Tesla Model 3: Pyrotechnic Battery Disconnect (Remove and Replace)

Pyrotechnic Battery Disconnect- 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)

Asy, Service Cover, Penthouse, Model 3 (1127845-00-A)

Dummy Disconnect, Pyro, Safety (1131071-00-A)

Kit, HV Pyro-disconnect Replacement, BRP (1133602-00-A )

Cap, Logic Conn, Inv, 3DU (1108272-00-B)

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

Warning: Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning: If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.

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 penthouse cover. See Cover - Penthouse (Remove and Replace).

Warning: HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.

2. If the logic connector cap is installed on the high voltage controller connector, remove it.
3. Set the penthouse service cover over the penthouse.

1st Generation

4. Remove the pyrotechnic battery disconnect shunt insulator(s).

2nd Generation

5. Remove and discard the bolts that attach the pyrotechnic battery disconnect to the HV battery, and then remove the pyrotechnic battery disconnect from the vehicle.

6. Install the dummy disconnect where the pyrotechnic battery disconnect was removed.

Pyrotechnic Battery Disconnect- Install

Install

1. Remove the dummy disconnect from where the pyrotechnic battery disconnect will install.
2. Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pryotechnic battery disconnect.

3. Position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect.

4. Install the new bolts that attach the pyrotechnic battery disconnect to the HV battery, and then mark the bolts with a paint pen after they are torqued. Torque 9 Nm

5. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the LH 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

6. Use the Hioki resistance meter to measure the resistance at the HV joint between the newly-installed pyrotechnic battery disconnect and the shunt.

Note: The maximum acceptable resistance is 0.045 mΩ (45 μΩ). If the resistance is above this value, escalate a Toolbox session, as appropriate.

1st Generation

2nd Generation

7. Install the pyrotechnic battery disconnect shunt insulator(s).
8. Remove the penthouse service cover from the penthouse.
9. Install the penthouse cover. See Cover - Penthouse (Remove and Replace).