Tesla Model 3: Contactor - Positive - HV Battery-Install

Install

Caution:

• Replace all patchbolts.
• Replace all nyloc nuts.

1. Use an IPA wipe to clean the high voltage mating surfaces of the HV battery terminal, positive busbar, and the HV battery positive contactor.
2. Tilt the rear of the HV battery positive contactor up, and then install the contactor into the penthouse.

3. Install the nuts (x3) that attach the HV battery positive contactor into the penthouse. Torque 8 Nm

4. 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

5. 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.

6. 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

7. 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.

8. Install the insulator caps to the HV battery positive contactor.

9. Connect the electrical harness to the HV battery positive contactor, and power conversion system LV and DC bus HV connectors.
10. Install the 12V DCDC passthrough. See Passthrough - DCDC - 12V (Remove and Replace).
11. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
12. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).

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