SB-18-16-013

R1

Tesla, Inc.

September 25, 2019

Service Bulletin

Inspect HV Battery Positive Contactor Fasteners
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.
This Service Document supersedes SB-18-16-013, dated 7-Dec-18. Each content change is marked by a vertical line in
the left margin. Discard the previous version and replace it with this one.

Condition
Certain Model 3 vehicles might have too few HV battery positive contactor mounting nuts installed, which can allow
movement that might affect the conductivity of the contactor terminals.

Correction
Inspect the vehicle for symptoms related to the condition. If symptoms are present, replace the mounting nuts, the
terminal fasteners, or the contactor itself.

Correction Description

Correction

Time

SB-18-16-013 Not Applicable

S011816013

0.00

Inspect Contactor, Fasteners Check OK

S021816013

1.00

Install Insulators, Inspect Contactor, Fasteners Check OK

S031816013

1.00

Inspect Contactor, Replace Fasteners

S041816013

1.05

Install Insulators, Inspect Contactor, Replace Fasteners

S051816013

1.10

Inspect And Replace Contactor

S061816013

1.35

Install Insulators, Inspect And Replace Contactor

S071816013

1.35

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Required Part(s): Part Number
1117669-00-A
1108907-00-A
1115916-00-A
1117252-00-A
1093060-00-A
If necessary:
1108958-00-A
1467483-00-A
2007207-00-A
1093060-00-A
2007104-00-B
1104475-00-C
1089334-00-H

Description
BOLT,5-LOBE,M6X19,[109],ZNNI,MAT,PTP,SEAL
BREATHER, NITTO Z-PLUG-S
BOLT,TE,M6X14,[88],ZNNI,SEAL,SDOG
BOLT,HF,M12X40,STL [109],ZN,ADH,MAT
NUT&WSHR,M8,STL[9],DOUBLE SEMS

Quantity
2
1
4-5
2
1

SEAL,PROBE LID,HVBAT
KIT, PENTHOUSE HV INSULATORS, M3
NUT HF M6-1.00[8]ZnAl
NUT&WSHR,M8,STL[9],DOUBLE SEMS
NUT HFPT M8X1.25 [10]-ZNNI
BOLTANDWSHR[DBL],M8X23,STL ZNFL,SDOG ADH
ASY, SWITCH, HV

1
1
3
1
1-2
1-2
1

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

1076927-00-A
1076928-00-A
1076921-00-B
1130480-00-A
1059330-00-B
1026636-00-A
1140501-00-A
1144879-00-A
1455410-00-A
1108272-00-B

Resistance meter, microohm, Hioki RM3548
Test Probes, Hioki 9461
Insulation Multimeter, Fluke 1507
Test Probes, Slim, Fluke TP38
Skt, 1/4in Dr, 5-Lobe Torx External
Pack Enclosure Leak Tester, HV Battery
Pack Kit, Enclosure, Leak Test, HV Battery, Complete
Kit, Encl Leak Test Adapters, HV Battery
Kit, Dummy Plug
Cap, Logic Conn, Inv, 3DU

Procedure
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.
1. Use the laptop to go to the Penthouse HV Joint Resistance Measurements webpage.
NOTE: Tesla credentials might be required to view and fill out the form.
2. In section 1, click on the calendar icon and select the date the service is being performed.
3. In section 2, type the vehicle’s VIN into the field.
4. Keep the webpage open to enter additional measurements in later steps.
5. Remove the penthouse cover (refer to Service Manual procedure 16101002).
NOTE: Install insulators if they are not installed (refer to Service Manual procedure 16302001).
6. Perform a zero adjust of the Hioki resistance meter (refer to Service Manual procedure 16300100).
7. Remove the insulator from the DC input busbar joints.

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8. Use the Hioki resistance meter to measure the resistance at the HV joint between the DC input negative busbar and
the fast charge contactor negative input (Figure 1).

Figure 1
9. Type the measured resistance in mOhms into section 3 of the Penthouse HV Joint Resistance Measurements
webpage.
NOTE: For example, if the resistance was 0.57 mOhms, type “0.57” into the field in section 3.
10. Use the Hioki resistance meter to measure the resistance at the HV joint between the DC input positive busbar and
the fast charge contactor positive input (Figure 2).

Figure 2
11. Type the measured resistance in mOhms into section 4 of the Penthouse HV Joint Resistance Measurements
webpage.
NOTE: For example, if the resistance was 0.55 mOhms, type “0.55” into the field in section 4.
12. Install the insulator onto the DC input busbar joints.

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13. Raise the high voltage controller to a vertical position (Figure 3).

Figure 3
14. Remove the insulator caps from the HV battery positive contactor (Figure 4).

Figure 4
15. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor
and the positive DC busbar (Figure 5).

Figure 5
16. Type the measured resistance in mOhms into section 5 of the Penthouse HV Joint Resistance Measurements
webpage.
NOTE: For example, if the resistance was 0.50 mOhms, type “0.50” into the field in section 5.
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17. Verify that all fields of the Penthouse HV Joint Resistance Measurements webpage are correctly filled out, and then
click Submit.
18. Visually inspect the nuts that attach the HV battery positive contactor to the penthouse floor (Figure 6).
•
•

If there are 3 nuts installed, skip to step 31.
If there are less than 3 nuts installed, describe which nuts are missing in the Cause Narrative field of the Repair
Order, and then continue to the next step.

Figure 6
19. Remove and discard the nuts that attach the HV battery positive contactor to the penthouse floor (Figure 6).
20. Install 3 new nuts to attach the HV battery positive contactor to the penthouse floor (torque 8 Nm) (Figure 6), and then
mark the nuts with a paint pen after they are torqued.
21. Visually inspect the positive DC busbar and insulator near the HV battery positive contactor, and where the busbar
attaches to the contactor, for any signs of damage (Figure 7).
•

If damage is seen, take photographs of the damage. Create a Toolbox session, attach the photos to the session,
and indicate Toolbox Article #44198 as the problem. Escalate the session, and wait for further instruction.

•

If damage is not seen, continue to the next step.

Figure 7

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22. Use the Hioki resistance meter to measure the resistance again at the HV joint between the HV battery positive
contactor and the positive DC busbar (Figure 8).

Figure 8
23. If the resistance at the HV joint between the HV battery positive contactor and the positive DC busbar:
•
•

Is 0.06 mOhms (60 µOhms) or less, skip to step 26.
Is greater than 0.06 mOhms (60 µOhms), continue to the next step.

24. Remove and discard the bolt, install a new bolt (torque 9 Nm), and then mark the bolt with a paint pen after it is
torqued.
25. Use the Hioki resistance meter to measure the resistance again at the HV joint between the HV battery positive
contactor and the positive DC busbar (Figure 8).
26. If the resistance:
•
•

Is 0.06 mOhms (60 µOhms) or less, skip to step 26.
Is still greater than 0.06 mOhms (60 µOhms), record the resistance in the Cause Narrative field of the Repair
Order, and then skip to step 33.

27. Use the Hioki resistance meter to measure the resistance at the HV joint between the HV battery positive contactor
and the center of the HV battery positive terminal (Figure 9).

Figure 9
28. If the resistance:
•
•

Is 0.11 mOhms (110 µOhms) or less, skip to step 31.
Is greater than 0.11 mOhms (110 µOhms), continue to the next step.

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29. Remove and discard the nut, install a new nut (torque 9 Nm), and then mark the nut with a paint pen after it is
torqued.
30. Use the Hioki resistance meter to measure the resistance again at the HV joint between the HV battery positive
contactor and the center of the HV battery positive terminal (Figure 9).
31. If the resistance:
•
•

Is 0.11 mOhms (110 µOhms) or less, skip to step 31.
Is still greater than 0.11 mOhms (110 µOhms), record the resistance in the Cause Narrative field of the Repair
Order, and then skip to step 33.

32. Install the insulator caps onto the HV battery positive contactor (Figure 4).
33. Lower the high voltage controller (Figure 3), and then skip to step 35.
34. Perform all of the steps to remove and discard the HV battery positive contactor (refer to Service Manual procedure
16302102).
35. Perform all of the steps to install a new HV battery positive contactor (refer to Service Manual procedure 16302102).
36. Install the penthouse cover and connect 12V power (refer to Service Manual procedure 16101002).

Affected VIN(s)

Affected Model 3 vehicles built between approximately May 1, 2018 and May 19, 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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