28/10/2024 14:38:41

Bracket - Skid Plate - Front - HV Battery (Remove and Replace)

Correction code 16102012 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.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Open all doors and lower all windows.
Place the vehicle on the 2-post lift.

Tip: Ensure the vehicle is not charging.
Place vehicle in service mode through UI

Note
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
Turn Off the AC and Blower motor

Note
Check temperature icon at the bottom of the screen, If it greyed, AC is already off, If it bright, press and hold it for 2 seconds or press it once and press the switch icon in pop-up menu
Turn on the drive rail

Note
Sit in the driver’s seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle
Access Thermal System routines using the UI

Note
Select Service mode > Thermal
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
Select ‘Actions/Autodiag’ and search for ‘Plus’
Select "PROC_ICE_X_ENTER-SERVICE-MODE-PLUS ", click "Run", and allow routine to complete

Note
Select "x" at the top right of the window to close once complete
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Select "Start Thermal Fill Drain (Coolant only)" using the UI

Note
Reference pictures for navigation, Wait for the coolant section to say "Ready for Fill/Drain" and turn green also for "Inactive" to turn green and say "Success"
Move LH front seat forward
Move RH front seat forward
Open hood

Note
Press "Open" button on the touchscreen to release the latch, Lift the lid manually
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box
Remove rear apron

Note
12x clips, Only store rear apron visible face upwards
Remove cabin intake upper duct assembly

Note
4x clips, Heat pump vehicles have 3x clips
Remove closeout panel from frunk assembly

Note
4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab closeout panel from bottom then pull it upward to release clips, Disconnect the switch
Remove bolts securing frunk assembly

Note
7x bolts, 10mm, 5 Nm, Lift up RBN covers to access upper fasteners, Newer vehicles may not be equipped with covers
Remove frunk assembly from vehicle

Note
12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles
Release positive terminal cover

Note
2x clips
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 12v battery
Install positive terminal cover

Note
2x clips
Disconnect 12V negative terminal

Note
1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
Disconnect first responder loop

Note
1x connector, Release locking tab
Remove 2nd row seat cushion and disconnect harness

Note
2x tabs, 2x connectors, Press tab toward LH side of vehicle on each side to release front edge of seat cushion
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf
Put on HV insulating gloves and leather over gloves

Note
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

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, 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

Note
Confirm no damage is present, Seal can be re-used
Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Raise vehicle fully and lower lift onto locks

Note
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 outer fasteners securing front aero shield

Note
9x bolts, 10mm, 5 Nm
Remove remaining nuts and remove front aero shield from vehicle

Note
2x nuts, 15mm, 5 Nm
Remove the clips securing the front LH and RH wheel liners to the front skid plate

Note
2x push clips
Remove bolts securing front skid plate

Note
4x bolts, EP10, 13 Nm
Remove skid plate from HV battery
Inspect Front Skid Plate Bracket for the damage

Note
If HV battery passed all the previous checks and there is no visible damage to the HV battery structure apart of Front Skid Plate Bracket, continue with further steps
Position coolant drain container below HV battery hose
Remove RH manifold tube from LH manifold tube

Note
1x spring clip, 2x plugs,Prepare plugs from Coolant Hose Plug Kit, red and 18mm black,Move the retaining spring clip up into the grooves in the quick release coolant hose connector, Separate connectors and plug both ends
Position coolant drain container underneath RH manifold tube inner connection to HV battery
Remove RH manifold tube

Note
1x spring clip, 2x plugs. Prepare plugs from Coolant Hose Plug Kit, Dark Green and 12mm black,Move the retaining spring clip up into the grooves in the quick release coolant hose connector, Separate connectors and plug both ends
Remove RH manifold tube

Note
Move RH manifold tube and secure it with cable tie
Remove coolant drain container from underneath vehicle
Remove bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Disconnect the FDU HV harness connector

Note
1x clip, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the FDU header are not damaged
Remove the FDU HV harness connector from the FDU and move aside

Note
1x connector
Disconnect both AC compressor and PTC heater HV harness connectors on HV battery

Note
2x locking connectors, 2 stage locking connectors, Disengage the red locking tab by pulling it away from the connector, then depress the green tab to release
Remove ancillary harness bracket from front of HV battery

Note
2x barrel clips
Wrap connectors

Note
Wrap connectors to prevent from debris or metal chips
Remove HV insulating gloves
Remove center ski cover from HV battery

Note
6x bolts, EP14, 34 Nm. Gently lower front of center ski cover to the floor
Use a spring loaded center punch to mark locations for drilling

Note
Use a center punch to create a small dimple in the center of each spot weld
Use spot weld cutters to remove the Front Skid Plate Bracket

Note
Use 3/8" size spot weld cutter,Use chiseling technique at high speed to allow the chips to fly out as the cut exits the aluminum, or clean the cutter manually after short drilling, Drill to a depth of no more than the thickness of the Skid Plate Bracket approximately 2.5mm,
Separate Skid Plate Bracket from HV battery

Note
When cutter is deep enough, use 38 mm Scraper or plastic wheel weight removal chisel and light hammer blows to try to separate the skid plate from the battery, If it didn't get off easy, try to drill a little deeper
Apply masking tape

Note
Mark mating surface with masking tape
Clean mating area

Note
Use 120 grit sand paper to remove paint on the mating surfaces
Create a stencil of holes for new skid plate bracket

Note
Stick the masking tape on old Skid Plate Bracket along the top edge,Use thin ballpoint pen to mark the holes and Skid Plate Bracket location on a masking tape peace
Mark the location of the new holes

Note
Remove a stencil from the old bracket and apply to the new one strictly in the same location,Use center punch to create a small dimple in the center of each circle
Drill holes in the new Skid Plate Bracket.
Note
Secure the new Skid Plate Bracket in a vise with a 5/16" Spot Weld Cutter. Use chiseling technique at high speed to allow the chips to fly out as the cut exits the hole, or clean the cutter manually after short drilling.
Tip: Use of the following tool(s) is recommended:
- Bench Vise
- Size Spot Weld Cutter
- Cordless Drill
- Safety Glasses
Remove masking tape

Note
Remove masking tape from the HV battery and Skid Plate Bracket
Clean mating area

Note
Use 120 grit sand paper to clean future mating surfaces
Fit the pieces together

Note
Try the Skid Plate Bracket on a HV battery and check that the flat surfaces fit snugly together
Clean mating areas with Isopropyl alcohol
Allow 1 minute dry time
Apply adhesive

Note
3M Static Mixing Nozzle for 200 ml cartridges; 3M Scotch-Weld EPX Manual applicator 200ml
Install the Skid Plate Bracket on a HV battery

Note
Install Skid Plate Bracket on a HV battery. Use the long bolt from the ski plate, screw it in by hand in the first hole,Apply slight pressure to the bracket using 2 wedges, slightly zip tie the wedge as shown on pictures
Set up temperature measurement tool

Note
Set up the Digital multimeter with thermocouple attached to it, Be careful with the polarity of the plug, Press LPF button to change from °F to C°, Turn switch to Temp position,Check if the temperature readings are real,Attach thermocouple to the skid plate
Use a heat gun to reduce curing time of adhesive

Warning
When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery. Attach the Bosch digitally adjustable temperature heat gun to the Transmission Jack with the zip ties, Install it facing the skid plate bracket 10 cm from it curing▪ 7 days at 23 ± 2 °C▪ 2 hours at 65 ± 2 °C
Allow adhesive to cure

Warning
When force curing adhesive in a repair area near the High Voltage Battery, do not allow the High Voltage Battery to reach a temperature above 74°C (165°F). Heating the High Voltage Battery above 74°C (165°F) for an extended period could result in injury to personnel and/or damage to the battery. Plug the heat gun to the power source, Turn it on and set up 100°C and air flow on average speed, Keep in mind, that temperature readings on a heat gun is not real but predicted,Monitor temperature on multimeter every 5 minutes for the first 30 minutes, every 10 minutes after establishment,If after 30 minutes temperature is less than 65°C or rising above adjust it on heat gun. Allow adhesive to cure for 2x hours
Allow adhesive to cure

Note
Allow adhesive to cure 2 hours
Remove wedges

Note
Cut the zip tie and remove wedges, Remove bolt from the center ski cover first hole
Touch Up bare metal spots

Note
Touch Up bare metal spots
Install center ski cover onto HV battery

Note
6x bolts, EP14, 34 Nm
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove masking tape from connectors
Install ancillary harness bracket to front of HV battery

Note
2x barrel clips
Connect both AC compressor and PTC heater HV harness connectors on HV battery

Note
2x locking connectors, 2 stage locking connector, After the connector is seated and there is an audible click, Engage the second lock by pressing towards the connector
Install FDU HV harness connector to FDU

Note
1x connector, Install HV connector lever lock to FDU HV cable connector, Align connector to FDU then remove HV connector lever lock before fully latching connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
Remove HV insulating gloves
Install bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Set free RH manifold tube

Note
Cut cable tie and set free RH manifold tube
Position coolant drain container underneath RH manifold tube inner connection to HV battery
Install RH manifold tube to front of HV battery

Note
1x spring clip, 2x plugs, Remove plugs from HV battery and manifold tube,Join quick release coolant hose connectors, Push the retaining spring clip to the place, Perform push-pull-push test to make sure hose is fully seated
Position coolant drain container below HV battery hose
Install RH manifold tube to LH manifold tube

Note
1x spring clip, 2x plugs, Remove plugs from HV battery and manifold tube,Join quick release coolant hose connectors, Push the retaining spring clip to the place, Perform push-pull-push test to make sure hose is fully seated
Remove coolant drain container from underneath vehicle
Install front skid plate onto HV battery

Note
2x tabs, Slide tabs onto front of HV battery
Install the bolts securing the front skid plate to the HV battery

Note
4x bolts, E10, 13 Nm
Install the clips securing the front LH and RH wheel liners to the front skid plate

Note
2x push clips
Position front aero shield to vehicle and install nuts

Note
2x nuts, 15mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
9x bolts, 10mm, 5 Nm
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove coolant bottle cap
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
Connect 2nd row seat cushion harness and install 2nd row seat cushion

Note
2x connectors, 2x clips, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips
Move RH front seat to original position
Move LH front seat to original position
Turn on the drive rail

Note
Sit in the driver’s seat and step on the brake pedal while key card is placed next to cup holder to turn on the drive rail and power on the vehicle
Access Thermal System routines using the UI

Note
Select Service mode > Thermal
Select "Stop Thermal Fill Drain" using the UI
Select "Start Coolant Air Purge" using the UI

Note
Wait till coolant pumps stop to run (audible noise), The Success sign will appear shortly, but pumps will run for 10 minutes, If you start next procedure during this time, it will fail, Make sure vehicle is not in "Drive", Plan is still running despite the stop message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Install frunk assembly to vehicle

Note
12x clips, Make sure frunk assembly is fully seated onto clips, Number of clips may vary on older vehicles
Install bolts securing frunk assembly

Note
7x bolts, 10mm, 5 Nm, Lower RBN covers after installing upper fasteners, Newer vehicles may not be equipped with covers
Install frunk close out panel

Note
4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align 3x tabs then push downward to secure clips
Install cabin intake upper duct assembly

Note
4x clips, Heat pump vehicles have 3x clips
Install rear apron

Note
12x clips
Close hood
Raise all windows
Exit Service Mode +

Note
Use UI screen to exit SM+
Close all four doors

Note
Unlatch rear doors before closing
Remove lift arms from below vehicle

Note
Lower rack arms fully and remove them from under vehicle