Tesla, Inc.

Service Bulletin

SB-18-16-006
December 28, 2023

R1

Replace Positive Busbar Nut and Additional
Bolts

Classification

Section/Group

Mobile Service

Model Year

Country/Region

Build Location

Campaign Bulletin

2018

16 - HV Battery System

Model

Model 3

United States, Canada

Cannot Perform

Configuration
All

Fremont

The model(s) and model year(s) listed are a general approximation 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.

Campaign Bulletin: This campaign bulletin addresses a non-safety-related condition and provides recommended technical diagnosis
and repair procedures. Apply this procedure to the applicable vehicles.

This Service Document supersedes SB-18-16-006, dated September 13, 2018. This new revision, R1, updates the word
“penthouse” to “ancillary bay”. Each content change is marked by a vertical line in the left margin. Discard the previous
version and replace it with this one.

Condition
On certain Model 3 vehicles, the positive busbar nut under the power conversion system and additional bolts within the
High Voltage (HV) battery ancillary bay 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

Replace And Torque Busbar Nut And Additional Bolts

S021816006

3

Part Number

Description

Quantity

Parts Required

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

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

Q1
1
2
5
1
5
1
2
1

If Necessary

1467483-00-A

KIT, ANCILLARY BAY HV INSULATORS, M3

1

These part numbers were current at the time of publication. Use the revisions listed or later, unless
otherwise specified in the Parts Catalog.

Special Tools

SB-18-16-006 R1

1076927-00-A
1126496-00-B
1059330-00-B
1144879-00-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
Page 1 of 6

Shop Supplies

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

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, Ancillary Bay, Model 3

1012820-00-A

Tesla G-48 Coolant
Butyl rope
Absorbent pads

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

SB-18-16-006 R1

Page 2 of 6

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).

SB-18-16-006 R1

Page 3 of 6

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).

SB-18-16-006 R1

Page 4 of 6

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 ancillary bay, and then remove the insulator from the
ancillary bay (Figure 7).

Figure 7

SB-18-16-006 R1

Page 5 of 6

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 ancillary bay (Figure 7).
17. Install the power conversion system (refer to Service Manual procedure 16301002).

SB-18-16-006 R1

Page 6 of 6
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