Tesla, Inc.

Service Bulletin

SB-20-16-003
December 28, 2023

Inspect Contactor DC Link Busbar Bolts

R1

Classification

Section/Group

Mobile Service

Model Year

Country/Region

Build Location

Campaign Bulletin

2018 - 2019

Model

Model 3

16 - HV Battery System

North America, Europe, Asia Pacific

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 known non-safety-related condition and provides recommended technical
diagnosis and repair procedures. Apply this procedure to all vehicles in the affected VIN list.

This Service Document supersedes SB-20-16-003, dated July 14, 2020. This new revision, R1, updates the word
“penthouse” to “ancillary”. 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 high voltage batteries may not have a sufficient quantity of bolts for the contactor DC link busbars,
which may prevent the vehicle from charging or powering properly.

Correction
Inspect the vehicle for symptoms related to the condition. If symptoms are present, install a sufficient quantity of bolts,
install contactors, or if conditions warrant, escalate a Toolbox session for further instruction.

Correction Description

Correction

Time

Inspect Contactor DC Link Busbar Bolts; Sufficient Quantity

S022016003

0.85

Inspect Contactor DC Link Busbar Bolts And Install Sufficient Quantity Of Bolts

S032016003

0.95

Inspect Contactor DC Link Busbar Bolts And Replace Negative Contactor

S042016003

1.05

Inspect Contactor DC Link Busbar Bolts And Replace Positive Contactor

S052016003

1.25

Inspect Contactor DC Link Busbar Bolts And Replace Both Contactors

S062016003

1.30

Inspect Contactor DC Link Busbar Bolts And Escalate Toolbox Session

S072016003

0.45

SB-20-16-003 Not Applicable

Part Number

S012016003

Description

0.00

Quantity

Parts Required 1117669-00-A
1093060-00-A
1508009-00-A
1117252-00-A

BOLT,5LOBE,M6x19,[109],ZNNI,MAT,PTP,SEAL
NUT&WSHR,M8,STL[9],DOUBLE SEMS
BOLT,TE,M6-1.0x14,[88],G1009,CA
BOLT,HF,M12x40,STL[109],ZN,ADH,MAT

2
1
5
2

If Necessary 1089334-02-J
1104654-00-B
1104475-00-F
1467483-00-A

ASY,PACK CONTACTORS,SWITCH,HV
NUT&WSHR[DBL],M8,BRS,SEALER
DSEMS,HX,M8-1.25x23,[98],G1009,SDOG,WAX
KIT, PENTHOUSE HV INSULATORS, M3

1-2
1-2
2-4
1

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

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SB-20-16-003
_

Special Tools 1076927-00-A
1126496-00-B
1059330-00-B
1053600-00-C
1108272-00-B
1133603-00-A
1131071-00-A
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
Drive Unit Pressure Test Fixture
Cap, Logic Conn, Inv, 3DU
Kit, HV Pyro-disconnect Replacement, BRP
Dummy Disconnect, Pyro, Safety
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

Shop Supplies Paint pen

Procedure
1. Prepare the Hioki resistance meter (refer to Service Manual procedure 16300100).
2. Disconnect 12V power (refer to Service Manual procedure 17010200).
3. Perform the vehicle isolation procedure (refer to Service Manual procedure 17010000).
4. Remove the ancillary cover, however do not install insulators at this time (refer to Service Manual procedure
16101002).

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SB-20-16-003
_

5. Inspect the negative contactor for the negative DC link busbar bolt, and the positive contactor for the positive DC
link busbar bolt (Figures 1 and 2).
•
•

If both bolts are present, skip to step 13.
If any bolt is missing (Figures 3 and 4), take very close up photos of the contactor and DC link busbar joint
where the bolts are missing, and then upload the photos to the Repair Order. Continue to the next step.

Figure 1 — Negative DC link busbar bolt present

Figure 2 — Positive DC link busbar bolt present

Figure 3 — Negative DC link busbar bolt missing

Figure 4 — Positive DC link busbar bolt missing

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SB-20-16-003
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6. Closely inspect the contactors and DC link busbar joints where the bolts are missing for discoloration (Figure 5),
melting (Figure 5), or burn marks evident of arcing (Figures 5 and 6).
•
•
•

If both contactors appear in good condition, without burn marks, skip to step 8.
If either contactor appears discolored or melted, but without burn marks, skip to step 7.
If there are any burn marks, regardless of discoloration or melting, escalate a toolbox session and wait for
further instruction.

Figure 5 — Discoloration, melting, and arcing burn
at negative DC link busbar joint

Figure 6 — Arching burn at positive DC link busbar
joint

7. Replace the discolored/melted contactors with new components, and then skip to step 9:
•
•

Negative contactor – Refer to Service Manual procedure 16302002
Positive contactor – Refer to Service Manual procedure 16302102

NOTE: Use a paint pen to mark “SB-20-16-003” on the affected contactors, and then return the contactors to
MRB.
8. Remove the pyrotechnic battery disconnect (refer to Service Manual procedure 16300002).
9. Install a new bolt where one is missing from a contactor DC link busbar joint, and then mark the bolt with a paint
pen after it is torqued (torque 9 Nm).

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SB-20-16-003
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10. Use the Hioki resistance meter to measure the contactor DC link busbar joint resistance where a missing bolt was
installed (Figure 7):
CAUTION: The acceptable resistance is between 0.020 mΩ (20 μΩ) and 0.060 mΩ (60 μΩ).
•
•
•

If the resistance is greater than 0.060 mΩ (60 μΩ), stop work and escalate a Toolbox session.
If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.
If the resistance is repeatedly between 0.00 mΩ and 0.020 mΩ (20 μΩ), proceed to next step.

Figure 7
11. Repeat steps 9 and 10 for the other joint, if necessary.
12. Install the pyrotechnic battery disconnect (refer to Service Manual procedure 16300002).
13. If missing, install the HV battery insulators (refer to Service Manual procedure 16302001).
14. Install the ancillary cover (refer to Service Manual procedure 16101002).
15. Connect 12V power (refer to Service Manual procedure 17010200).

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SB-20-16-003
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