SB-18-16-006

Tesla, Inc.

September 13, 2018

Service Bulletin

Replace Positive Busbar Nut and Additional Bolts
Classification

Campaign Bulletin

Section/Group

16 - HV Battery
System

Country/Region

United States,
Canada

Year

2018

Model

Model 3

Version

All

Bulletin Classification: This campaign bulletin addresses a known non-safety-related condition and provides
recommended technical diagnosis and repair procedures. Apply this procedure to all vehicles in the affected VIN range
listed. These instructions assume knowledge of motor vehicle and high voltage electrical component repairs, and should
only be executed by trained professionals. Tesla assumes no liability for injury or property damage due to a failure to
properly follow these instructions or repairs attempted by unqualified individuals.

Condition
On certain Model 3 vehicles, the positive busbar nut under the power conversion system and additional bolts within the
High Voltage (HV) battery penthouse were insufficiently torqued during manufacturing.

Correction
Replace and properly torque the positive busbar nut and the bolts.

Correction Description

Correction

Time

SB-18-16-006 Not Applicable

S011816006

0.0

Replace And Torque Busbar Nut And Additional Bolts

S021816006

2.5

Required Part(s): Part Number
1108958-00-A
1108907-00-A
1117669-00-A
1104475-00-C
1093060-00-A
1115916-00-A
2007104-00-B
1117252-00-A
1111033-00-D
If necessary:
1467483-00-A

Description
SEAL,PROBE LID,HVBAT
BREATHER, NITTO Z-PLUG-S
BOLT,5-LOBE,M6X19,[109],ZNNI,MAT,PTP,SEAL
BOLTANDWSHR[DBL],M8X23,STL ZNFL,SDOG ADH
NUT&WSHR,M8,STL[9],DOUBLE SEMS
BOLT,TE,M6X14,[88],ZNNI,SEAL,SDOG
NUT HFPT M8X1.25 [10]-ZNNI
BOLT,HF,M12X40,STL [109],ZN,ADH,MAT
M3 2R BOLSTER CLIP

Quantity
1
1
2
5
1
5
1
2
1

KIT, PENTHOUSE HV INSULATORS, M3

1

Shop supplies:
Absorbent pads
Tesla G-48 Coolant (1012820-00-A)
Butyl rope

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These part numbers were current at the time of publication. Use the revisions listed or later,
unless otherwise specified in the Parts Manual.
Special Tool(s):

1076927-00-A
1126496-00-B
1059330-00-B
1144879-00-A
1026636-00-A
1132185-00-B
1133843-00-A
1135762-00-A
1053600-00-C
1108272-00-B
1133603-00-A
1131071-00-A
1050448-00-A
1111868-00-B
1057602-00-A
1057603-00-A
1057607-00-A
1133768-00-A
1057606-00-A
1127845-00-A

Resistance meter, microohm, Hioki RM 3548
Wrench, Torque+Angle, 3/8" DR
Skt, 1/4in Dr, 5-Lobe Torx External
Kit, Encl Leak Test Adapters, HV Battery
Pack Enclosure Leak Tester, HV Battery
Kit, Coolant Leak Test Adapters, Model 3
Kit, Coolant Drain & Fill Adapters, M3
Kit, Svc Plug, Cooling Hose, Model 3
Drive Unit Pressure Test Fixture
Cap, Logic Conn, Inv, 3DU
Kit, HV Pyro-disconnect Replacement, BRP
Dummy Disconnect, Pyro, Safety
Refiller, Cooling System
Connector Removal, Coolant, PCS, M3
Ratchet, 1/4" Sq Dr, HV Insulated
Ext Bar, Wobble, 1/4" Dr, HV Insulated
Magnet, Flexible, HV Insulated, 18"
Socket, 1/4" Dr, Deep,10 mm,Thin Wall, Insul
Skt, 1/4" Sq Dr, 13mm, HV Insulated
Asy, Service Cover, Penthouse, Model 3

Procedure
1. Remove the power conversion system (refer to Service Manual procedure 16301002).
2. Remove the insulator cap from the HV positive busbar joint nut (Figure 1).

Figure 1

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3. Remove and discard the nut that attaches the positive busbars at the joint (Figure 2).

Figure 2
4. Install a new nut to attach the positive busbars at the joint, and then mark the nut with a paint pen after it is torqued
(torque 5 Nm +35°) (Figure 2).
5. Use the Hioki resistance meter to measure the resistance at the HV joint between the positive busbars (Figure 3).
NOTE: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a
Toolbox session, as appropriate.

Figure 3
6. Install the insulator cap onto the HV positive busbar joint nut (Figure 1).

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7. Remove the insulator cap from the HV battery positive contactor output terminal bolt (Figure 4).

Figure 4
8. Remove and discard the bolt that attaches the HV battery positive contactor to the positive busbar (Figure 5).

Figure 5
9. 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 5 Nm +60°) (Figure 5).

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10. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor
and the positive busbar (Figure 6).
NOTE: The maximum acceptable resistance is 0.060 mΩ (60 μΩ). If the resistance is above this value, escalate a
Toolbox session, as appropriate.

Figure 6
11. Install the insulator cap onto the HV battery positive contactor output terminal bolt (Figure 4).
12. Release the clips that attach the fuse access insulator to the penthouse, and then remove the insulator from the
penthouse (Figure 7).

Figure 7

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13. Remove and discard the bolts that attach the positive and negative busbars to the rear drive unit HV header (Figure
8).

Figure 8
14. Install new bolts to attach the positive and negative busbars to the rear drive unit HV header, and then mark the bolts
with a paint pen after they are torqued (torque 5 Nm +60°) (Figure 8).
15. Use the Hioki resistance meter to measure the resistance at the HV joint between the rear drive unit HV header and
the busbar at each bolt (Figure 9).
NOTE: The maximum acceptable resistance is 0.070 mΩ (70 μΩ). If the resistance is above this value, escalate a
Toolbox session, as appropriate.

Figure 9
16. Install the fuse access insulator, and then fasten the clips that attach the insulator to the penthouse (Figure 7).
17. Install the power conversion system (refer to Service Manual procedure 16301002).
Affected VIN(s)

Affected Model 3 vehicles built between approximately July 5, 2018 and July 12, 2018.
NOTE: This is a simplified summary of the affected VIN list. Refer to the VIN/Bulletin Tracker or
Customer/Vehicle profile to determine applicability of this bulletin for a particular vehicle.

For feedback on the accuracy of this document, email ServiceBulletinFeedback@tesla.com.

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