2026-03-04

Fuse - Ancillary Bay (Remove and Replace)

Correction code 16304202/16304402 1.14 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.

  • 2023-07-06: Added a video in step 4 of Install part.
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Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

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Note
Correction code usage:
  • A/C Compressor Fuse: 16304202
  • Power Conversion System Fuse: 16304402
Equipment:
  • 1467483-00-C - M3/Y Penthouse Service Insulator Kit
  • 1076927-00-A - HIOKI RM 3548
  • 1076928-00-A - TEST PROBES - HIOKI 9461

Torque Specifications

Table 1. Torque Specifications: Fuse - Ancillary Bay (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts that attach the ancillary bay fuse to the RH ancillary bay bus
2.5 Nm (1.8 lbs-ft)
  • Insulated 8 mm socket
 Replace 1104458-00-A

Remove

  1. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  2. Raise the high voltage controller, release the clips that attach the fuse access insulator to the RH ancillary bay bus cover, and remove the insulator.
  3. Remove and discard the nuts that attach the fuse to the RH ancillary bay bus and remove the fuse.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 8 mm socket
    Figure 1. Compressor fuse shown; the other 2 fuses are the same

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. Install the fuse to the RH ancillary bay bus, and then install new nuts to attach the fuse to the bus.
    2.5 Nm (1.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 8 mm socket
    Figure 2. Compressor fuse shown; the other 2 fuses are the same
  3. Use the Hioki resistance meter to measure the resistance at the HV joint between the ancillary bay bus and the LH side of the fuse body .
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.105 mΩ (105 μΩ). If 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 3. Generic Measurement - Actual busbars and fasteners might appear different
  4. Use the Hioki resistance meter to measure the resistance at the HV joint between the RH side of the fuse and the respective ring terminal plating.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.145 mΩ (145 μΩ). If 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 4. Generic Measurement - Actual busbars and fasteners might appear different
  5. Install the fuse access insulator on the RH ancillary bay bus cover, fasten the clips that attach the insulator to the cover, and lower the high voltage controller.
  6. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).