HV Battery (AWD) \(Remove and Replace\)
Correction code 16010202 FRT 4.98 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and 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. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-07-08: Added steps to replace the seat bolt, and remove HV battery bolts below rear end of both LH and RH front seat cushion.
- 1473522-00-A - KIT, COMPUTER PURGE ADAPTERS, MODEL 3
- 1129166-02-B - SPARES, HOIST, H-FRAME
- 1458818-00-B - BOLT PF M10-1 5X36 109 G0310 B SMAT
Torque Specifications
Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
---|---|---|---|---|
LH front footwell HV battery bolts |
|
|
Reuse | |
Bolts (X2) securing LH front seat to vehicleBolts (X2) securing LH rear seat to vehicle |
|
|
Replace | |
Bolt below rear end of LH front seat cushionBolt below rear end of RH front seat cushion |
|
|
Reuse | |
Rear HV battery interior bolts |
|
|
Reuse | |
Bolt that secures the busbar cover access door Bolts that attach the charge port busbar kit to the HV header |
|
|
Reuse | |
Nut that attaches the positive LV output to the PCS cable |
|
|
Replace | |
Bolts that attach the LH front wheel liner to the skid plate |
|
|
Reuse | |
HV battery center bolts |
|
|
Reuse | |
Bolts that attach the LH and RH front support brackets to vehicle |
|
|
Reuse | |
Bolts (x16) that attach the HV battery to vehicle |
|
|
Reuse | |
Bolts (x2) that attach the center ski cover to the HV battery |
|
|
Reuse |
Remove
- Remove the LH and RH rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Open all doors and lower all windows.
- Remove all the floor mats. See Kit - Floor Mat - LHD (Remove and Replace).
- Partially release the LH front primary door seal.
- Remove the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Remove the drive footwell cover. See Cover - Footwell - Driver (Remove and Replace).
- Remove and discard LH front seat bolts.
- Remove the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
-
Remove LH front main cabin carpet
clips (x2), and then fold the LH front main cabin carpet aside for access.
NoteThe number of clips on new vehicles may vary.NoteDead pedal and foam block are also part of the carpet.
-
Remove the LH front footwell HV
battery bolts (x2).
Tip: Use of the following tool(s) is recommended:
- Torx Plus EP20 socket
- Cordless Ratchet/Impact Driver
- 3/8 in to ½ in adapter
- 3 in extension
- Ratchet/torque wrench
-
Remove HV battery bolt below rear end of LH front seat cushion.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
- Repeat step 4 through step 10 for the RH side.
-
Remove HV battery bolt below rear end of RH front seat cushion.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
- Remove the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
- Release push clips (x2) and pull back the rear carpet to access the rear HV battery interior bolts.
-
Remove the rear HV battery interior
bolts (x2).
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Close the LH and RH rear door latches
manually.
- Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
-
Place the vehicle in Service Mode
Plus.
- Enter the last six digits of VIN into the Vehicle Ops mobile app.
- Select vehicle from the list.
-
Swipe to the left, and then select
Enable Service Mode Plus
.
- Unlock the vehicle gateway. See Gateway Unlock.
-
On the touchscreen, tap the Service
Mode "wrench" (at the bottom of the touchscreen UI), and then tap Run, and allow the routine to
complete.
, select NoteThe Thermal Fill/Drain routine has a 50-minute time limit. After 50 minutes the routine must be performed again.
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
-
Remove the bolt that secures the
busbar cover access door.
Tip: Use of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Insulated Ratchet/torque wrench
- Insulated 10 in extension
-
Remove the bolts (x2) that attach the
charge port busbar kit to the HV header.
Tip: Use of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Insulated Ratchet/torque wrench
- Insulated 10 in extension
- Lift the busbar kit connector to remove it from the HV header.
- Remove the HV insulating gloves.
- Open the RH rear door.
-
Disconnect the HVC logic connector and
install the logic cap.
NoteRelease the locking tab then push the handle downward to release the connector.
- Remove the DCDC busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
-
Remove and discard the nut that
attaches the positive LV output to the PCS cable, and move the cable aside.
Tip: Use of the following tool(s) is recommended:
- 4 in extension
- Ratchet/torque wrench
- 13 mm socket
- Remove the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
- Remove the push clips (x6) that attach the lower rear edge of LH and RH front wheel liners to vehicle for access to the coolant hose.
-
Remove the bolts (x2) that attach the
LH front wheel liner to the skid plate.
Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
- Ratchet/torque wrench
- Use bungee strap to pull back the LH and RH front wheel liners and secure them to the subframe.
- Position a coolant drain container underneath the LH front of HV battery.
- Attach hose extension to the coolant drain hose for extra length.
- Connect the battery flush fitting adapter to the coolant cart drain hose.
- Disconnect the HV battery return hose at the LH side of vehicle and connect the battery flush fitting to the male side.
-
Attach the battery drain fitting
adapter to the female side of the HV battery return tube.
NoteMake sure the valve is set to closed. Perform a push-pull test to verify the adapter is fully engaged.
- Attach the battery drain fitting adapter to the coolant cart pressure hose.
- Turn the valve knob to vertical position to open the valve on the battery drain fitting adapter.
- Slowly open the valve on the pressure regulator and allow the coolant to drain out of the HV battery return tube. Once no coolant is draining, close the valve.
- Disconnect the compressed air from the coolant cart.
- Set the valve knob to closed position, and then remove the battery drain fitting adapter from the female side of the HV battery return tube.
- Remove the battery flush fitting adapter from the male side of the HV battery return tube, and plug the end of fittings as soon as possible.
- Position the coolant drain container underneath the RH front of HV battery.
- Disconnect the powertrain supply hose from the powertrain supply tube, and plug the ends of fittings as soon as possible to avoid coolant loss.
- Disconnect the powertrain return hose from the powertrain return tube, and plug the ends of fittings as soon as possible to avoid coolant loss.
- Disconnect the HV battery manifold hose, and plug the ends of fittings as soon as possible to avoid coolant loss.
- Remove the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
- Remove manifold tube from front of HV battery, and plug the ends of fittings as soon as possible to avoid coolant loss.
-
Disconnect the A/C compressor HV
harness connector.
NotePull back the red tab to unlock the connector, then push the orange lip and pull back, and then push the green lip and pull back to disconnect the connector.
- Release the front drive unit ground strap, but do not remove the last bolt that attaches the front drive unit ground strap to the HV battery. See Ground Straps - Front Drive Unit (Remove and Replace).
- Remove the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
- Perform an ancillary bay coolant leak test. See Ancillary Bay Coolant Leak Test (Inspection).
-
Disconnect the rear drive unit outlet
hose from the PT return tube, and plug the ends of fittings as soon as possible to avoid
coolant loss.
NoteThe hose is the lower hose located at the RH rear of HV battery. Use a shop towel to clean any residue coolant if necessary.NoteCoolant loss greater than 1L requires vacuum fill.
- Remove the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
-
Hand-tighten the bolts (x2) that
attach LH and RH sides of subframe to body.
- Remove the support stand from under the vehicle.
- Remove the rear drive unit HV harness. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
-
With assistance, place the HV battery
table into position and lower the vehicle to support HV battery.
NoteLine up the table so the center 4 bolts are accessible through the opening in table. Adjust the final battery table position using adjustable caster jacks on the table.
-
Remove the central bolts (x4) that
secure the HV battery center ski cover.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- Insulated 6 in extension
- External Torx Plus EP14
- Flex head ratchet/flex head torque wrench
-
Remove the bolts (x8) that attach the
LH and RH front support brackets to vehicle.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm socket
- 3 in extension
- Ratchet/torque wrench
-
Remove the bolts (x16) that attach the
HV battery to vehicle.
Tip: Use of the following tool(s) is recommended:
- 3 in extension
- 13 mm socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- With assistance, raise the vehicle free of the HV battery, and then remove the battery from under the vehicle.
- Remove and discard the ancillary bay engagement seal from the HV battery pack.
- Release the clips (x2) that attach the HV battery return tube to the rear of HV battery.
- Release the clips (x5) that attach the HV battery return tube to the LH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
- Release the clips (x5) that attach the PT supply tube to the RH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
- Release the clips (x5) that attach the PT return tube to the RH side of HV battery, then remove all coolant plugs from the hose and allow the hose to fully drain.
- Attach the HV battery H-frame to gantry and raise into position.
-
With assistance, position the HV
battery under the gantry.
NoteIf the original pack is RWD and the supplied pack is DM, a center ski transfer will be needed.
-
Lower the H-frame onto the HV battery
and hand-tighten the bolts that attach the H-frame to the battery.
NoteThe number of fasteners may vary.
- Remove the barrel clips (x2) that attach the ancillary harness bracket to the front of HV battery.
- Release the red locking tab and rotate the lever arm to disconnect the ancillary harness connector from the RH rear of HV battery.
- Raise the HV battery off of the battery table.
-
With assistance, remove the bolts (x2)
that attach the center ski cover to the HV battery, and leave the cover on the battery
table.
Tip: Use of the following tool(s) is recommended:
- Ratchet/torque wrench
- External Torx Plus EP14
- Position the gantry over pallet, and then lower the battery onto the pallet.
- Remove the H-frame from the old HV battery.
- Raise the gantry and the H-frame from the old HV battery.
- Remove the logic cap from the old battery pack.
Install
- With assistance, open the top of the crate with the new high voltage battery pack. Confirm the part number specific to vehicle configuration.
- Remove the nuts that attach the new HV battery to crate.
- Position the gantry over the new HV battery crate, and hand-tighten the bolts that attach the H-frame to the battery.
- Lift the new HV battery out of crate.
- With assistance, move the gantry away from the HV battery crate and over the HV battery table.
-
With assistance, lower the HV battery
onto the battery table.
NoteMake sure to align the HV battery onto the center ski.
- Install the barrel clips (x2) that attach the ancillary harness bracket to the front of HV battery.
-
Hand-tighten the outer bolts (x2) that
attach the center ski cover to the HV battery, and then torque to specification.Tip: Use of the following tool(s) is recommended:
- Ratchet/torque wrench
- External Torx Plus EP14
-
Connect the ancillary harness
connector to the RH rear of HV battery.
NoteHold the connector level with header and secure the connector with even upward force. Rotate the lever arm and secure the locking tab. Verify that the latch is fully secured and not damaged.
- Release the H-frame from the HV battery and raise the gantry.
- With assistance, remove the HV battery from under the gantry, and then position the gantry over the old HV battery.
- Lower the H-frame onto the old HV battery and hand-tighten the bolts that attach the H-frame to battery.
- Raise the old HV battery above the height of the HV battery crate.
-
Position the HV battery crate
underneath the old HV battery, and then lower the old HV battery into the crate.
NoteUse caution to align the 4 studs and do not damage the battery.
- Remove the H-frame from the old HV battery.
- Raise the gantry and the H-frame from the old HV battery.
- Lower the gantry and remove the HV battery H-frame from the gantry.
- Hand-tighten the 15mm nuts (x4) that attach the HV battery to crate.
- With assistance, close the crate top housing of the old HV battery.
- Install the logic cap onto the new battery pack.
- Secure the clips (x5) to install the HV battery return tube onto the LH side of HV battery.
-
Remove the plugs on the ends of
fittings, and connect the HV battery return tube to the LH and RH rear of HV
battery.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteCoolant loss greater than 1L requires vacuum fill.
- Install the clips (x2) that attach the HV battery return tube onto the rear of HV battery.
-
Install the clips (x5) that attach the
PT supply tube to the RH side of HV battery.
NoteCoolant loss greater than 1L requires vacuum fill.
-
Install the PT supply tube to the RH
rear of HV battery.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteUse a shop towel to clean any residue coolant if necessary.NoteCoolant loss greater than 1L requires vacuum fill.
- Install the clips (x5) that attach the PT return tube to the RH side of HV battery.
-
Remove the plugs on the ends of
fittings, and then install the clips (x4) that attach the manifold tube onto the front
of HV battery.
NotePerform a push-pull-push test to make sure that the hose is fully secured.
-
Install the ancillary bay engagement
seal onto the HV battery pack.
NoteThis seal is disposable and should be replaced each time a HV battery pack is removed from vehicle or installed onto a new HV battery pack if not equipped.
- Install the HV battery alignment rods to the body at front of the vehicle and to the battery near the ancillary bay.
- With assistance, position the HV battery under the vehicle.
-
With assistance, lower the vehicle
onto the HV battery and align the holes.
NoteBe sure that the coolant hoses do not get caught on the alignment rods. Caution not to damage the HV cable. Do not fully lower vehicle onto battery (this will help with installing battery bolts).
-
Use cordless impact to set the bolts
(x16) that attach the HV battery to vehicle.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting.NoteFlush down the bolts. Do not over tighten bolts. Fully torque at later step.
- Remove the HV battery alignment rods.
-
Use cordless impact to set the bolts
(x8) that attach the LH and RH front support brackets to vehicle.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting.NoteFlush down the bolts. Do not over tighten bolts. Fully torque at later step.
-
Use cordless impact to set the central
bolts (x4) that secure the HV battery center ski cover.
NoteEnsure smooth thread engagement and the bolts are not cross threaded into casting.NoteFlush down the bolts. Do not over tighten bolts. Fully torque at later step.
-
Hand-tighten the bolts (x4) that
attach the HV battery to body at the LH and RH shear plate areas.
- Install the rear drive unit HV harness. See HV Harness - HV Battery to Rear Drive Unit (Remove and Replace).
-
Remove the plugs on the ends of
fittings, and then connect the rear drive unit outlet hose to the PT return tube.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteUse shop towel to clean any coolant residue if necessary.NoteCoolant loss greater than 1L requires vacuum fill.
-
Remove the plugs on the ends of
fittings, and then connect the rear drive unit inverter inlet hose to the LH rear of HV
battery.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteCoolant loss greater than 1L requires vacuum fill.
- Install the rear skid plate enclosure. See Skid Plate - HV Battery - Rear (Remove and Replace).
- With assistance, lower the vehicle onto the pack completely.
-
Torque the bolts (x16) that attach the
HV battery to vehicle.Tip: Use of the following tool(s) is recommended:
- 3 in extension
- 13 mm socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
-
Torque the bolts (x8) that attach the
LH and RH front support brackets to vehicle.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm socket
- 3 in extension
- Ratchet/torque wrench
-
Torque the central bolts (x4) that
secure the HV battery center ski cover.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- Insulated 6 in extension
- External Torx Plus EP14
- Flex head ratchet/flex head torque wrench
-
Raise the vehicle to a comfortable
working height, and lower the lift onto locks, then remove battery table from under
vehicle.
CAUTION
Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.
Make sure that the doors are clear of surrounding objects.
- Use an underhoist stand to support the front portion of the rear subframe.
-
Remove the smaller fasteners (x4) for
the LH and RH shear plates.
- Install the LH and RH shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
- Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
- Remove the plugs on the ends of fittings, and then connect the HV battery manifold hose.
-
Remove the plugs on the ends of
fittings, and then connect the PT supply hose.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteCoolant loss greater than 1L requires vacuum fill.
-
Remove the plugs on the ends of
fittings, and then connect the PT return hose.
NotePerform a push-pull-push test to make sure that the hose is fully secured.NoteCoolant loss greater than 1L requires vacuum fill.
- Install the front skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
-
Release the LH and RH front wheel
liners from the bungee straps and remove the straps from the vehicle.
-
Install the bolts (x2) that attach the
LH and RH front wheel liners to the skid plate.Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
- Ratchet/torque wrench
- Connect the HV battery return hose.
- Connect the A/C compressor HV harness connector.
- Install the front drive unit ground strap. See Ground Straps - Front Drive Unit (Remove and Replace).
- Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
- Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
-
Position the busbar kit connector and
lower it onto the HV header.
NoteShift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
-
Install the bolts (x2) that attach the
charge port busbar kit to the HV header.Tip: Use of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Insulated Ratchet/torque wrench
- Insulated 10 in extension
-
Install the bolt that secures the
busbar cover access door.Tip: Use of the following tool(s) is recommended:
- Insulated 10 mm 12-point deep socket
- Insulated Ratchet/torque wrench
- Insulated 10 in extension
- Install the DCDC busbar. See Harness - Busbar - 12V DCDC (Remove and Replace).
- Connect the DCDC positive cable to the right body harness.
- Remove the logic cap and connect the HVC logic connector. Align the connector then pull the handle to locking position to get the connector fully seated.
- Connect the first responder loop but leave the LV battery disconnected.
- Connect an LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
- On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Run, and allow the routine to complete. , click
- Select High Voltage Battery Replacement Routine, click Run, and allow the routine to complete.
- Disconnect the LV maintainer.
- Remove the lift arms from below the vehicle.
- On the touchscreen, tap , and then allow the routine to complete.
-
Inspect the coolant level, top off as
necessary.
NoteEnsure that the coolant level is at the "Max" line.
-
On the touchscreen, select
Run, and then allow the routine to complete.
, click Note
- The routine will last for a while after the stop message displays. The coolant pumps are audible.
- The test lasts for approximately 10 mins. Do not start another routine during this time.
- Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
- The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
- If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
-
Install the LH and RH rear HV battery
interior bolts (x2).NoteLift up the carpet for access.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Install HV battery bolt below rear end of LH and RH front seat cushion.
Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- 16 mm deep socket
- Flex head ratchet/flex head torque wrench
- Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
-
Close both rear doors.
NoteRelease the latches before closing if they are manually latched.
- Open the LH front door.
-
Install the LH front footwell HV
battery bolts (x2).Tip: Use of the following tool(s) is recommended:
- Torx Plus EP20 socket
- Cordless Ratchet/Impact Driver
- 3/8 in to ½ in adapter
- 3 in extension
- Ratchet/torque wrench
-
Install the push clips that attach the
LH front main cabin carpet to the vehicle.
NoteNumber of clips on new vehicles may vary.
- Install the LH console side panel carpet. See Carpet - Side - Center Console - LH (Remove and Replace).
- Install the drive footwell cover. See Cover - Footwell - Driver (Remove and Replace).
-
Install the LH front seat bolts.Tip: Use of the following tool(s) is recommended:
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- ¼ in to 3/8 in adapter
- Install the LH lower A-pillar trim. See Trim - A-Pillar - Lower - LH (Remove and Replace).
- Install the LH front primary door seal.
- Repeat step 80 through step 87.
- Install all the floor mats. See Kit - Floor Mat - LHD (Remove and Replace).
-
Inspect the coolant level, top off as
necessary, and then install the coolant bottle cap.
NoteEnsure that the coolant level is at the "Max" line.
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Install the LH and RH rocker panel covers. See Cover - Rocker Panel - Lower - LH (Remove and Replace).
- Exit Service Mode. See Service Mode.
- Raise all windows.
- Close both front doors.