04/06/2024 18:04:02

Switch - Pack Contactors - Ancillary Bay - HV Battery (Remove and Replace)

Correction code 16309902 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.

  • 2024-01-09: Rewrite the procedure according to the latest validation in which the pack contactors are removed without removing PCS and installing without performing the coolant drain/fill test and the pressure test.
Table 1. Torque Specifications: Switch - Pack Contactors - Ancillary Bay - HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes

Bolt that attaches the positive pack contactor to the positive busbar

Nut that attaches the positive pack contactor to the module 4 rear terminal
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
    • 6 in extension
    • 13 mm socket
  • Paint Pen
  • Electrical Protective Gloves
 Replace

Bolt: 1104475-00-F

Nut: 1104654-00-B
Nuts that attach the positive pack contactor to the ancillary bay
8 Nm (5.9 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
    • Flexible Magnet
    • Extension 1/4 Dr. Wobble 10.5"
    • 10 mm socket
    • Insulated Magnetic Pick Up Tool - 1057607-00-A
  • Electrical Protective Gloves
  • Paint Pen
 Reuse

Bolt that attaches the negative pack contactor to the DC link busbar joint

Nut that attaches the negative pack contactor to HV battery tall silicon terminal
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
    • 6 in extension
    • 13 mm socket
  • Electrical Protective Gloves
  • Paint Pen
 Replace

Bolt: 1104475-00-F

Nut: 1104654-00-B
Nuts that attach the negative pack contactor to the ancillary bay
8 Nm (5.9 lbs-ft)
  • Insulated tools:
    • Ratchet/torque wrench
    • 6 in extension
    • 10 mm socket
    • 10 mm 12-point deep socket
    • Insulated Magnetic Pick Up Tool - 1057607-00-A
  • Electrical Protective Gloves
  • Paint Pen
 Reuse
  • 1133602-00-A M3/Y Pyro Disconnect Kit
  • 1057607-00-A Insulated Magnetic Pick Up Tool

Procedure

  1. Open all doors and lower all windows.
  2. Place the vehicle in Service Mode through UI. See Service Mode.
  3. Remove the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  4. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  5. Remove the LH 2nd row seat back assembly from the vehicle. See Seat Back - 2nd Row - LH (Remove and Replace).
  6. Remove the RH 2nd row seat back assembly from the vehicle. See Seat Back - 2nd Row - RH (Remove and Replace).
  7. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  8. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  9. Remove the ancillary bay cover from the HV battery. See Cover - Ancillary Bay (Remove and Replace).
  10. Lift the HV Controller up to gain access to the fuse access insulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a bungee cord to hold the HVC assembly and the tray in an upward position.
  11. Install the clips (x3) that secure the fuse access insulator.
  12. Install the HV joint insulators (x2) onto the positive pack contactor.
  13. Install the HV joint insulators (x2) onto the negative pack contactor.
  14. Install an insulator for the DC input assembly to the fastcharge busbar inlet side.
  15. Install the negative AC inlet terminal cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as the clips are very easy to damage.
  16. Install the positive AC inlet terminal cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as the clips are very easy to damage.
  17. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  18. Disconnect the power conversion system (PCS) to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. Use a plastic trim tool to help lift the connector upward as needed.
  19. Disconnect the PCS logic connector from PCS.
  20. Disconnect the PCS LV connector from PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. Use a plastic trim tool to help lift the connector upward as needed.
  21. Remove the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace).
  22. Disconnect the ancillary bay harness connectors (x2) from the positive pack contactor.
  23. Disconnect the ancillary bay harness clip from the positive pack contactor.
  24. Remove the HV joint insulators (x2) from the positive pack contactor.
  25. Remove and discard the bolt that attaches the positive pack contactor to the positive busbar.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Paint Pen
    • Electrical Protective Gloves
  26. Remove and discard the nut that attaches the positive pack contactor to the module 4 rear terminal.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Paint Pen
    • Electrical Protective Gloves
  27. Remove the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • Flexible Magnet
      • Extension 1/4 Dr. Wobble 10.5"
      • 10 mm socket
      • Insulated Magnetic Pick Up Tool - 1057607-00-A
    • Electrical Protective Gloves
    • Paint Pen
  28. Remove the positive pack contactor from ancillary bay.
  29. Position the positive pack contactor to the ancillary bay for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the 2 guide pins.
  30. Install the nuts (x3) that attach the positive pack contactor to the ancillary bay.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use insulated magnet as needed to position the nuts onto the studs. The number of nuts on newer vehicles may vary.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • Flexible Magnet
      • Extension 1/4 Dr. Wobble 10.5"
      • 10 mm socket
      • Insulated Magnetic Pick Up Tool - 1057607-00-A
    • Electrical Protective Gloves
    • Paint Pen
  31. Install a new bolt (1104475-00-F) to attach the positive pack contactor to the positive busbar.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Paint Pen
    • Electrical Protective Gloves
  32. Install a new nut (1104654-00-B) to attach the positive pack contactor to the module 4 rear terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Paint Pen
    • Electrical Protective Gloves
  33. Measure resistance from the HV joint between the HV battery positive contactor and the center of the HV battery positive terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.110 mΩ (110 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
  34. Perform Hioki impedance test at the HV joint of the positive pack contactor to DC link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x HV joint, The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ), If the resistance is greater than 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. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  35. Connect the ancillary bay harness connectors (x2) to the positive pack contactor.
  36. Connect the ancillary bay harness clip to the positive pack contactor.
  37. Install the HV joint insulators (x2) onto the positive pack contactor.
  38. Install the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Busbar Type) (Remove and Replace).
  39. Connect the PCS LV connector to PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the connector and engage the red locking tab. Make sure the connector is fully seated.
  40. Connect the PCS logic connector to PCS.
  41. Connect the PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the connector and engage the red locking tab. Make sure the connector is fully seated.
  42. If needed, remove the ancillary bay harness clip around negative pack contactor area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Newer pack has this harness clip further away from contactor thus does not require removal for access.
  43. Disconnect the ancillary bay harness connectors (x2) from the negative pack contactor.
  44. Remove the HV joint insulators (x2) from the negative pack contactor.
  45. Remove and discard the bolt that attaches the negative pack contactor to the DC link busbar joint.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  46. Remove and discard the nut that attaches the negative pack contactor to HV battery tall silicon terminal.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  47. Remove the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnet to retrieve the nuts after removal. The number of nuts on newer vehicles may vary.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 10 mm socket
      • 10 mm 12-point deep socket
      • Insulated Magnetic Pick Up Tool - 1057607-00-A
    • Electrical Protective Gloves
    • Paint Pen
  48. Remove the negative pack contactor from the ancillary bay.
  49. Position the negative pack contactor to ancillary bay for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the 2 guide pins.
  50. Install the nuts (x3) that attach the negative pack contactor to the ancillary bay.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an insulated magnet as needed to position the nuts onto the studs. The number of nuts on newer vehicles may vary. Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 10 mm socket
      • 10 mm 12-point deep socket
      • Insulated Magnetic Pick Up Tool - 1057607-00-A
    • Electrical Protective Gloves
    • Paint Pen
  51. Install a new bolt (1104475-00-F) to attach the negative pack contactor to the DC link busbar joint.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  52. Install a new nut (1104654-00-B) to attach the negative pack contactor to HV battery tall silicon terminal.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark after torque.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • Ratchet/torque wrench
      • 6 in extension
      • 13 mm socket
    • Electrical Protective Gloves
    • Paint Pen
  53. Perform Hioki impedance test at the HV joint of the negative pack contactor to negative DC link busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ). If the resistance is greater than 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. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
  54. Perform Hioki impedance test at the negative pack contactor to module 1 rear terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.110 mΩ (110 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
  55. Connect the ancillary bay harness connectors (x2) to the negative pack contactor.
  56. Install the ancillary bay harness clip around the negative pack contactor area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Newer pack has this harness clip further away from contactor thus does not require removal for access.
  57. Install the HV joint insulators (x2) to the negative pack contactor.
  58. Install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  59. Remove the HV joint insulators (x2) from the negative pack contactor.
  60. Remove the HV joint insulators (x2) from the positive pack contactor.
  61. Remove the insulator for the DC input assembly from the fastcharge busbar inlet side.
  62. Remove the negative AC inlet terminal cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as the clips are very easy to damage.
  63. Remove the positive AC inlet terminal cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution as the clips are very easy to damage.
  64. Release the clips (x3) that secure the fuse access insulator and remove the insulator.
  65. Lower the HV Controller back into place.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the tool which holds the HV controller up for access.
  66. Install the ancillary bay cover from the HV battery. See Cover - Ancillary Bay (Remove and Replace).
  67. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  68. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  69. Install the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  70. Install the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  71. Connect the LV battery power. See 12V/LV Power (Disconnect and Connect).
  72. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  73. Move both front seats to original position.
  74. Exit Service Mode through UI. See Service Mode.
  75. Raise all windows and close all doors.