Tesla Model 3: Insulators - HV Battery (Install)
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.
Install
Note: This procedure supplements removing the penthouse
cover for when HV insulators are missing. After completing this procedure,
continue to the procedure that required the penthouse cover to be removed.

- Install the squarish insulator caps onto the pyrotechnic battery
disconnect busbar bolt heads.
.png)
- Install the round insulator caps onto the HV battery positive contactor
busbar bolt heads.
.png)
- Install the round insulator caps onto the HV battery negative contactor
busbar bolt heads.
.png)
- Raise the high voltage controller, install the fuse access insulator
onto the RH penthouse bus cover, fasten the clips that attach the insulator
to the cover, and lower the high voltage controller.
.png)
- Install the special insulator onto the DC input assembly busbar bolt
heads.

- Install the AC inlet terminal covers over the positive and negative ring
terminal bolts, and fasten the clips that attach the AC inlet terminal
covers to the HV battery fast charge contactor cover.
- Continue to the procedure that required the penthouse cover to be
removed.
READ NEXT:
SPECIAL TOOLS
Skt, 1/4in Dr, 5-Lobe Torx Plus External (1059330-00-B)
Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)
Remove
Remove the high voltage controller. See
Controller - High Vol
Install
Use an IPA wipe to clean the mating surfaces of the DCDC passthrough,
and the DCDC harness.
Install the 12V DCDC passthrough into the penthouse, install the bolts
that attach the 1
SEE MORE:
SPECIAL TOOLS
Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)
Wrench, Diverter Valve, Model 3 (1447556-00-A)
Remove
Remove the superbottle. See Superbottle (Dual Motor) (Remove and
Replace).
Remove the screws that attach the 5-way valve actuator to the 5-way
valve cover.
Remove
Warning: The side impact airbag deployment depends on the front door
sensor's ability to detect a side impact from air pressure. Make sure that there
are no uncovered holes in the front door shells. Additionally, always reinstall
plugs or tape when servicing or inspecting the front doors and thei