04/06/2024 18:03:21

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.

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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

    1. Open all four doors
      Informational PurposesAn informational icon, calling your attention
      Note
      Latch rear doors to prevent accidental closing when power is down
    2. Lower all windows
    3. Move LH front seat forward
    4. Move RH front seat forward
    5. Open hood
    6. Remove rear apron
      Informational PurposesAn informational icon, calling your attention
      Note
      14x clips
    7. Remove 2nd row seat cushion
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector, Lift front edge of seat cushion upward to release foam from frame
    8. Partially remove LH rear door seal
    9. Remove LH rear sill trim
      Informational PurposesAn informational icon, calling your attention
      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
    10. Partially remove RH rear door seal
      Informational PurposesAn informational icon, calling your attention
      Note
      Pillar and sill trim have tabs seated underneath seal
    11. Remove RH rear sill trim
      Informational PurposesAn informational icon, calling your attention
      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
    12. Remove clips securing rear main cabin carpet to vehicle
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      Note
      3x push clips
    13. Remove fasteners securing 40 seat frame to body
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
    14. Fold the 40 seat in down position
      Informational PurposesAn informational icon, calling your attention
      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
    15. Disconnect 40 frame connector
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      Note
      1x connector
    16. Remove 2R 40 seat assembly from vehicle
      Informational PurposesAn informational icon, calling your attention
      Note
      Recommend assistance
    17. Remove fasteners securing 60 seat frame to body
      Informational PurposesAn informational icon, calling your attention
      Note
      5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
    18. Fold the 60 seat in down position
      Informational PurposesAn informational icon, calling your attention
      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
    19. Disconnect logic connector at LH seat frame
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      Note
      1x connector
    20. Remove connector harness clip from LH seat frame
      Informational PurposesAn informational icon, calling your attention
      Note
      1x clip, engage tabs on clips to avoid damage
    21. Remove 2nd row 60 seat assembly from vehicle
      Informational PurposesAn informational icon, calling your attention
      Note
      Recommend assistance
    22. Power off vehicle from center display
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      Note
      Via Controls > Safety & Security > Vehicle Power > Power Off
    23. Disconnect 12V negative terminal and first responders loop
      Informational PurposesAn informational icon, calling your attention
      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
    24. Remove all items from pockets and ensure not wearing metal items
    25. Inspect HV insulating gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
    26. Put on HV insulating gloves and leather over gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure to wear Electrical Protective Gloves any time Hioki tester is used
    27. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
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      Note
      2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
    28. Remove the ancillary bay probe lid cover from the ancillary bay cover
    29. Verify no high voltage
      Informational PurposesAn informational icon, calling your attention
      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
    30. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
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      Note
      Confirm no visual damage present
    31. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
      Informational PurposesAn informational icon, calling your attention
      Note
      2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
    32. Remove HV insulating gloves
    33. Remove fastener securing busbar cover access door
      Informational PurposesAn informational icon, calling your attention
      Note
      1x bolt, 10mm, 9 Nm
    34. Remove bolts securing charge port busbar kit to HV header
      Informational PurposesAn informational icon, calling your attention
      Note
      2x bolts, 10mm, 9 Nm
    35. Lift busbar kit connector to remove from HV header
    36. Disconnect the HVC logic connector and install logic cap
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      Note
      1x connector, 1x cap, Release locking tab then push the handle downward to release connector
    37. Remove fasteners securing ancillary bay cover to high voltage controller (HVC)
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, E10, 5 Nm + 30 degrees, Discard after removal
    38. Remove HVC logic cap
      Informational PurposesAn informational icon, calling your attention
      Note
      1x cap
    39. Remove bolts securing ancillary bay cover to HV battery
      Informational PurposesAn informational icon, calling your attention
      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
    40. Inspect HV insulating gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
    41. Put on HV insulating gloves and leather over gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure to wear Electrical Protective Gloves any time Hioki tester is used
    42. Remove ancillary bay cover from HV battery
      Informational PurposesAn informational icon, calling your attention
      Note
      Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
    43. Install the battery pyro and shunt insulators
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      Note
      2x insulators
    44. Install the HV joint insulators onto positive pack contactor
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      Note
      2x insulators
    45. Install the HV joint insulators to negative pack contactor
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      Note
      2x insulators
    46. Install the insulator for DC input assembly to both fastcharge busbars inlet side
      Informational PurposesAn informational icon, calling your attention
      Note
      1x insulator
    47. Install the negative AC inlet terminal cover
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      Note
      1x cover, 3x clips, Use caution as the clips are very easy to damage
    48. Install the positive AC inlet terminal cover
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      Note
      1x cover, 3x clips, Use caution as the clips are very easy to damage
    49. Install fuses access insulator
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      Note
      3x clips
    50. Install HVC logic cap
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      Note
      1x cap
    51. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    52. Remove the insulator for DC input assembly to both fastcharge busbar inlet side
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      Note
      1x insulator,
    53. Remove bolt securing negative fastcharge busbar inlet side and negative DC input assembly busbar
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      Note
      1x patch bolt, 13mm, 9 Nm, Discard after removal
    54. Remove bolt securing positive fastcharge busbar inlet side and positive DC input assembly busbar
      Informational PurposesAn informational icon, calling your attention
      Note
      1x patch bolt, 13mm, 9 Nm, Discard after removal
    55. Disconnect the megaharness connector from DC input assembly
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector
    56. Remove the bolts securing the busbar DC input assembly to ancillary bay
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, E10 5-Lobe, 10 Nm, Discard after removal
    57. Remove the Busbar DC input assembly from ancillary bay
    58. Install the Busbar DC input assembly to ancillary bay
      Informational PurposesAn informational icon, calling your attention
      Note
      Ensure seal is not damaged and seated properly
    59. Install the bolts securing the Busbar DC input assembly to ancillary bay
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, E10 5-Lobe, 10 Nm, Install new bolts, Mark after torque
    60. Install the bolt securing negative fastcharge busbar inlet side and negative DC input assembly busbar
      Informational PurposesAn informational icon, calling your attention
      Note
      1x patch bolt, 13mm, 9 Nm, Mark after torque, Install new patch bolt
    61. Install the bolt securing positive fastcharge busbar inlet side and positive DC input assembly busbar
      Informational PurposesAn informational icon, calling your attention
      Note
      1x patch bolt, 13mm, 9 Nm, Mark after torque, Install new patch bolt
    62. Perform 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
    63. Install the insulator for DC input assembly to both fastcharge busbars inlet side
      Informational PurposesAn informational icon, calling your attention
      Note
      1x insulator
    64. Connect the megaharness connector to DC input assembly
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector
    65. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
    66. Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
      Informational PurposesAn informational icon, calling your attention
      Note
      4x studs
    67. Inspect 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
    68. Inspect ancillary bay cover seal to confirm it has no visual damage
      Informational PurposesAn informational icon, calling your attention
      Note
      Image up close for clarity, Delaminated and torn seals cannot be reused
    69. Remove HVC logic cap
      Informational PurposesAn informational icon, calling your attention
      Note
      1x cap
    70. Position the ancillary bay cover to HV battery for installation
      Informational PurposesAn informational icon, calling your attention
      Note
      Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
    71. Install HVC logic cap
      Informational PurposesAn informational icon, calling your attention
      Note
      1x cap
    72. Install bolts securing ancillary bay cover to HV battery
      Informational PurposesAn informational icon, calling your attention
      Note
      18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
    73. Install fasteners securing ancillary bay cover to high voltage controller (HVC)
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, E10, 5 Nm + 30 degrees, Install new bolts
    74. Remove HV insulating gloves
    75. Remove logic cap and connect the HVC logic connector
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
    76. Clean busbar HV connector contact surface of residual Penetrox_x000A_
      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
    77. Clean 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
    78. Apply Penetrox onto HV connector joints
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      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
    79. Position busbar kit connector and lower onto HV header
    80. Install bolts securing charge port busbar kit to HV Header
      Informational PurposesAn informational icon, calling your attention
      Note
      2x bolts, 10mm, 9 Nm
    81. Inspect HV insulating gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
    82. Put on HV insulating gloves and leather over gloves
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure to wear Electrical Protective Gloves any time Hioki tester is used
    83. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
      Informational PurposesAn informational icon, calling your attention
      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.
    84. Remove HV insulating gloves
    85. Install fastener securing busbar cover access door
      Informational PurposesAn informational icon, calling your attention
      Note
      1x bolt, 10mm, 9 Nm
    86. Install 2R 40 seat assembly into vehicle
      Informational PurposesAn informational icon, calling your attention
      Note
      Recommend assistance
    87. Connect 40 seat frame connector to body harness
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector
    88. Fold the 40 seat into vertical position
      Informational PurposesAn informational icon, calling your attention
      Note
      Remove seat cushion protection
    89. Secure 40 seat frame to vehicle
      Informational PurposesAn informational icon, calling your attention
      Note
      4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
    90. Install RH rear sill trim
      Informational PurposesAn informational icon, calling your attention
      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
    91. Reseat RH rear door seal
      Informational PurposesAn informational icon, calling your attention
      Note
      Seat pillar and sill trim tabs underneath seal
    92. Install 2nd row 60 seat assembly
      Informational PurposesAn informational icon, calling your attention
      Note
      Recommend assistance
    93. Install connector harness clip to LH seat frame
      Informational PurposesAn informational icon, calling your attention
      Note
      1x clip
    94. Connect logic connector at LH seat frame
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector
    95. Fold the 60 seat into vertical position
      Informational PurposesAn informational icon, calling your attention
      Note
      Remove seat back protection if necessary
    96. Install fasteners securing 60 seat frame to body
      Informational PurposesAn informational icon, calling your attention
      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
    97. Install LH rear sill trim
      Informational PurposesAn informational icon, calling your attention
      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
    98. Reseat LH rear door seal
      Informational PurposesAn informational icon, calling your attention
      Note
      Seat pillar and sill trim tabs underneath seal
    99. Install clips securing rear main cabin carpet to vehicle
      Informational PurposesAn informational icon, calling your attention
      Note
      3x push clips
    100. Install 2nd row seat cushion
      Informational PurposesAn informational icon, calling your attention
      Note
      1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
    101. Connect first responder loop and 12V negative terminal
      Informational PurposesAn informational icon, calling your attention
      Note
      1x nut, 10mm, 6 Nm, 1x connector, Connect FRL first before connecting 12V to avoid damage to car computer
    102. Install rear apron
      Informational PurposesAn informational icon, calling your attention
      Note
      14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
    103. Close hood
    104. Move LH front seat to original position
    105. Move RH front seat to original position
    106. Raise all windows
    107. Close all four doors
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      Note
      Unlatch rear doors before closing