04/06/2024 18:00:57

Contactor - Positive - HV Battery (Non-Structural Pack) (Remove and Replace)

Correction code 16302102 1.62 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.

    • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
    • 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
    • 1057607-00-A Magnet, Flexible, HV Insulated, 18"
    • 1133768-00-A Socket, 1/4" Dr, Deep,10 mm,Thin Wall, Insul
    • 1076927-00-A Resistance meter, microohm, Hioki RM 3548
    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.

    Remove

    1. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    2. Remove the high voltage controller. See Controller - High Voltage (Non-Structural Pack) (Remove and Replace).
    3. Remove the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace) or Passthrough - DCDC - 12V (Cable Type) (Remove and Replace).
    4. Disconnect the electrical harness from the power conversion system LV connector and DC bus HV connector, and from the HV battery positive contactor connectors.
    5. Remove the insulator caps from the HV battery positive contactor.
    6. Remove and discard the bolt that attaches the HV battery positive contactor to the positive busbar.
    7. Remove and discard the nut that attaches the HV battery positive contactor to the battery terminal.
    8. Remove the nuts (x3) that attach the positive HV battery power switch to the ancillary bay.
    9. Tilt the rear of the HV battery positive contactor up, and then remove the contactor from the ancillary bay.

    Install

    1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
    2. Use an IPA wipe to clean the high voltage mating surfaces of the HV battery terminal, positive busbar, and the HV battery positive contactor.
    3. Tilt the rear of the HV battery positive contactor up, and then install the contactor into the ancillary bay.
    4. Install the nuts (x3) that attach the HV battery positive contactor into the ancillary bay.
      8 Nm (5.9 lbs-ft)
    5. Install a new nut to attach the HV battery positive contactor onto the HV battery terminal, and then mark the nut with a paint pen after it is torqued.
      9 Nm (6.6 lbs-ft)
    6. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the HV battery terminal.
      Informational PurposesAn informational icon, calling your attention
      Note
      The maximum acceptable resistance is 0.110 mΩ (110 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
      Figure 1. Generic Measurement - Actual busbars and fasteners might appear different
    7. Install a new bolt to attach the HV battery positive contactor onto the positive busbar, and then mark the bolt with a paint pen after it is torqued.
      9 Nm (6.6 lbs-ft)
    8. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor and the positive busbar.
      Informational PurposesAn informational icon, calling your attention
      Note
      The maximum acceptable resistance is 0.060 mΩ (60 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
      Figure 2. Generic Measurement - Actual busbars and fasteners might appear different
    9. Install the insulator caps to the HV battery positive contactor.
    10. Connect the electrical harness to the HV battery positive contactor, and power conversion system LV and DC bus HV connectors.
    11. Install the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace) or Passthrough - DCDC - 12V (Cable Type) (Remove and Replace).
    12. Install the high voltage controller. See Controller - High Voltage (Non-Structural Pack) (Remove and Replace).
    13. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).