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
- Drain the coolant from the power conversion system. See
Penthouse Coolant (Drain and Refill).
- Remove the HV battery negative contactor. See
Contactor - Negative - HV Battery (Remove and Replace).
- Remove the power conversion system coolant output tube. See
Tube - Output - Coolant - Power Conversion System (Remove and Replace).
- Remove the clip that attaches the HV battery penthouse harness to the HV
battery fast charge contactor.
- Release the clips that attach the HV battery probing guide to the HV
battery and remove the guide from the penthouse.
- 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.
- Disconnect the HV battery AC inlet harness from the power conversion
system connector.
- Release the clips that attach the HV battery AC inlet harness cover to
the power conversion system.
- Remove the insulator for the DC input assembly.
- Remove and discard the bolts that attach the negative and positive
busbars to the DC links and DC input.
- Disconnect the electrical harness from the DC input assembly connector.
- Remove the bolts that attach the DC input assembly to the penthouse, and
then remove the DC input assembly from the vehicle.
- Remove the clips that attach the HV battery penthouse harness to HV
battery fast charge contactor cover.
- Remove the nut and bolts that attach the fast charge contactor to the
penthouse, and remove the contactor with the harness from the vehicle.
- Remove the HV battery AC inlet harness from the contactor. See
Harness - AC Inlet - HV Battery (Remove and Replace).
- Remove and discard the bolts that attach the busbars to the fast charge
contactor, and then remove the busbars from the contactor.
- Remove the bolts that attach the fast charge contactor to the insulator,
and remove the contactor from the insulator.
READ NEXT:
Install
Use IPA wipes to clean the high voltage mating surfaces of the fast
charge contactor and the positive and negative DC link and DC input busbars.
Install the HV battery fast charge contact
SPECIAL TOOLS
Ratchet, 1/4" Sq Dr, HV Insulated (1057602-00-A)
Ext Bar, Wobble, 1/4" Dr, HV Insulated (1057603-00-A)
Magnet, Flexible, HV Insulated, 18" (1057607-00-A)
Socket, 1/4" Dr, Deep,10 mm,Th
SEE MORE:
Note:
This procedure was formulated using a release candidate or production
model. Follow safety requirements and use extreme caution when working on or
near high-voltage systems and components.
Remove
Remove the LH and RH center console side panel carpets. See Carpet -
Side Panel - Center
Remove
Raise and support the vehicle.
Remove the rear underhood apron.
Remove the cabin intake duct.
Remove the hood latch cover.
Remove the underhood storage unit.
Remove the front fascia assembly.
Remove the front bumper.
Disconnect the electrical harness from the LH front end