2025-02-11

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 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.

  • 2025-02-11: Split topic into Remove and Install sections and condensed procedure.

Remove

  1. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace), Cover - Ancillary Bay (7-Seat) (Remove and Replace). Cover - Ancillary Bay (Structural Pack) (Remove and Replace) or Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to install all HV insulators caps, if not present. See Insulators - HV Battery (Install and Remove).
  2. Remove the bolt that attaches the busbar cover access door.
  3. Remove the bolts that attach the charge port busbar kit to the HV header.
  4. Lift the busbar kit connector to remove it from the from the HV header.
  5. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  6. Remove the insulator for DC input assembly to both fastcharge busbar inlet side.
  7. Remove and discard the bolt that attaches the negative fastcharge busbar inlet side and negative DC input assembly busbar.
  8. Remove and discard the bolt that attaches the positive fastcharge busbar inlet side and positive DC input assembly busbar.
  9. Disconnect the megaharness connector from the DC input assembly.
  10. Remove and discard the bolts (x4) that attach the busbar DC input assembly to the ancillary bay.
  11. Remove the Busbar DC input assembly from the ancillary bay.

Install

  1. Install the Busbar DC input assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the seal is not damaged and is properly seated.
  2. Install new bolts (x4) that attach the Busbar DC input assembly to the ancillary bay (torque 10 Nm).
  3. Install a new bolt that attaches the negative fastcharge busbar inlet side and negative DC input assembly busbar (torque 9 Nm).
  4. Install a new bolt that attaches the positive fastcharge busbar inlet side and positive DC input assembly busbar.
  5. Perform a Hioki resistance test at the HV joints of the DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    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
  6. Install the insulator for the DC input assembly to both fastcharge busbars inlet sides.
  7. Connect the megaharness connector to the DC input assembly.
  8. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  9. Clean the HVC studs and ancillary bay cover underside with isopropyl alcohol
  10. Inspect the ancillary bay walls for damage.
    Informational PurposesAn informational icon, calling your attention
    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.
  11. Inspect ancillary bay cover seal to confirm it has no damage
    Informational PurposesAn informational icon, calling your attention
    Note
    Image up close for clarity. Delaminated or torn seals cannot be reused
  12. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace), Cover - Ancillary Bay (7-Seat) (Remove and Replace). Cover - Ancillary Bay (Structural Pack) (Remove and Replace) or Cover - Ancillary Bay (Structural Pack) (3-Phase) (Remove and Replace).
  13. Connect the HVC logic connector.
  14. Clean the busbar HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox. It is necessary to clean HV connector during re-use of busbar./
  15. Clean the HV connector contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox. New busbar comes with Penetrox applied to HV connector.
  16. Apply Penetrox onto HV connector joint.
    Informational PurposesAn informational icon, calling your attention
    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.
  17. Position the busbar kit connector and lower it onto the HV header.
  18. Install the bolts (x2) that attach the charge port busbar kit to the HV Header (torque 9 Nm).
  19. Put on HV insulating gloves and leather over gloves.
  20. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 50 𝜇Ω and 195 𝜇Ω. If the resistance is more 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.
  21. Remove the HV insulating gloves.
  22. Install the bolt that attaches the busbar cover access door (torque 9 Nm).
  23. Install the second row RH seat back assembly back into the vehicle. See Seat Back - 2nd Row - RH (Remove and Replace).
  24. Install the 2nd row LH seat back assembly into the vehicle. See Seat Back - 2nd Row - LH (Remove and Replace).
  25. Install the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  26. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  27. Install the rear underhood apron.