.
  9. Release the clip that attaches the shunt harness branch to the tray.
  10. Disconnect the fast charge contactor connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push on both side of connector to release the tabs, and then pull upward to disconnect.
  11. Remove and discard the bolt that attaches the AC filter harness to the negative DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  12. Remove and discard the bolt that attaches the AC filter harness to the positive DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  13. Release the clips (x2) that attach the AC filter harness to the tray.
  14. Release the securing tabs (x3), and then remove the FC contactor cover.
  15. Lift the HV battery fast charge negative inlet busbar to remove it from the tray assembly.

Install

  1. Install the HV battery fast charge negative inlet busbar into the vehicle.
  2. Position the FC contactor cover into the vehicle, and then secure the tabs (x3) that secure the cover to the vehicle.
  3. Install the DC fast charge HV connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to pinch the harness.
  4. Secure the DC fast charge HVIL connector to the tray.
  5. Connect the ancillary bay harness to the HV connector harness, and then engage the connector lock.
  6. Install a new bolt that attaches the AC filter harness to the positive DC inlet busbar.
    15 Nm (11.1 lbs-ft) -180 degrees
    5 Nm (3.7 lbs-ft) +60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  7. Install a new bolt that attaches the AC filter harness to the negative DC inlet busbar.
    15 Nm (11.1 lbs-ft) -180 degrees
    5 Nm (3.7 lbs-ft) +60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm +60 degrees.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  8. Use a Hioki resistance meter to measure the resistance at the HV joint between the AC filter harness and the positive DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 150µΩ or less.
  9. Use a Hioki resistance meter to measure the resistance at the HV joint between the AC filter harness and the negative DC inlet busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 150µΩ or less.
  10. Connect the fast charge contactor connector.
  11. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  12. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  13. Exit Service Mode. See Service Mode.
  14. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  15. Raise all the windows and close all the doors.