15/12/2023 01:29:24

Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace)

Correction code 16306002 1.38 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.

  • 2023-05-22: Added caution for correct positive DC cable connection.
  • 2023-08-07: Restructured the procedure.
  • 1130480-02-A Slim Test Probes
  • 1059330-00-B Skt, 1/4in Dr, 5-Lobe Torx Plus External
  • 1076921-00-A Fluke 1587
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1131071-00-A Dummy Disconnect, Pyro, Safety
  • 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
Table 1. Torque Specifications: Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches the positive 12V output to the power conversion system cable
9 Nm (6.6 lbs-ft)
  • 13 mm 12-point deep socket
  • 6 in extension
  • 3 in extension
  • Ratchet/torque wrench
  • Paint Pen
 Replace
Bolts that attach the DCDC passthrough to the ancillary bay
10 Nm (7.4 lbs-ft)
  • Insulated tools:
    • 2 in extension
    • Ratchet/torque wrench - 1057602-00-A
  • Electrical Protective Gloves
  • External Torx E10 5-Lobe - 1059330-00-B
  • Ratchet/torque wrench
  • Paint Pen
 Reuse

Remove

  1. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  2. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  3. Install the pyrotechnic disconnect dummy.
  4. Disconnect the power conversion system LV connector.
    Tip: Release the locking tab by pulling upward. Use plastic trim tool to help lift the connector upward as needed. Lift the HV controller up from the front.
  5. Remove the DCDC ground strap from the HV battery. See Busbar - DCDC Ground (Remove and Replace).
  6. Release the positive 12V output cover from the power conversion system cable.
  7. Remove and discard the nut that attaches the positive 12V output to the power conversion system cable, and then move the cable aside.
    Use of the following tool(s) is recommended:
    • 13 mm 12-point deep socket
    • 6 in extension
    • 3 in extension
    • Ratchet/torque wrench
    • Paint Pen
  8. Remove the bolts (x2) that attach the DCDC passthrough to the ancillary bay.
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 2 in extension
      • Ratchet/torque wrench - 1057602-00-A
    • Electrical Protective Gloves
    • External Torx E10 5-Lobe - 1059330-00-B
    • Ratchet/torque wrench
    • Paint Pen
  9. Remove the DCDC passthrough from the ancillary bay.

Install

  1. Position the DCDC passthrough to the ancillary bay for installation, and then install the bolts (x2) that attach the DCDC passthrough to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Tip: Mark the bolts after torque.
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 2 in extension
      • Ratchet/torque wrench - 1057602-00-A
    • Electrical Protective Gloves
    • External Torx E10 5-Lobe - 1059330-00-B
    • Ratchet/torque wrench
    • Paint Pen
  2. Install the new nut that attaches the positive 12V output to the power conversion system cable.
    9 Nm (6.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the rubber boot is not pinched between the cable terminal and the passthrough.
    Use of the following tool(s) is recommended:
    • 13 mm 12-point deep socket
    • 6 in extension
    • 3 in extension
    • Ratchet/torque wrench
    • Paint Pen
  3. Install the positive 12V output cover.
  4. Install the DCDC ground strap to the HV battery. See Busbar - DCDC Ground (Remove and Replace).
  5. Connect the power conversion system LV connector.
    Tip: Push the connector downward, and then push the locking tab downward to install the connector. Make sure the connector is fully seated. Lift the HV controller up from the front.
  6. Remove the fuse access insulator and the pyrotechnic disconnect dummy.
  7. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  8. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).