Tesla Model 3: DC Input Assembly - HV Battery (Remove and Replace)

DC Input Assembly - HV Battery- Remove

SPECIAL TOOLS

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

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

Magnet, Flexible, HV Insulated, 18" (1057607-00-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. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).

2. Remove the insulator for the DC input assembly.

3. Remove and discard the bolts that attach the DC input busbars to the fast charge contactor busbars.

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

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

DC Input Assembly - HV Battery- Install

Install

1. Install the DC input assembly to the penthouse, install the bolts (x4) that attach the DC input assembly to the penthouse, and then mark the bolts with a paint pen after they are torqued. Torque 6 Nm

2. Install new bolts (x2) to attach the DC input busbars to the fast charge contactor busbars, and then mark the bolts with a paint pen after they are torqued. Torque 9 Nm

Generic Measurement - Actual busbars and fasteners might appear different

3. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive DC input busbar and the positive (LH) fast charge contactor 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.

Generic Measurement - Actual busbars and fasteners might appear different

4. Use the Hioki resistance meter to measure the resistance at the HV joint between the negative DC input busbar and the negative (RH) fast charge contactor 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.

5. Install the insulator for the DC input assembly.

6. Connect the electrical harness to the DC input assembly connector.
7. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).