2026-11-06

HV-Batterie (Allradantrieb) (Nicht Strukturpack)(Ausbauen und Ersetzen)

Korrekturcodes 16010202 5.40 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Persönlicher Schutz to make sure wearing proper PPE when performing the below procedure. NOTE: See for safe and healthy working practices.

  • 2026-11-06: Added steps to disconnect and connect the 2nd row 40 seat connector, and remove and install the 2nd row 60 seat.
  • 2026-05-28: Add a note of visual inspection before install the HV battery.
  • 2026-05-20: Added warnings to never move the gantry with a suspended load or put any part of the body underneath a suspended load.
  • 2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
  • 2025-05-28: Modified step for attaching pyrotechnic battery disconnect when shipping the HV battery.
  • 2025-04-08: Added step for attaching pyrotechnic battery disconnect when shipping the HV battery.
  • 2025-02-19: Added a note to replace the ancillary bay cover with a compatible part while removing the pyro disconnect, if necessary.
  • 2025-01-08: Added images of HV battery alignment rods for clarification.
  • 2025-01-03: Added notes regarding the potential absence of the ancillary bay cover volcano brackets and fasteners for newer Model 3/Y vehicle builds. Replaced pyro disconnect steps with pyro removal service manual link.
  • 2024-12-19: Added a step to verify the front HV battery coolant passthrough fittings on the new HV battery to determine if the updated front HV battery coolant manifold hose 1734606-00-D is needed.
  • 2024-12-18: Added step to determine if HV battery parameters are within safe limits before removing the pyro disconnect.
  • 2024-11-07: Added 3-phase harness disconnect/connect steps.
  • 2024-10-31: Updated HV battery discharge steps.
  • 2024-09-11: Added step to support the LV system.
  • 2024-06-13: Updated lift pad adapter PNs.
  • 2024-06-10: Added pyro disconnect removal steps.
  • 2023-11-21: Added new lift pad instructions.
  • 2023-11-13: Add note to further clarify fasten the HV battery pack to crate before shipping.
  • 2023-08-25: - Updated EPB Service Mode reference.
  • 2023-05-22: Added conspicuous discharge warning table.
  • 2023-05-22: Added caution for correct positive DC cable connection.
  • 2023-03-16: Updated Discharge section and added steps to configure the HV battery.
Equipment:
  • 1936724-00-A – Universal-Hubkissenadapter
  • 1133787-00-A Schlüssel, Sicherheitsgurtfreigabe, Model 3
  • 1020566-00-F BGR, Batteriehubtisch, manuell
  • 1020566-99-A Obere Platte, Batteriehubtisch, manuell
  • 1129166-00-A Hebebühne mit H-Rahmen, EMEA
  • 1073363-00-A Gantry, Adjustable, Aluminum
  • 1134523-00-A Kit, Ausrichtungsstäbe, Batterie, Model 3
  • 1140311-00-A Hebelverriegelung, HV-Steckverbinder, Model 3
  • 1053600-00-B Druckprüfgerät, Antriebseinheit
  • 1130942-00-B Adapter, Kühlmittel-Ausgleichsbehälter, Druckprüfung
  • 1132185-00-B Kit, Kühlmittel-Leckprüfadapter, Model 3
  • 1133843-00-A Kit, Kühlmittel-Ablass- und -Fülladapter, M3
  • 1135762-00-A Kit, Service-Stecker, Kühlschlauch, Model 3
  • 1065131-00-A Kit, Batterie-Kühlmittelablass und -füllung
  • 1026636-00-A Packung, Gehäuseleckprüfer, HV-Batterie
  • 1140501-00-A Packungs-Kit, Gehäuse, Leckprüfung, HV-Batterie, Komplett
  • 1144879-00-A Kit, Geh. Leckprüfadapter, HV-Batterie
  • 1108272-00-B Kappe, Logikverbindung, Umr., 3DU
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.

Technische Daten zum Drehmoment

Table 1. Technische Daten zum Drehmoment: HV-Batterie (Allradantrieb) (Nicht Strukturpack)(Ausbauen und Ersetzen)
Beschreibung Drehmomentwert Empfohlene Werkzeuge Wiederverwenden/Ersetzen Hinweise
LH front inner HV battery bolt
136 Nm (100.3 lbs-ft)
  • Torx Plus-Steckschlüssel EP20
Wiederverwenden
LH middle inner HV battery bolt
66 Nm (48.7 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
LH rear inner HV battery bolt
66 Nm (48.7 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
Bolts that secure the 2nd row 60 seat frame to the body
37 Nm (27.3 lbs-ft)
  • 11 mm socket
  • Cordless 3/8in Dr Impact
  • 6 in extension
Ersetzen 1616775-00-B
Bolt that secures the busbar cover access door
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 10 mm, tief
Wiederverwenden
Bolts that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 10 mm, tief
Wiederverwenden
Nut that attaches the DCDC ground strap to the HV battery
9 Nm (6.6 lbs-ft)
  • Zwölfkantsteckschlüssel, 13 mm, tief
Ersetzen PN - 1093060-00-A
Nut that attaches the positive 12V output to the PCS cable
9 Nm (6.6 lbs-ft)
  • Steckschlüssel, 13 mm
Ersetzen PN - 1093060-00-A
Bolt that attaches the LH front wheel liner to the HV battery
5 Nm (3.7 lbs-ft)
  • Steckschlüssel, 10 mm
Wiederverwenden
Bolt that attaches the FDU HV harness to the FDU
10 Nm (7.4 lbs-ft)
  • Außen-Torx Plus EP10
Wiederverwenden
Bolt that attaches the ground strap to the HV battery
10 Nm (7.4 lbs-ft)
  • 10mm ratcheting combination flex head wrench
 Wiederverwenden
Smaller bolts that attach the LH shear plate to the body
35 Nm (25.8 lbs-ft)
  • Steckschlüssel, 13 mm
Wiederverwenden
Larger bolt that attaches the LH shear plate to the body
130 Nm (95.9 lbs-ft)
  • Steckschlüssel, 21 mm
Ersetzen PN - 1461657-00-A
Nut that attaches the RDU HV electrical harness bracket to the HV battery
10 Nm (7.4 lbs-ft)
  • Steckschlüssel, 10 mm
Wiederverwenden
Center bolts (x4) that attach the HV battery through the HV battery center rail ski cover
35 Nm (25.8 lbs-ft)
  • Außen-Torx Plus EP14
Wiederverwenden
Bolts that attach the HV battery LH and RH support brackets to the vehicle
110 Nm (81.1 lbs-ft)
  • Steckschlüssel, 16 mm
Wiederverwenden
Bolts (x16) that attach the HV battery to the vehicle
35 Nm (25.8 lbs-ft)
  • Steckschlüssel, 13 mm
Wiederverwenden
Note
Some vehicles are equipped with self-tapping bolts in bolt position #8-15 from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.

Discharge

WARNUNG: Zur Erfüllung örtlicher Gesetze müssen Lithium-Hochvoltbatterien vor dem Verpacken für den Versand entladen werden. Außerdem müssen HV-Batterien vor der Lagerung entladen werden. Zu versendende HV-Batterien müssen einen Ladezustand (SoC) von weniger als 25 % oder 45 % je nach Region aufweisen. Wenn die Versandmethode unbekannt oder unsicher ist oder die Batterie gelagert werden soll, wird ein Entladen der HV-Batterie auf weniger als 25 % empfohlen.

WARNUNG: Warten Sie nach der Entladung 20 Minuten, und achten Sie darauf, dass der SoC unter dem Zielwert liegt. Während dieser Wartezeit kann sich die Leerlaufspannung (OCV) stabilisieren, was für eine genaue Messung unerlässlich ist. Fahren Sie mit dem Entladen fort, wenn der SoC nicht den erforderlichen Wert hat.

Erfassen Sie mit dem HV-Batterie-Kommunikationswerkzeug sämtliche Versanddaten für die HV-Batterie, möglichst vor dem Ausbau der HV-Batterie aus dem Fahrzeug.

WARNUNG: Eine HV-Batterie mit beschädigter Hochspannungsisolierung darf weder versandt noch gelagert werden. Prüfen Sie vor dem Verpacken für den Versand oder die Lagerung, ob die Isolierung der HV-Batterie intakt ist. Verwenden Sie das in Toolbox-Artikel 41977 oder Kundendokument CD-21-16-003 beschriebene HV-Batterie-Kommunikationswerkzeug, um zu bestimmen, ob die Parameter der HV-Batterie innerhalb der sicheren Grenzwerte für Versand oder Lagerung liegen.
Note
Sofern möglich, führen Sie das Entladeverfahren aus, und erfassen Sie die Versanddaten der HV-Batterie, bevor Sie die HV-Batterie ausbauen. Diese Methode erfordert weniger Zeit und Benutzerinteraktion als die Verwendung des Batterieentladewerkzeugs, nachdem die Batterie ausgebaut wurde. Das Batterieentladewerkzeug kann nur von zertifizierten Technikern verwendet werden..
Note
Die Schritte des Entladeverfahrens sind größtenteils Bearbeitungszeit und können von Serviceberatern/Mitarbeitern im Kundenkontakt sowie von Servicetechnikern durchgeführt werden..
  1. Enable Service Mode Plus. See .
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to step 6 of this sub-procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, use the HV Battery Communication Tool to collect HV battery shipping data, and then move the vehicle to the service bay.

Ausbauen

  1. Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See .
  2. Remove the LH lower rocker panel cover. See Abdeckung – Trittbrettformteil – Unten – LH (Ausbauen und Ersetzen).
  3. Remove the LH rocker panel carrier. See Träger – Trittbrett – Links (Ausbauen und Ersetzen).
  4. Remove the butyl patches that cover the LH rocker access hole.
  5. Repeat step 2 through step 4 for the RH side of the vehicle.
  6. Install lift pad adapters.
    • For EMEA only, install Adapter, Hubkissen, Model Y (1614078-00-A)
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning
    DO NOT use any other lift pad adapters.
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Hubkissen, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.
    Note
    In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

    Instructions for Universal Lift Pad Adapters:

    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  7. Open all doors and lower all windows.
    Note
    Latch the rear doors to prevent accidental lockout.
  8. Enable the EPB Service Mode. See
  9. Remove the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
  10. Remove the LH instrument panel end cap. See #GUID-F966829B-F227-486B-9AE8-55F4F733BE58.
  11. Remove the LH middle A-pillar trim. See #GUID-E1DDEA4B-6FBC-438D-997F-B3BD26910740.
  12. Remove the LH lower A-pillar trim. See #GUID-2B48046D-F15C-4E02-B2C9-82D80BB25389.
  13. Move the driver seat fully rearwards.
  14. Remove the driver footwell cover. See #GUID-9E8372EB-55A4-4F04-A950-5D769CD36C14.
  15. Remove the LH center console side panel carpet. See #GUID-F4937396-BA44-41B6-87B7-8A7CFE6939D3.
  16. Remove the clip that attaches the LH front carpet to the vehicle, and then fold the carpet rearward.
  17. Remove the foam plugs in the padding underneath LH front carpet, and then remove the LH front inner HV battery bolts (x2).
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Torx Plus-Steckschlüssel EP20
  18. Raise the LH front seat fully.
  19. Repeat step 10 through step 18 for the RH side of the vehicle.
  20. Remove the 2nd row floor mat from the vehicle.
  21. Lift the flap in the carpet underneath the RH front seat, and then remove the RH middle inner HV battery bolt that attaches the HV battery to the vehicle. Repeat this step for the LH side of the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  22. Remove the 2nd row seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen)
  23. Remove the LH lower C-pillar trim. See .
  24. Remove the clip securing the LH lower B-pillar to body.
  25. Repeat steps 23 and 24 for the RH side of the vehicle.
  26. Remove the clips (x3) that attach the rear carpet to the vehicle.
  27. Position a folded shop towel underneath the rear cabin carpet to raise the carpet and allow access to the rear inner HV battery bolts, and then remove the LH and RH bolts.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
    • 6-Zoll-Verlängerung
  28. Disconnect 12V power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden).
  29. Perform the Vehicle HV Disablement procedure.
  30. Disconnect the 2nd row 40 seat connector.
    Note
    There may be a red locking tab on newer models.
  31. Remove and discard the bolts (x5) that attach the 2nd row 60 seat frame to the body.
    Note
    Bottom seat bolts are located behind the main carpet.
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    • Cordless 3/8in Dr Impact
    • 6 in extension
  32. Fold the 2nd row 60 seat back downward.
    Note
    Protect the seat back upholstery if necessary. Do not put weight on seat in folded position without cushion present due to risk of bending locator tab on frame.
  33. Disengage the locking tab and disconnect the 2nd row 60 seat connector.
  34. Release the 2nd row 60 seat connector from the LH seat frame.
    Note
    Pinch tabs on clip to avoid damage.
  35. Remove the 2nd row 60 seat assembly from the vehicle.
    Note
    Recommend assistance. If the seat that is not being replaced does not have the ISOFIX flag for child locks, the seat cover will also require replacement.
  36. Disconnect the logic electrical connector at the LH seat frame.
  37. Release the clip that attaches the logic electrical harness to the LH seat frame.
  38. Remove the bolt that secures the busbar cover access door.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  39. Remove the bolts that attach the charge port busbar kit to the HV header, and then lift to remove the kit from the header.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  40. If there is a 3-phase (AC) connection between the charge port and HV battery, disconnect it:
    1. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
    2. Fully raise the handle on the 3-phase connector.
    3. Remove the 3-phase connector from the ancillary bay 3-phase header.
  41. Disconnect the HVC logic connector, and then install the logic cap.
  42. Remove and discard the nut that attaches the DCDC ground strap to the HV battery, and then remove the strap from the battery.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Zwölfkantsteckschlüssel, 13 mm, tief
  43. Release the positive 12V output cover from the PCS cable, remove and discard the nut that attaches the positive 12V output to the PCS cable, and then move the cable aside.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  44. Verwenden Sie das in Toolbox-Artikel 41977 oder Kundendokument CD-21-16-003 beschriebene HV-Batterie-Kommunikationswerkzeug, um zu bestimmen, ob die Parameter der HV-Batterie innerhalb der sicheren Grenzwerte liegen, bevor Sie fortfahren.
  45. Remove the pyrotechnic battery disconnect prior to shipping the HV battery. See .
    Note
    If the old HV battery ancillary bay cover has volcano brackets, and the new ancillary bay cover does not have the same brackets or vice versa, replace the ancillary bay cover with a compatible part while removing the pyro disconnect.
    Note
    Reinstall the ancillary bay cover after removing the pyro battery disconnect. Newer built vehicles may be equipped with ancillary covers without volcano brackets and the bolts will not be present.
  46. Close all doors.
    Note
    Doors will be unlatched at a later step.
  47. Remove the wheel chocks from the wheel.
  48. With assistance, push the vehicle onto the lift, then re-chock the wheels when the vehicle is in position.
    CAUTION
    Only push the vehicle for a very short distance and at less than 1 MPH.
  49. Install lift pad adapters.
    • For EMEA only, install Adapter, Hubkissen, Model Y (1614078-00-A)
    • For other regions, install Universal Lift Pad Adapters (1936724-00-A)
    Warning
    DO NOT use any other lift pad adapters.
    Note
    Outside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Hubkissen, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.
    Note
    In EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.

    Instructions for Universal Lift Pad Adapters:

    1. Depending on the lift type, install the correct thread adapter onto the lift adapter.
    2. Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
    3. Install the lift adapters onto the lift arms so that the black lift pad is toward the vehicle.
      Warning
      Make sure the adapter is install in the correct orientation.
    4. Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
    5. Lift the lift arms to fully seat the lift pads into the vehicle.
    6. Make sure all 4 adapters are fully seated into the vehicle.
  50. Raise and lock the vehicle at a comfortable working height.
    CAUTION
    Verify that the vehicle is stable on the lift.
  51. Remove the front aero shield panel. See Verkleidung – Windabweiser – Vorne (Nicht Strukturpack)(Ausbauen und Ersetzen).
  52. Remove the bolt and clips that attach the LH front wheel liner to the HV battery and lower wheel well area. Repeat this step for the RH side of the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  53. Remove the front HV battery skid plate. See #GUID-D1A9F588-4A89-45F3-838D-5987DEA421F9.
  54. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Außen-Torx Plus EP10
  55. Slide the release to unlock the front drive unit HV connector handle of the front drive unit to HV battery harness from the secured position.
  56. Fully raise the handle on the front drive unit HV connector.
  57. Remove the front drive unit HV connector from the front drive unit HV header.
  58. Remove the bolt that attaches the ground strap to the HV battery.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • 10mm ratcheting combination flex head wrench
  59. Release the bracket that secures the HV connectors to the bulkhead.
  60. Disconnect the A/C compressor electrical connector from the HV harness.
  61. Install bungee straps to pull the LH and RH front wheel arch liners away from the HV battery and expose the coolant hoses.
  62. Perform a rear powertrain coolant drain. See .
  63. Perform a platter enclosure coolant drain. See .
  64. Remove the mid aero shield panel. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  65. Position the support stand underneath the front portion of the rear subframe.
  66. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  67. Remove the smaller bolts that attach the LH shear plate to the body.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  68. Remove and discard the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 21 mm
  69. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  70. Repeat step 66through 69 for the RH shear plate.
  71. Remove the support stand from underneath the rear subframe
  72. Remove the rear HV battery skid plate. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
  73. Position the coolant drain under the rear LH side of the HV battery.
  74. Release the clip and disconnect the rear drive unit inverter inlet hose from the rear of the HV battery, and immediately plug the male and female fittings.
  75. Position the coolant drain under the rear RH side of the HV battery.
  76. Release the clip and disconnect the coolant outlet hose to rear powertrain return coupling, and immediately plug the male and female fittings.
  77. Remove the coolant drain from underneath the vehicle.
  78. Remove the nut that attaches the rear drive unit HV electrical harness bracket to the HV battery.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  79. Slide the release to unlock the HV battery rear drive unit connector handle of the rear drive unit to HV battery harness from the secured position.
  80. Fully raise the handle on the HV battery rear drive unit connector.
  81. Remove the HV battery rear drive unit connector from the HV battery header.
  82. With an assistant, put the battery table in position, and then lower the vehicle to support the HV battery.
    Note
    Line up the battery table so that the center 4 bolts of the HV battery are accessible through the opening in the battery table.
  83. Remove the center bolts (x4) that attach the HV battery through the HV battery center rail ski cover.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Außen-Torx Plus EP14
  84. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  85. Remove the bolts (x16) that attach the HV battery to the vehicle.
    Note
    Record the positions of any installed washers, as they will be reinstalled to the same locations during the installation procedure.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  86. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  87. Turn the adjustable elements (x4) clockwise to remove them from the ancillary bay cover.
    Note
    Keep the adjustable elements so that they can be installed onto the replacement HV battery.
  88. Release the clip and disconnect the LH inner HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  89. Release the clip and disconnect the LH outer HV battery supply hose fitting from the LH front of the HV battery platter enclosure.
  90. Release the clip and disconnect the RH inner coolant hose fitting from the RH front of the HV battery.
  91. Release the clip and disconnect the RH outer HV battery supply hose fitting from the RH front of the HV battery platter enclosure, and remove the hose assembly from the HV battery.
  92. Release the clips (x5) that attach the powertrain return (lower) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  93. Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the ancillary bay.
  94. Release the clips (x5) that attach the powertrain supply (upper) hose to the RH side of the HV battery, and remove the hose from the HV battery.
  95. Use the gantry and H-frame hoist to lift the HV battery from the manual lift battery table.
    Warning
    Never stand or place any part of your body underneath a suspended load.
    Warning
    Never attempt to move a gantry while a load is suspended.
    Warning
    Refer to the gantry manufacturer's instructions for safety and operational information.
  96. Use the gantry and H-frame hoist to lower the HV battery into the shipping container.
  97. Remove the logic cap from old battery.
    Note
    Please make sure correctly fasten the HV battery pack to the crate before shipping.
  98. If the HV battery is being shipped, attach the old pyrotechnic battery disconnect to the brackets on the ancillary bay cover of the old HV battery using cable ties. If the ancillary bay cover is not equipped with brackets, attach the old pyrotechnic battery disconnect to the RH rear corner of the old HV battery using cable ties.
    Note
    Put a piece of paper under the pyrotechnic battery disconnect. Use masking tape if necessary to prevent movement.
    Figure 1. Pyrotechnic battery disconnect attached to brackets on the ancillary bay cover
    Figure 2. Pyrotechnic battery disconnect attached to RH rear corner of HV battery

Montieren

  1. Use the gantry and H-frame hoist to lift the new HV battery out of the shipping container.
  2. Transfer all of the HV header and coolant port caps from the front and rear of the new HV battery to the old HV battery for return shipment.
  3. With assistance, lower the HV battery onto the battery table.
    Note
    Perform a visual inspection of the bolt holes and HV headers to make sure that terminals are aligned and threads are not damaged before installing a bolt or mating a connector.
    Note
    If it is not possible to fit the caps onto the old HV battery, include the caps in the shipping crate.
    Note
    Align HV battery onto center ski.
  4. Inspect the top cover of the HV battery for the presence of NVH pads.
    • If the HV battery does not have NVH pads, install the NVH pads. See .
      Note
      Add correction code 16103101 to the Repair Order separately. The labor time to install the NVH pads is not included in this parent procedure.
    • If the HV battery already has NVH pads, continue to the next step.
  5. Install the logic cap onto the new HV battery.
  6. Install the powertrain supply hose to the upper clips on the RH side of the HV battery, fasten the clips (x5) and install a plug to the coolant hose.
  7. Connect the RH outer coolant hose to the rear of the HV battery, and then fasten the clip.
    Note
    Perform a push-pull test to verify that the hose is fully seated.
    Note
    Use a shop towel to clean any residue coolant if necessary.
  8. Install the powertrain return hose to the lower clips on the RH side of the HV battery, fasten the clips (x5) and install hose plugs.
  9. Verify if the new HV battery front coolant passthrough fittings (x4) are male fittings or female fittings.
    1. If the HV battery front coolant passthrough fittings (x4) are male fittings, no further action is required. Continue to the next step in this procedure.
      Figure 3. HV battery coolant passthrough fittings; Male
    2. If the HV battery front coolant passthrough fittings (x4) are female fittings, perform the HV battery front manifold coolant passthrough hose retrofit procedure. See .
    Figure 4. HV battery coolant passthrough fittings; Female
  10. Position the HV battery supply hose assembly onto the HV battery, connect the RH outer HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
    Note
    Perform a push-pull test to verify that the hose is fully seated.
    Note
    Use a shop towel to clean any residue coolant if necessary.
  11. Connect the RH inner HV battery supply hose fitting to the RH front of the HV battery platter enclosure, and then fasten the clip.
  12. Connect the LH outer coolant hose to the front of the HV battery, and then fast the clip.
    Note
    Ensure the locking clip is fully seated.
    Note
    Use a shop towel to clean any residue coolant if necessary.
  13. Connect the LH inner HV battery supply hose to the front of the HV battery platter enclosure, and then fasten the clip.
    Note
    Ensure the locking clip is fully seated.
    Note
    Use a shop towel to clean any residue coolant if necessary.
  14. Install and hand-tighten the adjustable elements (x4) on the ancillary bay cover counter-clockwise so that they are fully engaged.
    CAUTION
    Hand-tighten only.
  15. Install a new HV battery cover gasket. See #GUID-B23AA3A3-4BCA-4ED3-9785-7F5E2ADA314B.
  16. Clean the busbar HV connector contact surface of residual Penetrox.
    Note
    Allow one minute of drying time after removing Penetrox.
  17. Clean the HV connector contact surface of residual Penetrox.
    Note
    Allow one minute of drying time after removing Penetrox.
  18. Install the HV battery alignment rods; 2 at the front of the vehicle and 2 at the HV battery near the ancillary bay.
    Figure 5. RH front alignment rod shown; LH similar
    Figure 6. Rear alignment rods
  19. With an assistant, position the HV battery underneath the vehicle.
  20. Lower the vehicle to the HV battery, and with an assistant, align the holes with the alignment rods.
    Note
    Do not fully lower the vehicle onto the HV battery. The battery will still need to slightly move to install the bolts in the following steps.
    CAUTION
    Make sure that the coolant hoses and HV harnesses are not caught on the alignment rods or sandwiched between the HV battery and the vehicle.
  21. Install and hand-tighten the smaller bolts that would attach the LH and RH shear plates to the body.
    Note
    Do not install the shear plates at this time.
    Figure 7. LH shown, RH similar
  22. Install and hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
    Note
    Install the washers to the locations recorded earlier during removal.
  23. Remove HV battery front alignment rods.
  24. Install and hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  25. Install and hand-tighten the bolts (x4) that attach the center portion of the HV battery through the HV battery center rail ski cover.
  26. Open the LH rear door
  27. Remove the HV battery alignment rod from the LH rear inner bolt location.
  28. Install and hand-tighten the LH rear inner HV battery bolts.
  29. Lift the carpet flap, and then install and hand-tighten the LH middle inner HV battery bolt.
  30. Close the LH rear door.
  31. Open the LH front door.
  32. Install and hand-tighten both LH front inner HV battery bolts.
  33. Repeat step 26 through step 32 step for the RH side of the vehicle.
  34. Fully lower the vehicle onto the HV battery.
  35. Torque the LH and RH bolts (x16) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  36. Torque the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
    110 Nm (81.1 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  37. Torque the bolts (x4) that attach the center portion of the HV battery through the center ski cover.
    35 Nm (25.8 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Außen-Torx Plus EP14
  38. With an assistant, raise the vehicle, and then remove the battery table from underneath the vehicle.
  39. Set the vehicle to a comfortable working height, and then lower the vehicle into locks.
  40. Position the support stand to support the front portion of the rear subframe.
  41. Remove the smaller bolts (x2) and the larger bolt that are used to attach the LH shear plate to the vehicle.
    Figure 8. LH shown, RH similar
  42. Install the LH shear plate, and then install and hand-tighten the larger bolt that attaches the shear plate to the vehicle.
  43. Install and hand-tighten the smaller bolts (x2) that attach the shear plate to the HV battery.
    Figure 9. LH shown, RH similar
  44. Torque the large bolt that attaches the LH shear plate to the body.
    130 Nm (95.9 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 21 mm
  45. Torque the small bolts that attach the LH shear plate to the body.
    35 Nm (25.8 lbs-ft)
    Note
    Some vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  46. Repeat step 41 through step 45 for the RH shear plate.
  47. Remove the support stand from underneath the rear subframe
  48. Fasten the fir tree clips that attach the coolant hoses to the LH and RH shear plates.
    Figure 10. LH shown, RH similar
  49. Fully raise the handle on the HV battery rear drive unit connector of the rear drive unit to HV battery harness.
  50. Install the HV connector special tool onto the HV battery rear drive unit connector.
  51. Use both hands to firmly connect the HV battery rear drive unit connector of the rear drive unit to HV battery harness to the HV battery header.
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  52. Remove the HV connector special tool from the HV battery rear drive unit connector.
  53. While pressing the HV battery rear drive unit connector onto the HV battery header, fully lower the handle.
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  54. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  55. Verify that the HV battery rear drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  56. Install the nut that attaches the rear drive unit HV electrical harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  57. Position the coolant drain beneath the RH rear of the HV battery.
  58. Remove the hose plugs, and then connect coolant outlet hose to rear power train return hose.
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  59. Position the coolant drain underneath the LH rear of the HV battery.
  60. Remove the hose plugs, and then connect rear drive unit inverter inlet hose to the rear of HV battery.
    CAUTION
    Perform a push-pull test to verify that the hose is fully seated.
  61. Remove the coolant drain from underneath the vehicle.
  62. Install the rear HV battery skid plate, but only hand-tighten the fasteners. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
  63. Torque the fasteners that attach the rear skid plate to the vehicle. See #GUID-C28DE945-C6EF-450D-A7A4-98E5CC2C2DA1.
    Note
    Some vehicles are equipped with self-tapping bolts from the factory. If the vehicle is equipped with a bolt with a hexagonal indentation on the bolt head (1637725-00-A), the torque value is 64 Nm.
  64. Install the mid aero shield panel. See Verkleidung – Windabweiser – Hinten (Ausbauen und Ersetzen).
  65. Position the coolant drain under the front LH side of the HV battery.
  66. Fasten the clips that attach the HV battery front manifold hose to the body.
  67. Remove the plugs from the chiller to HV battery hose and the manifold at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  68. Remove the plugs from the HV battery return hose at the LH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  69. Position the coolant drain under the front RH side of the HV battery.
  70. Remove the plugs from the rear powertrain supply hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  71. Remove the plugs from the powertrain return hose at the RH side of the vehicle, immediately connect the male and female fittings, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  72. Remove the coolant drain from underneath the vehicle.
  73. Remove the plastic bracket that attaches the HV connectors to the HV battery.
  74. If not present, apply abrasion tape to the A/C compressor HV connector harness.
  75. Connect the A/C compressor HV connector, and then engage the connector lock.
  76. Install the A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  77. Install the bolt that attaches the ground strap to the HV battery
    10 Nm (7.4 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • 10mm ratcheting combination flex head wrench
  78. Fully raise the handle on the front drive unit HV connector of the front drive unit to HV battery harness.
  79. Install the HV connector special tool onto the front drive unit HV connector.
  80. Use both hands to firmly connect the front drive unit HV connector of the front drive unit to HV battery harness to the front drive unit HV header.
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  81. Remove the HV connector special tool from the front drive unit HV connector.
  82. While pressing the front drive unit HV connector onto the front drive unit HV header, fully lower the handle.
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  83. Slide the release to lock the front drive unit HV connector handle in the secured position.
  84. Verify that the front drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Note
    An improperly seated connector might lead to connector damage and front drive unit problems later on.
  85. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
    Tip
    • Außen-Torx Plus EP10
  86. Install the front HV battery skid plate. See #GUID-D1A9F588-4A89-45F3-838D-5987DEA421F9.
  87. Remove the bungee straps from the LH and RH wheel arch liners.
  88. Install the bolt and clips that attach the LH front wheel liner to the HV battery and lower wheel well area. Repeat this step for the RH side of the vehicle.
    5 Nm (3.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm
  89. Install the front aero shield panel. See Verkleidung – Windabweiser – Vorne (Nicht Strukturpack)(Ausbauen und Ersetzen).
  90. Lower the vehicle fully, and chock a wheel.
  91. Remove the chock, and with an assistant, push the vehicle away from the lift to a stall, and then re-chock the wheel.
    CAUTION
    Push the vehicle for a very short distance and at less than 1 MPH.
  92. Install the nut that attaches the positive 12V output to the PCS cable, and then close the cover.
    9 Nm (6.6 lbs-ft)
    CAUTION
    Ensure the rubber boot is not pinched between the cable terminal and passthrough.
    CAUTION
    Make sure the positive output cable is positioned properly and in the right direction against the plastic anti-rotation edge on the DCDC passthrough.
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 13 mm
  93. Install a new nut that attaches the DCDC ground strap to the HV battery.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Zwölfkantsteckschlüssel, 13 mm, tief
  94. Remove the logic cap, and then connect the HVC logic connector.
  95. Apply a small amount of Penetrox onto the HV connector joints.
  96. Position the busbar kit connector and lower onto the HV header.
  97. Install the bolts that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  98. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances. See .
  99. Put on the HV insulating gloves and leather over gloves.
  100. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  101. Repeat step the previous step for the other charge port busbar connector lead and DC input HV header bolt head.
  102. Remove the HV insulating gloves and leather over gloves.
  103. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 10 mm, tief
  104. Connect the 2nd row 40 seat connector.
    Note
    There may be a red locking tab on newer models.
  105. Position the 2nd row 60 seat assembly into the vehicle.
    Note
    Recommend assistance.
  106. Move the 2nd row 60 seat back to vertical position.
  107. Install the new bolts (x5) (1616775-00-B) that attach the 2nd row 60 seat frame to the body, and torque them in the sequence: outboard front → both inboard rear → outboard rear → inboard front.
    37 Nm (27.3 lbs-ft)
    Note
    Bottom seat bolts are located behind the main carpet.
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    • Cordless 3/8in Dr Impact
    • 6 in extension
  108. Connect the 2nd row 60 seat connector and engage the locking tab.
  109. Secure the 2nd row 60 seat connector to the LH seat frame.
  110. If there is a 3-phase (AC) connection between the charge port and HV battery, connect it:
    1. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
    2. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase header.
      CAUTION
      Make sure that the connector fits the header squarely and tightly.
    3. While pressing the 3-phase connector onto the 3-phase header, fully lower the handle.
      CAUTION
      Make sure that the handle does not bind as it is lowered.
    4. Slide the release to lock the 3-phase connector handle in the secured position.
    5. Verify that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
      Note
      An improperly seated connector might lead to connector damage and charging problems later on.
  111. Install the clip that attaches the logic electrical harness to the LH seat frame.
  112. Connect the logic connector at the LH seat frame.
  113. Torque the LH and RH rear inner HV battery bolts.
    66 Nm (48.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  114. Remove the folded shop towel from underneath the rear cabin carpet.
  115. Install the clips (x3) that attach the rear carpet to the vehicle.
  116. Install the clip securing the LH lower B-pillar to body.
  117. Install the LH lower C-pillar trim. See .
  118. Repeat steps 116 and 117 for the RH side of the vehicle.
  119. Install the 2nd row seat cushion. See Sitzkissen – Unten – 2. Sitzreihe (Ausbauen und Ersetzen).
  120. Torque the LH middle inner HV battery bolt, and then fold the carpet to its original position. Repeat this step on the RH side of the vehicle.
    66 Nm (48.7 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Steckschlüssel, 16 mm
  121. Install the 2nd row floor mat into the vehicle.
  122. Torque both RH front inner HV battery bolts, and then install the foam plugs.
    136 Nm (100.3 lbs-ft)
    Tip
    Es wird empfohlen, die folgenden Werkzeuge zu verwenden:
    • Torx Plus-Steckschlüssel EP20
  123. Fold the RH front main cabin carpet forward to its original position, and then install the clip that attaches the LH carpet to the vehicle.
  124. Install the RH lower A-pillar trim. See #GUID-2B48046D-F15C-4E02-B2C9-82D80BB25389.
  125. Install the RH middle A-pillar trim. See #GUID-E1DDEA4B-6FBC-438D-997F-B3BD26910740.
  126. Install the RH instrument panel end cap. See #GUID-F966829B-F227-486B-9AE8-55F4F733BE58.
  127. Install the RH center console side panel carpet. See #GUID-F4937396-BA44-41B6-87B7-8A7CFE6939D3.
  128. Install the RH front floor mat.
  129. Install the front passenger footwell cover. See #GUID-9E8372EB-55A4-4F04-A950-5D769CD36C14.
  130. Repeat step 122 through step 129 for the LH side of the vehicle.
  131. Connect 12V power. See 12-V-/Niederspannungsversorgung (Trennen und Verbinden).
  132. Connect an LV maintainer to the vehicle, but do not disconnect the LV battery. See .
    Note
    On 12V lead acid batteries, connect the 12V maintainer to the lead acid battery terminals.
  133. Shift into Park to release the Electronic Parking Brake service mode, and then remove the wheel chock.
  134. Connect a laptop with Toolbox 3 to the vehicle. See .
  135. Enable Service Mode Plus. See .
  136. Perform a cooling system vacuum refill. See .
  137. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  138. Under High-Voltage-Battery, touch High Voltage Battery Replacement.
  139. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
  140. Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
  141. Disable Service Mode Plus. See .
  142. Disconnect the laptop with Toolbox 3 from the vehicle. See .
  143. Disconnect the 12V/LV battery maintainer.
  144. Install the rear underhood apron. See Unterhaubenschürze – Hinten (Ausbauen und Ersetzen).
  145. Raise all windows and close all doors.
  146. Remove lift pads from the LH rocker.
  147. Install the butyl patch that covers the LH rocker access holes.
  148. Install the LH rocker panel carrier. See Träger – Trittbrett – Links (Ausbauen und Ersetzen).
  149. Install the LH lower rocker panel cover. See Abdeckung – Trittbrettformteil – Unten – LH (Ausbauen und Ersetzen).
  150. Repeat step 146 though step 149 for the RH side of the vehicle.