直流导线总成，正极，高压电池 ((拆卸和更换))

Raise and support vehicle

注

Ensure vehicle is not charging

Open all four doors

注

If vehicle is being powered down, Latch rear doors to prevent accidental closure

Lower all four windows

Move LH front seat forward

Move RH front seat forward

Open hood

Remove rear underhood apron

注

14x clips

Power off vehicle from center display

注

Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

Disconnect LV battery and First Responder Loop

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2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

Raise vehicle fully and lower lift onto locks

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Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects

Remove LH and RH clips securing rear aero shield to wheel house liner

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2x clips

Remove rear aero shield

注

11x bolts, 10mm, 5 Nm

Release LH side hose clip from rear battery skid plate enclosure

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1x fir tree clip

Release RH side hose clips from rear battery skid plate enclosure

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2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

注

2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count

Remove upper nut securing HV battery rear skid plate enclosure

注

1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles

Remove upper bolts securing HV battery rear skid plate enclosure

注

4x bolts, 13mm, 35 Nm

Remove HV battery rear skid plate enclosure

Position coolant drain container underneath LH rear of HV battery

Disconnect LH coolant hose from rear of HV battery

注

1x spring clip, 2x plugs, Plug both the coolant hose and passthrough

Remove fir tree clip securing coolant hose to rear subframe shear plate

注

1x fir tree clip

Disconnect RDU inverter inlet tube from LH rear of HV battery

注

1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill

Attach coolant drain hose adapter to PCS outlet hose coupling

注

Use adapter with 90 degree angle, Make sure locking tab is fully seated

Attach coolant drain hose adapter to coolant hose extension

Attach coolant hose extension to coolant drain hose

注

Use caution as coolant may spill, Make sure to wear safety glasses

Position coolant drain container underneath RH rear of vehicle

Disconnect rear PT supply hose from rear of HV battery

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1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill

Attach coolant pressure tester to PCS inlet hose coupling

注

This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated

Attach coolant pressure tester to pressure fitting adapter

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

注

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

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Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

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Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

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Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

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Once timer is complete, select Stop Reset

Close regulator valve

Disconnect compressed air from coolant pressure tester

Remove coolant pressure tester from PCS inlet hose coupling

Position coolant drain container underneath LH rear of HV battery

Remove coolant drain adapter with hose from PCS outlet hose coupling

注

1x spring clip

Attach coolant pressure tester with hose to PCS outlet hose coupling

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1x spring clip, Make sure the locking tab is fully seated

Position coolant drain container underneath RH rear of vehicle

Attach coolant drain adapter with hose to PCS inlet hose coupling

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1x spring clip, Make sure the locking tab is fully seated

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

注

Use caution as coolant may spill, Make sure to wear safety glasses

Open 2nd valve slowly

注

Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 1 minutes and select start

注

Once timer is complete, select Stop Reset

Close regulator valve

Set timer for 1 minutes and select start

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Once timer is complete, select Stop Reset

Open regulator valve slowly

Set timer for 1 minutes and select start

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Once timer is complete, select Stop Reset

Close regulator valve

Disconnect compressed air from coolant pressure tester

Disconnect coolant hose extension from coolant drain hose

Disconnect coolant drain hose adapter from coolant hose extension

Remove coolant drain hose adapter from PCS inlet hose coupling

注

1x spring clip, Install plug to inlet hose coupling

Position coolant drain container underneath LH rear of HV battery

Remove pressure fitting adapter from coolant pressure tester

Remove coolant pressure tester from PCS outlet hose coupling

注

1x spring clip, Install plug to outlet hose coupling

Remove coolant drain container from underneath vehicle

Lower vehicle fully

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Release 2nd row seat cushion and disconnect harness

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2x clips, 2x connectors, Press tabs backward then pull front edge up

Verify operation of multimeter

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Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

注

Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf

Put on HV insulating gloves and leather over gloves

注

Make sure to wear Electrical Protective Gloves any time Hioki tester is used

Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

注

2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover from ancillary bay cover

Verify no high voltage

注

Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

注

Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

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2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners

Remove HV insulating gloves

Disconnect HVC logic connector and install logic cap

注

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Remove bolts securing ancillary bay cover to HVC

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3x bolts, E10, 5 Nm + 30 degrees

Remove bolts securing ancillary bay cover to HV battery

注

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

Inspect HV insulating gloves

注

Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf

Put on HV insulating gloves and leather over gloves

注

Make sure to wear Electrical Protective Gloves any time Hioki tester is used

Remove ancillary bay cover from HV battery

Inspect ancillary bay for any missing insulators

注

Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary

Remove bolts securing pyro disconnect to ancillary bay

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1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal

Remove pyro disconnect from ancillary bay

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1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay

Install pyro disconnect dummy

Use bungee to secure HVC in an upwards position

注

Wrap bungee around RH headrest

Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping

Disconnect PCS coolant inlet hose from PCS

注

2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose

Disconnect PCS coolant outlet hose from PCS

注

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS and hose

Disconnect PCS to DC bus HV connector

注

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS logic connector from PCS

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1x connector

Disconnect PCS LV connector from PCS

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1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS to AC harness connector

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1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove bolts securing PCS to HV battery

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5x bolts, 8mm, 18 Nm, Ensure onlythe 8mm fasteners are removed, Do not remove the T30 fasteners

Secure suction cups to PCS

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Continue pressing plunger until red line is no longer visible

Lift PCS up and out of ancillary bay area and remove from vehicle

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Slightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Install HV joint insulator for positive busbar module 2 to pyro disconnect

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1x insulator

Install HV joint insulator for negative busbar module 3 to shunt

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1x insulator

Install HV joint insulator for positive DC link to module 4

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1x insulator

Disconnect ancillary bay harness connectors from positive pack contactor

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2x connectors

Remove ancillary bay harness clip from positive pack contactor

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1x clip

Remove HV joint insulators from positive HV switch

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2x insulators

Remove bolt securing positive pack contactor to positive busbar

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1x patch bolt, 13mm, 9 Nm, Discard after removal

Remove nut securing positive pack contactor to module 4 rear terminal

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1x patch nut, 13mm, 9 Nm, Discard after removal

Remove nuts securing positive pack contactor to ancillary bay

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3x nuts, 10mm, 8 Nm, Use insulated magnet to retrieve the nuts after removal, The number of nuts on newer vehicles may vary

Remove positive pack contactor from ancillary bay

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2x guide pins

Release positive LV output cover from PCS cable

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1x cover

Remove bolt securing DCDC ground busbar to body

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1x bolt, 12mm, 20 Nm

Remove nut securing DCDC ground busbar to HV battery

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1x nyloc nut, 13mm, 9 Nm, Discard nut after removal

Remove DCDC ground busbar

Remove nut securing positive LV output from PCS cable and move cable aside

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1x nut, 13mm, 15 Nm, Discard after removal

Remove bolts securing DCDC pass through to ancillary bay

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2x bolts, E10 5-Lobe, 10 Nm

Remove DCDC pass through from ancillary bay

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Electrical Protective Gloves

Remove HV joint insulator for positive DC link to module 4

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1x insulator

Remove nut securing DC link to module 4

注

1x patch nut, 13mm, 9 Nm, Discard after removal

Move positive DC link out to allow access to ancillary bay harness clips

Remove ancillary bay harness clips from positive DC link

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3x clips

Remove positive DC link from ancillary bay

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2x guide pins

Position the positive DC link for installation

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2x guide pins

Install ancillary bay harness clips to positive DC link

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3x clips

Install nut securing joint DC link to module 4

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1x patch nut, 13mm, 9 Nm, Install new patch bolt, Mark after torque

Perform resistance measurement on DC link to module 4 and busbar

注

1x HV joint, 60_xD835__xDF07_Ω or less

Install HV joint insulator for positive DC link to module 4

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1x insulator

Position DCDC pass through to ancillary bay for installation

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Electrical Protective Gloves

Install bolts securing DCDC pass through to ancillary bay

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2x bolts, E10 5-Lobe, 10 Nm, Mark the bolts after torque

Install positive LV output

注

1x nut, 13mm, 9 Nm, Make sure rubber boot is not pinched between cable terminal and pass through

Install positive LV output cover to PCS cable

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1x cover

Install DCDC ground busbar

注

Slotted hole goes to body side

Install bolt securing DCDC ground busbar to body

注

1x bolt, 12mm, 20 Nm

Install nut securing DCDC ground busbar to HV battery

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1x nyloc nut, 13mm, 9 Nm, Install new nyloc nut

Position positive pack contactor to ancillary bay for installation

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2x guide pins

Install nuts securing positive pack contactor to ancillary bay

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3x nuts, 10mm, 8 Nm, Use insulated magnet as needed to position nuts onto studs, The number of nuts on newer vehicles may vary

Install bolt securing positive pack contactor to positive busbar

注

1x patch bolt, 13mm. 9 Nm, Install new patch bolt, Mark after torque

Install nut securing positive pack contactor to HV battery tall terminal to module 4 rear terminal

注

1x patch nut, 13mm, 9 Nm, Install new patch nut, Mark after torque

Measure resistance from HV joint between HV battery positive contactor and the center of HV battery positive terminal

注

1x HV joint, 110_xD835__xDF07_Ω or less

Perform Hioki impedance test at HV joint of positive pack contactor to DC link busbar

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1x HV joint, 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), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is less than 0.020 mΩ (20 μΩ), reposition the probes and measure again.

Install HV joint insulators onto positive pack contactor

注

2x insulators

Install ancillary bay harness clip to positive pack contactor

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1x clip

Connect ancillary bay harness connectors to positive pack contactor

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2x connectors

Position the PCS into ancillary bay

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Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary

Remove suction cups from PCS

Install bolts securing PCS to HV battery

注

5x bolts, 8mm, 18 Nm

Connect PCS to fastcharge contactor HV harness connector

注

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS LV connector to PCS

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1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS logic connector to PCS

注

1x connector

Connect PCS to DC bus HV connector

注

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Replace o-ring on PCS side inlet hose

注

1x o-ring, Apply light amount of Krytox 203

Connect PCS coolant inlet hose to PCS

注

2x clips, 1xplug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated

Replace o-ring on PCS side outlet hose

注

1x o-ring, Apply light amount of Krytox 203

Connect PCS coolant outlet hose to PCS

注

2x clips, 1x plug, Remove plug from PCS, Place absorbent sheet under hose to catch excess coolant, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Lay HVC in original position

注

Release bungee from back of headrest

Remove pyro disconnect dummy

Clean mating surfaces

注

Allow to 1 minute dry time,Use an IPA wipe to clean the HV mating surfaces of the shunt, busbar, and the pyrotechnic battery disconnect

Set multimeter to "LoZ" (low impedance) mode

Measure voltage between busbar and shunt

注

While still measuring the voltage, have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, and then press the pyrotechnic battery disconnect down onto the busbars

Position pyro disconnect to ancillary bay for installation

注

1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way

Install bolts securing pyro disconnect to ancillary bay

注

2x patch bolts, 13mm, 9 Nm

Measure resistance from module 2 busbar to pyro disconnect

注

1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing

Measure resistance from pyro disconnect to shunt

注

1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing

Remove service insulator kit

Inspect ancillary bay walls for damage

注

Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused

Inspect ancillary bay cover seal to confirm it has no visual damage

注

Image up close for clarity, Delaminated and torn seals cannot be reused

Position ancillary bay cover to HV battery for installation

注

Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.

Remove HV insulating gloves

Install bolts securing ancillary bay cover to HV battery

注

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

Install bolts securing ancillary bay cover to HVC

注

3x bolts, E10, 5 Nm + 30 degrees

Remove logic cap and connect HVC logic connector

注

1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

Connect 2nd row seat harness and secure cushion

注

2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test

Raise vehicle fully and lower lift onto locks

注

Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side

Position coolant drain container underneath RH rear of vehicle

Install coolant pressure test plug adapter to PCS inlet hose coupling

注

1x spring clip, 1x plug, Remove plug from inlet hose coupling, Make sure the locking tab is fully seated

Position coolant drain container underneath LH rear of HV battery

Install coolant pressure tester to PCS outlet hose coupling

注

1x spring clip, 1x plug, Remove plug from outlet hose coupling, Make sure the locking tab is fully seated

Install pressure fitting adapter to coolant pressure tester

Connect compressed air to coolant pressure tester

Open regulator valve then slowly adjust regulator to 50 psi

Slowly open valve on pressure regulator and allow pressure to reach specification

Close the valve and let pressure settle

注

Wait 2 minutes for pressure to settle, Record the reading

Perform the coolant pressure leak test

注

Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails

Remove pressure fitting adapter from coolant pressure tester

Remove coolant pressure tester from PCS outlet hose coupling

注

1x spring clip

Remove plug from HV battery and connect RDU inverter inlet tube

注

1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged

Connect LH coolant hose to rear of HV battery

注

1x spring clip, 2x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

Position coolant drain container underneath RH rear of vehicle

Remove coolant pressure test plug adapter from PCS inlet hose coupling

注

1x spring clip

Connect rear PT supply hose to rear of HV battery and plug hose

注

1x spring clip, 1x plugs, Remove plugs, Perform push-pull-push test to make sure hose is fully seated.Vacuum fill required if > 1L lost during repair

Remove coolant drain container from underneath vehicle

Position HV battery rear skid plate enclosure onto HV battery for installation

注

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

注

4x bolts, 13mm, 35 Nm, Torque at later step

Install upper nut securing HV battery rear skid plate enclosure hand tight

注

1x nut, 10mm, 13 Nm, Torque at later step

Install lower bolts securing HV battery rear skid plate enclosure

注

2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts

Torque bolts securing HV battery rear skid plate enclosure to vehicle

注

4x bolts, 13mm, 35 Nm

Torque upper nut securing HV battery rear skid plate enclosure

注

1x nut, 10mm, 13 Nm

Install RH side hose clips to HV battery rear skid plate enclosure

注

2x fir tree clips

Install LH side hose clip to HV battery rear skid plate enclosure

注

1x clip

lnstall rear aero shield

注

11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts

Install LH and RH clips securing rear aero shield to wheel house liner

注

2x clips

Lower vehicle fully

注

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Remove coolant bottle cap

Place empty coolant container into front storage area

Fill container with at least 15L of coolant

Place filled coolant container into front storage area

Install refill tool cap onto coolant bottle assembly

Setup vacuum refill tool

注

Verify all valves on refill tool are in the closed position, See image for clarity

Install vacuum refill hose into refill cap on coolant bottle

注

Perform push-pull-push test to verify hose is fully engaged

Position overflow hose into empty container

Place refill hose inside filled coolant container

注

Make sure hose end is fully submerged into coolant

Connect shop air supply to coolant refill tool

注

If not already done, Verify refill valve is set to off

Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

注

Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant

注

This purges trapped air from the hose

Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system

Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve

Slowly open refill valve to allow coolant to be drawn into system

注

Make sure hose end of refill hose is fully submerged during entire process

Once gauge reads zero, close refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Remove vacuum refill hose from refill cap on coolant bottle

Remove coolant refill tool from vehicle

Remove both coolant containers from inside underhood area

Connect First Responder Loop and LV battery

注

2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

Place vehicle in service mode through UI

注

Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box

Unlock vehicle gateway

注

After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information

Access Thermal System routines using the UI

注

Select Service mode > Thermal

Select "Start Coolant Air Purge" using the UI

注

等待冷却液泵停止运行（可听见噪音），界面上将出现“例行程序完成”，但冷却液泵将继续运行 10 分钟，如果在这段时间内开始执行下一例行程序，该例行程序将运行失败。确保车辆未处于“前进挡”，即使出现完成消息，例行程序仍在运行，怠速 = 约1500 RPM，测试中，速度将在 3500-6500 RPM 之间变化，启动的阀门将在串联和并联之间切换，将车辆置于“行驶”状态，此例行程序将停止。如果速度在 7000 RPM 左右徘徊，则说明冷却液泵存在气锁状况，请进行真空加注；继续添加冷却液并排空空气，直至冷却液液位介于冷却液罐上的 NOM 与 MAX 线之间