04/09/2024 12:55:27

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

Correction code 16302002 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.

  • 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 clip that attaches the HV battery ancillary bay harness to the HV battery fast charge contactor.
    3. Disconnect the electrical harness from the HV battery negative contactor connectors.
    4. Remove the insulator caps from the HV battery negative contactor.
    5. Remove and discard the bolt that attaches the HV battery negative contactor to the negative busbar.
    6. Remove and discard the nut that attaches the HV battery negative contactor to the battery terminal.
    7. Remove the nuts (x2 or x3) that attach the HV battery negative contactor to the ancillary bay, and then remove the contactor from the ancillary bay.
      Tip: If the contactor is equipped with 3 nuts, one of the nuts is partially obscured by the lip of the ancillary bay. To easily remove the nut, make sure to use the special tools listed in this procedure and use the magnetic insert to help guide the insulated socket onto the nut. Refer to the following video for a demonstration of how to approach this nut.

    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, negative busbar, and the HV battery negative contactor.
    3. Install the HV battery negative contactor into the ancillary bay, and then install the nuts (x2 or x3) that attach the contactor into the ancillary bay.
      8 Nm (5.9 lbs-ft)
    4. Install a new nut to attach the HV battery negative 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)
    5. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative 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
    6. Install a new bolt to attach the HV battery negative contactor onto the negative busbar, and then mark the bolt with a paint pen after it is torqued.
      9 Nm (6.6 lbs-ft)
    7. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery negative contactor and the negative 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
    8. Install the insulator caps to the HV battery negative contactor.
    9. Connect the electrical harness to the HV battery negative contactor connectors.
    10. Install the clip that attaches the HV battery ancillary bay harness to the HV battery fast charge contactor.
    11. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).