Pyrotechnic Battery Disconnect (Remove and Replace)
Correction code 16300002 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-04-18: Added link to the ancillary bay cover (7-seater).
- 2024-01-31: Added images of real parts in the Hioki resistance test steps.
- 2023-07-25: Added step to record replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
- 1057602-00-A Ratchet, 1/4" Sq Dr, HV Insulated
- 1057603-00-A Ext Bar, Wobble, 1/4" Dr, HV Insulated
- 1057606-00-A Skt, 1/4" Sq Dr, 13mm, HV Insulated
- 1057607-00-A Magnet, Flexible, HV Insulated, 18"
- 1127845-00-A Asy, Service Cover, Penthouse, Model 3
- 1131071-00-A Dummy Disconnect, Pyro, Safety
- 1133602-00-A Kit, HV Pyro-disconnect Replacement, BRP
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
- 1076927-00-A Resistance meter, microohm, Hioki RM 3548
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.
Torque Specifications
Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
---|---|---|---|---|
Bolt that attaches the pyrotechnic battery disconnect to the HV battery |
|
|
Replace |
Remove
-
Remove the ancillary bay
cover. See Cover - Ancillary Bay (Remove and Replace) or Cover - Ancillary Bay (7-Seat) (Remove and Replace).
WarningHV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
- If the logic connector cap is installed on the high voltage controller connector, remove it.
- Set the ancillary bay service cover over the ancillary bay.
-
Remove the pyrotechnic battery disconnect shunt insulator(s).
- Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.
- Install the dummy disconnect where the pyrotechnic battery disconnect was removed.
Install
- Tesla internal users only: record the replacement pyrotechnic battery disconnect serial number and part number for later entry into SCA.
-
Perform a zero adjust of the
Hioki resistance meter in preparation to measure resistances later in this
procedure. See Resistance Meter (Zero Adjust).
WarningHV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
- Remove the dummy disconnect from where the pyrotechnic battery disconnect will install.
- Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect.
-
Set the multimeter to the
"LoZ" (low impedance) mode.
NoteFor Fluke multimeters without "LoZ" mode on the mode selector, see Multimeter (LoZ Setting).
-
Measure the voltage between the busbar (left) and shunt (right) for at
least 10 seconds, so as to balance the voltage across the pyrotechnic
battery disconnect mount points.
NoteThe voltage displayed on the multimeter is not as important as balancing the mount points.
- While still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars.
- Continue to measure the voltage for another 10 seconds after the pyrotechnic battery disconnect has been set onto the busbars.
-
Install the new bolts that
attach the pyrotechnic battery disconnect to the HV battery, and then mark
the bolts with a paint pen after they are torqued.Tip: Use of the following tool(s) is recommended:
- Insulated tools:
- 13 mm socket
- 6 in extension
- Ratchet/torque wrench
- Insulated tools:
-
Use the Hioki resistance
meter to measure the resistance at the HV joint between the newly-installed
pyrotechnic battery disconnect and the LH busbar.
NoteThe 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
-
Use the Hioki resistance
meter to measure the resistance at the HV joint between the newly-installed
pyrotechnic battery disconnect and the shunt.
NoteThe maximum acceptable resistance is 0.045 mΩ (45 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
-
Install the pyrotechnic
battery disconnect shunt insulator(s).
- Remove the ancillary bay service cover from the ancillary bay.
- Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace) or Cover - Ancillary Bay (7-Seat) (Remove and Replace).