Tesla Model 3: Contactor - Fast Charge - HV Battery - Remove

SPECIAL TOOLS

Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)

Ext Bar, Wobble, 1/4" Dr, HV Insulated (1057603-00-A)

Skt, 1/4" Sq Dr, 13mm, HV Insulated (1057606-00-A)

Magnet, Flexible, HV Insulated, 18" (1057607-00-A)

Connector Removal, Coolant, PCS, M3 (1111868-00-B)

Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)

Skt, 1/4in Dr, 5-Lobe Torx Plus External (1059330-00-B)

Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)

Warning:

Only technicians who have been trained in High Voltage Awareness 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.

Remove

1. Drain the coolant from the power conversion system. See Penthouse Coolant (Drain and Refill).
2. Remove the HV battery negative contactor. See Contactor - Negative - HV Battery (Remove and Replace).
3. Remove the power conversion system coolant output tube. See Tube - Output - Coolant - Power Conversion System (Remove and Replace).

1. Remove the clip that attaches the HV battery penthouse harness to the HV battery fast charge contactor.

5. Release the clips that attach the HV battery probing guide to the HV battery and remove the guide from the penthouse.

6. Disconnect the electrical harness from the HV battery fast charge contactor connector.

Note: Squeeze the tabs on either side of the harness connector, to release the tabs from the contactor connector.

Caution:

Do not pry the connectors apart, as this action breaks the tabs and connectors, and necessitates harness replacement.

7. Disconnect the HV battery AC inlet harness from the power conversion system connector.

8. Release the clips that attach the HV battery AC inlet harness cover to the power conversion system.

9. Remove the insulator for the DC input assembly.

10. Remove and discard the bolts that attach the negative and positive busbars to the DC links and DC input.

11. Disconnect the electrical harness from the DC input assembly connector.

12. Remove the bolts that attach the DC input assembly to the penthouse, and then remove the DC input assembly from the vehicle.

13. Remove the clips that attach the HV battery penthouse harness to HV battery fast charge contactor cover.

14. Remove the nut and bolts that attach the fast charge contactor to the penthouse, and remove the contactor with the harness from the vehicle.
15. Remove the HV battery AC inlet harness from the contactor. See Harness - AC Inlet - HV Battery (Remove and Replace).

16. Remove and discard the bolts that attach the busbars to the fast charge contactor, and then remove the busbars from the contactor.

17. Remove the bolts that attach the fast charge contactor to the insulator, and remove the contactor from the insulator.

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