15/12/2023 01:27:39

DC Input Assembly - HV Battery (Busbar Type) (Remove and Replace)

Correction code 16302402 1.56 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

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.

Procedure

Open all four doors

Note
Latch rear doors to prevent accidental closing when power is down
Lower all windows
Move LH front seat forward
Move RH front seat forward
Open hood
Remove rear apron

Note
14x clips
Remove 2nd row seat cushion

Note
1x connector, Lift front edge of seat cushion upward to release foam from frame
Partially remove LH rear door seal
Remove LH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
Partially remove RH rear door seal

Note
Pillar and sill trim have tabs seated underneath seal
Remove RH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of RH rear sill trim working your way back towards rear of sill trim
Remove clips securing rear main cabin carpet to vehicle

Note
3x push clips
Remove fasteners securing 40 seat frame to body

Note
4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
Fold the 40 seat in down position

Note
Protect the seat cushion, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
Disconnect 40 frame connector

Note
1x connector
Remove 2R 40 seat assembly from vehicle

Note
Recommend assistance
Remove fasteners securing 60 seat frame to body

Note
5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
Fold the 60 seat in down position

Note
Protect the seat back upholstery if necessary, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
Disconnect logic connector at LH seat frame

Note
1x connector
Remove connector harness clip from LH seat frame

Note
1x clip, engage tabs on clips to avoid damage
Remove 2nd row 60 seat assembly from vehicle

Note
Recommend assistance
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off
Disconnect 12V negative terminal and first responders loop

Note
1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove the ancillary bay probe lid cover from the ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
Remove HV insulating gloves
Remove fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Remove bolts securing charge port busbar kit to HV header

Note
2x bolts, 10mm, 9 Nm
Lift busbar kit connector to remove from HV header
Disconnect the HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Discard after removal
Remove HVC logic cap

Note
1x cap
Remove bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove ancillary bay cover from HV battery

Note
Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
Install the battery pyro and shunt insulators

Note
2x insulators
Install the HV joint insulators onto positive pack contactor

Note
2x insulators
Install the HV joint insulators to negative pack contactor

Note
2x insulators
Install the insulator for DC input assembly to both fastcharge busbars inlet side

Note
1x insulator
Install the negative AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Install the positive AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Install fuses access insulator

Note
3x clips
Install HVC logic cap

Note
1x cap
Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
Remove the insulator for DC input assembly to both fastcharge busbar inlet side

Note
1x insulator,
Remove bolt securing negative fastcharge busbar inlet side and negative DC input assembly busbar

Note
1x patch bolt, 13mm, 9 Nm, Discard after removal
Remove bolt securing positive fastcharge busbar inlet side and positive DC input assembly busbar

Note
1x patch bolt, 13mm, 9 Nm, Discard after removal
Disconnect the megaharness connector from DC input assembly

Note
1x connector
Remove the bolts securing the busbar DC input assembly to ancillary bay

Note
4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
Remove the Busbar DC input assembly from ancillary bay
Install the Busbar DC input assembly to ancillary bay

Note
Ensure seal is not damaged and seated properly
Install the bolts securing the Busbar DC input assembly to ancillary bay

Note
4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
Install the bolt securing negative fastcharge busbar inlet side and negative DC input assembly busbar

Note
1x patch bolt, 13mm, 9 Nm, Mark after torque, Install new patch bolt
Install the bolt securing positive fastcharge busbar inlet side and positive DC input assembly busbar

Note
1x patch bolt, 13mm, 9 Nm, Mark after torque, Install new patch bolt
Perform Hioki resistance test at the HV joints of the DC input assembly busbar

Note
2x HV joints, 60 𝜇Ω or less, Test from negative fastcharge busbar to negative DC input busbar and positive fastcharge busbar to positive DC input busbar
Install the insulator for DC input assembly to both fastcharge busbars inlet side

Note
1x insulator
Connect the megaharness connector to DC input assembly

Note
1x connector
Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
Clean HVC studs and ancillary bay cover underside with isopropyl alcohol

Note
4x studs
Inspect ancillary bay walls for damage

Note
Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
Inspect ancillary bay cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Remove HVC logic cap

Note
1x cap
Position the ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Install HVC logic cap

Note
1x cap
Install bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
Install fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Install new bolts
Remove HV insulating gloves
Remove logic cap and connect the HVC logic connector

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
Clean busbar HV connector contact surface of residual Penetrox_x000A_

Note
Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
Clean HV connector contact surface of residual Penetrox

Note
Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
Apply Penetrox onto HV connector joints

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
Position busbar kit connector and lower onto HV header
Install bolts securing charge port busbar kit to HV Header

Note
2x bolts, 10mm, 9 Nm
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head

Note
2x HV joints, The acceptable resistance is between 50 𝜇Ω and 195 𝜇Ω. If the resistance is greater than 195 𝜇Ω, stop work and escalate the Toolbox session. If the resistance is lower than 50 𝜇Ω, reposition the probes and measure again. If the resistance is repeatedly between 0 𝜇Ω and 50 𝜇Ω, hioki test passed, proceed to next step.
Remove HV insulating gloves
Install fastener securing busbar cover access door

Note
1x bolt, 10mm, 9 Nm
Install 2R 40 seat assembly into vehicle

Note
Recommend assistance
Connect 40 seat frame connector to body harness

Note
1x connector
Fold the 40 seat into vertical position

Note
Remove seat cushion protection
Secure 40 seat frame to vehicle

Note
4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
Install RH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips
Reseat RH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Install 2nd row 60 seat assembly

Note
Recommend assistance
Install connector harness clip to LH seat frame

Note
1x clip
Connect logic connector at LH seat frame

Note
1x connector
Fold the 60 seat into vertical position

Note
Remove seat back protection if necessary
Install fasteners securing 60 seat frame to body

Note
5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
Install LH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of LH rear sill trim into trunk side trim and work your way forward securing clips
Reseat LH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Install clips securing rear main cabin carpet to vehicle

Note
3x push clips
Install 2nd row seat cushion

Note
1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Connect FRL first before connecting 12V to avoid damage to car computer
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move LH front seat to original position
Move RH front seat to original position
Raise all windows
Close all four doors

Note
Unlatch rear doors before closing