2026-08-09

分流器 - 高压电池（结构化电池组）（拆卸和更换）

校正代码 16303632 2.34 注意：除非本程序中另有明确规定，否则上文所列校正代码及相关 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。 注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。 注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。注意：请参阅人体工程学注意事项查看安全健康的作业规程。

  • 2026-07-09: Updated torquing method for bolt that attaches the shunt to the busbar and updated the steps to connect/disconnect the LV maintainer.
  • 2025-12-15: Updated the way of performing the Write Shunt Resistance routine from Toolbox to UI.
警告
本程序为“草案”。虽已通过验证，但可能仍有“警告”和“注意”事项缺失。请遵守安全要求，处理或靠近高压系统和部件时，请谨慎操作。

拆卸

  1. Open all four doors
  2. Lower all four windows
  3. Place vehicle in service mode with touchscreen
    注
    Hold Tesla T icon at top of center display for four seconds and then type "service" into dialog box
  4. Remove the ancillary bay cover. See 盖板 - 高压电池仓（结构化电池组）（拆卸和更换）.
  5. 拆下烟火电池隔离开关。请参阅烟火电池断接开关（结构化电池组）（拆卸和安装）。
  6. Disconnect the HV controller connectors (x7).
    注
    Lift the hinge upwards to release the levered connection.
  7. Release the harness clips (x3) from the HVC hinge tray and route the harness away.
  8. Remove bolts securing HV controller hinge tray to HV battery
    注
    2x bolts, 8mm, 2 Nm
  9. Remove the HV controller and tray from the ancillary bay.
  10. Disconnect PCS to DC bus HV connector
    注
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  11. Disconnect PCS logic connector from PCS
    注
    1x connector
  12. Disconnect PCS LV connector from PCS
    注
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  13. Remove bolts securing PCS to HV battery
    注
    6x bolts, 8mm, 6 Nm, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners
  14. Disconnect shunt assembly
    注
    1x connector
  15. Disconnect fast charge contactor
    注
    1x connector, Push on both side of connector to release tabs and pull upward
  16. Release shunt harness branch from tray
    注
    1x clip
  17. Remove bolt securing AC filter harness to negative DC inlet busbar
    注
    1x bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
  18. Remove bolt securing AC filter harness positive DC inlet busbar
    注
    1x bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Discard after removal
  19. Release AC filter harness from tray
    注
    2x clips
  20. Disconnect AC filter harness
    注
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
  21. Remove AC filter harness from ancillary bay
  22. Lift front side of PCS and support
    注
    Recommend assistance, Be cautious of coolant hoses and surrounding components. Use air bladder and plastic tool or similar to keep PCS upright
  23. Remove flex jumper busbar insulator
    注
    8x securing tabs, Be very gentle when releasing these tabs as they are very brittle, If damage occurs, replace insulator
  24. Remove bolt securing shunt assembly
    注
    1x bolt, 13mm, 5 Nm + 60 degrees, Discard bolt after removal
  25. Remove pyro disconnect dummy cover
  26. Remove shunt assembly from ancillary bay
    注
    Use trim tool to lift one side to ease removal

安装

  1. Position shunt assembly into ancillary bay
  2. Install pyro disconnect dummy cover
  3. Install a new bolt that attaches the shunt assembly.
  4. Perform Hioki measurement at joint from shunt to shunt pyro jumper busbar
    注
    1x HV joint, 60µΩ or less
  5. Install flex jumper busbar insulator
    注
    8x securing tabs, If damage is present, replace insulator
  6. Lower front side of PCS back into position for installation
    注
    Remove tooling supporting PCS
  7. Install bolts securing PCS to HV battery
    注
    6x bolts, 8mm, 6 Nm
  8. Connect PCS to DC bus HV connector
    注
    1x connector, Secure connector and engage red locking tab, Make sure the connector is fully seated
  9. Connect PCS logic connector to PCS
    注
    1x connector
  10. Connect PCS LV connector to PCS
    注
    1x connector, Secure connector and engage red locking tab, Make sure the connector is fully seated
  11. Connect PCS to fastcharge contactor HV harness connector
    注
    1x connector, Secure connector and engage red locking tab, Make sure the connector is fully seated
  12. Secure AC filter harness onto tray
    注
    2x clips
  13. Install bolt securing AC filter harness positive DC inlet busbar
    注
    1x bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Install new bolt
  14. Install bolt securing AC filter harness to negative DC inlet busbar
    注
    1x bolt, 13mm, 15 Nm, Minus 180 degrees, 5 Nm + 60 degrees, Install new bolt
  15. Perform Hioki impedance measurement at joint from AC filter harness to positive DC inlet busbar
    注
    1x HV joint, 150µΩ or less
  16. Perform Hioki impedance measurement at joint from AC filter harness to negative DC inlet busbar
    注
    1x HV joint, 150µΩ or less
  17. Secure shunt harness branch onto tray
    注
    1x clip
  18. Connect fast charge contactor
    注
    1x connector, Push on both side of connector to release tabs and pull upward
  19. Connect shunt assembly
    注
    1x connector
  20. 测量烟火电池隔离开关安装点间的电压，然后安装烟火电池隔离开关。请参阅烟火电池断接开关（结构化电池组）（拆卸和安装）。
  21. Inspect ancillary bay phantom seal to verify no damage is present
    注
    If damage is present, Replace ancillary bay phantom seal
  22. Install ancillary bay cover onto HV battery
    注
    Recommend assistance, Guide LH side in, Maneuver cover past body casting and into position with charge port components
  23. Install perimeter bolts securing ancillary bay to HV battery
    注
    22x captured bolts, EPL 10, 5 Nm, Thread bolts in evenly and torque
  24. Secure doubler and install fasteners securing charge port header to ancillary bay cover
    注
    2x bolts, 10 EPL, 10 Nm, Secure doubler onto header and install bolts, Take note of small tabs on shielding
  25. Install fasteners securing PCS LVDC header to ancillary bay cover
    注
    3x bolts, T20, 2.5 Nm
  26. Install fasteners securing ancillary bay cover to high voltage controller
    注
    3x bolts, E10, 10 Nm
  27. Install NVH insulation onto ancillary bay cover
  28. Connect power connector to HV battery
    注
    1x connector, Push red locking tab down to secure connection
  29. Connect HVC logic connector
    注
    1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
  30. Clean busbar HV connector contact surface of residual Penetrox
    注
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  31. Clean HV connector contact surface of residual Penetrox
    注
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  32. Apply Penetrox onto HV connector joints
    注
    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
  33. Position busbar kit connector and lower onto HV header
  34. Install bolts securing charge port busbar kit to HV Header
    注
    2x bolts, 10mm, 9 Nm
  35. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    注
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 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 lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
  36. Install fastener securing busbar cover access door
    注
    1x bolt, 10mm, 9 Nm
  37. Remove HV insulating gloves
  38. Engage LH body harness onto rear body
    注
    1x clip
  39. Raise vehicle fully and lower lift onto locks
    注
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  40. Secure RDU HV harness onto HV battery
    注
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
  41. Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
    注
    11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
  42. Install push clips at left and right wheel house liner to mid aero shield
    注
    2x clips
  43. Lower vehicle fully
    注
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  44. Connect first responder loop and leave LV battery disconnected
    注
    1x connectors, Secure FRL only, Leave LV battery disconnected
  45. Connect 12V/LV power. See 12V/低压电源（断开和连接）.
  46. Connect a LV maintainer. See 低压维护设备（连接和断开）.
  47. Remove the HVC bolt
    注
    1x bolt, E10, 5 Nm + 30 degrees
  48. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  49. SelectHigh Voltage > Procedures > Shunt Replacement > Write Shunt Resistance and WRITE operation, enter the shunt bar resistance value previously recorded, and select corresponding shunt type based on the Part number. Click Run and allow the routine to complete.
    注
    The unit of the input resistance value is nΩ.
    注
    Shunt types includes Vishay whose part number looks like 2084224-XX-X and Cyntec whose part number looks like 1078835-XX-X or 1588177-XX-X.
  50. Disconnect the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
  51. Install HVC bolt
    注
    1x bolt, E10, 5 Nm + 30 degrees
  52. Disconnect the LV maintainer. See 低压维护设备（连接和断开）.
  53. Install washer tank neck to washer tank
    注
    1x O-ring, Ensure washer hose is properly routed after installation
  54. Secure frunk to washer fluid reservoir neck
    注
    1x bolt, 10mm, 5 Nm
  55. Install the rear underhood apron. See 前备箱挡板 - 后部（拆卸和更换）.
  56. Install the RH 2nd row seat back. See 座椅靠背 - 第二排 - RH（拆卸和更换）.
  57. Install the RH lower c-pillar trim. See 饰板 - C 柱 - 下 - 左侧（拆卸和更换）.
  58. Install the LH 2nd row seat back. See 座椅靠背 - 第二排 - 左侧（拆卸和更换）.
  59. Install the LH lower c-pillar trim. See 饰板 - C 柱 - 下 - 左侧（拆卸和更换）.
  60. Install clips securing rear main cabin carpet to vehicle
    注
    3x push clips
  61. Install the 2nd row lower seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
  62. Move LH front seat to original position
  63. Move RH front seat to original position
  64. Exit Service Mode through UI
    注
    Controls > Service Mode > Exit Service Mode
  65. Remove vehicle from lift
    注
    Lower rack arms fully and remove from under vehicle
  66. Raise all four windows
  67. Close all four doors
    注
    If 12V is powered up, Unlatch rear doors before closing