Tesla Model 3: Contactor - Positive - HV Battery-Install
Install
Caution:
- Replace all patchbolts.
- Replace all nyloc nuts.
- Use an IPA wipe to clean the high voltage mating surfaces of the HV
battery terminal, positive busbar, and the HV battery positive contactor.
- Tilt the rear of the HV battery positive contactor up, and then install
the contactor into the penthouse.
- Install the nuts (x3) that attach the HV battery positive contactor into
the penthouse.
Torque 8 Nm
- Install a new nut to attach the HV battery positive contactor onto the
HV battery terminal, and then mark the nut with a paint pen after it is
torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear
different
- Use the Hioki resistance meter to measure the resistance at the HV joint
between the HV battery positive contactor and the HV battery terminal.
Note: The maximum acceptable resistance is 0.110 mΩ (110 μΩ). If
the resistance is above this value, escalate a Toolbox session, as appropriate.
- Install a new bolt to attach the HV battery positive contactor onto the
positive busbar, and then mark the bolt with a paint pen after it is torqued.
Torque 9 Nm
Generic Measurement - Actual busbars and fasteners might appear
different
- Use the Hioki resistance meter to measure the resistance at the HV joint
between the HV battery positive contactor and the positive busbar.
Note: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the
resistance is above this value, escalate a Toolbox session, as appropriate.
- Install the insulator caps to the HV battery positive contactor.
- Connect the electrical harness to the HV battery positive contactor, and
power conversion system LV and DC bus HV connectors.
- Install the 12V DCDC passthrough. See
Passthrough - DCDC - 12V (Remove and Replace).
- Install the high voltage controller. See
Controller - High Voltage (Remove and Replace).
- Install the pyrotechnic battery disconnect into the penthouse. See
Pyrotechnic Battery Disconnect (Remove and Replace).
READ NEXT:
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 minimu
Install
If a new 4-bolt high voltage controller is replacing an old 5-bolt high
voltage controller, perform these additional steps to retrofit a 28-bolt
penthouse cover with an aluminum retrofit
SEE MORE:
Install
Inspect the condition of the LH front door and the LH front door trim
panel. Replace any broken clips and repair any damage.
Bring the trim panel to the door, and rest it on the door edge.
If present, remove and discard the highlighted clip.
Route the harness as illustrated,
Remove
Remove the 2nd row lower seat cushion. See
Seat Cushion - Lower - 2nd Row (Remove and Replace).
Remove the LH 2nd row seat side bolster. See
Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
Remove the LH 2nd row seat back. See
Seat Back - 2nd Row - LH (Remove and Install).