Tesla Model 3 Owners & Service Manuals

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

Tesla Model 3 2017-2025 Service Manual / Battery System / HV Battery Electrical Components / Contactor - Fast Charge - HV Battery (Remove and Replace) / Contactor - Fast Charge - HV Battery - Remove

Contactor - Fast Charge - HV Battery (Remove and Replace)

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).

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

  1. 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.

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

  1. Remove the insulator for the DC input assembly.

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

Contactor - Fast Charge - HV Battery - Remove

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

    READ NEXT:

     Contactor - Fast Charge - HV Battery - Install

    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

     Contactor - Negative - HV Battery (Remove and Replace)

     Contactor - Negative - 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) Magnet, Flexible, HV Insulated, 18" (1057607-00-A) Socket, 1/4" Dr, Deep,10 mm,Th

    SEE MORE:

     Solenoid - Glove Box (Remove and Replace)

    Remove Remove the glove box. See Glove Box (LHD) (Remove and Replace). Remove and discard the NVH pad from the glove box. Note: The NVH pad is one time use only. Release the clips that attach the glove box solenoid electrical harness to the glove box. Remove the bolts that

     Buckle - 1st Row - LH (Remove and Replace)

    Remove Open all four doors, lower all four windows, and then move both front seats forward. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace). Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace). Remove the LH ins

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