04/06/2024 18:02:11

Contactor - Negative - HV Battery (Structural Pack) (Remove and Replace)

Correction code 16302012 1.98 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.

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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

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. Disconnect the HV battery negative contactor connectors (x2).
  6. Release the clip that attaches the ancillary bay harness to the vehicle.
  7. Remove and discard the bolts (x2) that attach the negative contactor to the busbars.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  8. Remove the bolts (x3) that attach the negative contactor to the assembly tray.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  9. Remove the HV battery negative pack contactor from the ancillary bay.

Install

  1. Position the HV battery negative contactor into the ancillary bay.
  2. Install the bolts (x3) that attach the negative contactor to the assembly tray.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start bolts to verify the contactor is centered.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
  3. Install new bolts (x2) that attach the negative contactor to the busbars.
    5 Nm (3.7 lbs-ft) + 60 degrees
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  4. Use a Hioki resistance meter to measure the resistance at the HV joint between the newly-installed negative contactor and the negative DC link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.004 mΩ (4 μΩ) and 0.050 mΩ (50 μΩ). If the resistance is greater than 0.050 mΩ (50 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. If the resistance is less than 0.004 mΩ (4 μΩ), reposition the probes and measure again.
  5. Use a Hioki resistance meter to measure the resistance at the HV joint between the newly-installed negative contactor and the negative terminal flex assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.004 mΩ (4 μΩ) and 0.050 mΩ (50 μΩ). If the resistance is greater than 0.050 mΩ (50 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. If the resistance is less than 0.004 mΩ (4 μΩ), reposition the probes and measure again.
  6. Install the clip that attaches the ancillary bay harness to the vehicle.
  7. Connect the negative contactor connectors (x2).
  8. 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).
  9. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  10. Exit Service Mode. See Service Mode.
  11. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  12. Raise all the windows and close all the doors.