2023-12-15

Ferrite - Shunt Harness - Ancillary Bay - HV Battery (Structural Pack) (Retrofit)

Correction code 16305026 1.80 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.

  • 2023-12-14: Updated note about revisions.
  • 2019928-00-A YSB, PH, FERRITE 46 ROUND CABLE CORE ASS
  • 1922330-00-A TAPE, PET FLEECE, RUBBER

Procedure

Informational PurposesAn informational icon, calling your attention
Note
This retrofit procedure can be performed on revision 1616706-00-F of the ancillary bay harness, or an earlier version that has been reworked with a solid core ferrite on the HV+ sense harness branch. For earlier revisions, first replace the harness with the -F revision. See Harness - Ancillary Bay - HV Battery (Structural Pack) (Remove and Replace).
  1. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  2. Remove the pyro disconnect insulators (x2).
  3. Remove the bolts (x2) that attach the pyrotechnic battery disconnect to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, discard after removal.
  4. Remove the pyrotechnic battery disconnect from the ancillary bay.
  5. Release the securing tab from the pyrotechnic battery disconnect connector, and then disconnect the connector.
  6. Install the pyrotechnic battery disconnect dummy cover.
  7. Disconnect the shunt harness, and loosen the clips (x2) that attach the shunt harness to the HV battery trim.
  8. Release the connectors (x2) and clips (x2) of the ancillary bay harness between the PCS and the negative contactor.
  9. Remove the leather outer gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    This is a one-time exception to remove only the leather gloves for the next three steps. Make sure the HV gloves are not damaged during rework.
  10. Apply a piece of tape to the first 50 mm of the ancillary bay harness, starting at the location where the shunt harness is attached.
  11. Install the clip-on ferrite to the shunt harness, as close as possible to the ancillary bay harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the clip-on ferrite around the harness to confirm the ferrite is installed correctly and does not pinch the harness.
  12. Apply tape onto the clip-on ferrite and the ancillary bay harness to prevent movement of the ferrite.
  13. Put on the leather outer gloves.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Removal of the leather outer gloves is only permitted for installing the clip-on ferrite and applying the tape. Do not perform the rest of this procedure without leather outer gloves.
  14. Reconnect the connectors of the ancillary bay harness between the PCS and the negative contactor, and then fasten the clips (x2) of the ancillary bay harness.
  15. Connect the shunt harness, and fasten the clips (x2) that attach the shunt harness to the plastic HV battery trim.
  16. Remove the pyrotechnic battery disconnect dummy cover.
  17. Connect the pyrotechnic battery disconnect connector.
  18. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect, and allow at least 1 minute to fully dry.
  19. Set the multimeter to the "LoZ" (low impedance) mode.
    Informational PurposesAn informational icon, calling your attention
    Note
    For Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
  20. Measure the voltage between the shunt (left) and busbar (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points.
    Informational PurposesAn informational icon, calling your attention
    Note
    The voltage displayed on the multimeter is not as important as balancing the mount points.
  21. Position the pyrotechnic battery disconnect into the ancillary bay, align the pins of the connector with the disconnect, and then press the disconnect straight down onto the busbars.
  22. Install bolts securing pyro disconnect to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x patch bolts, 13mm, 5 Nm +60 degrees, Install new fasteners.
  23. Measure resistance from pyro disconnect to busbar (right).
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 0.060 mΩ (60 μΩ) or less, Verify Hioki tester is properly zeroed before usage, If the impedance is higher, escalate a Toolbox session, as appropriate.
  24. Measure resistance from the pyro disconnect to shunt (left).
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, 0.045 mΩ (45 μΩ) or less, Verify Hioki tester is properly zeroed before usage, If the impedance is higher, escalate a Toolbox session, as appropriate.
  25. Install the pyro disconnect insulators.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x insulators.
  26. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).