2026-11-06

高压电池（全轮驱动）（拆卸和更换）

校正代码 16010202 4.92 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 人员保护 to make sure wearing proper PPE when performing the below procedure. NOTE: See 人体工程学注意事项 for safe and healthy working practices.

  • 2026-10-28: Revised procedure based on latest procedure validation.
  • 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.
  • 2026-04-02: Added PTC heater electronics, charge port components and center ski harness retrofit steps.
  • 2025-10-13: Updated procedure so that the coolant vacuum fill is performed before LV is reconnected.
  • 2025-10-10: Changed procedure sequence for cleaning the HV busbar and HV header connector contact surfaces.
  • 2025-10-10: Updated steps to remove/install the bolts (x4) that attach the front of the HV battery to the vehicle.
  • 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.
  • 2024-10-31: 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.
  • 2023-10-25: Reorganized logic for PTC fuse check and installation.
  • 2023-07-11: Reorganized steps to accommodate service while standing.
  • 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 - 通用举升机垫适配器
  • 1133787-00-A 安全带释放按键，Model 3
  • 1020566-00-F ASY, Battery Table, Manual Lift
  • 1020566-99-A 电池操作台手动升降机顶板
  • 1129166-00-A Hoist, H-Frame EMEA
  • 1073363-00-A Gantry, Adjustable, Aluminum
  • 1134523-00-A 电池校准杆套件，Model 3
  • 1140311-00-A Lever Lock, HV Connector, Model 3
  • 1053600-00-B 驱动单元压力测试固定装置
  • 1130942-00-B 冷却液储液罐压力测试适配器
  • 1132185-00-B 冷却液泄漏测试适配器套件，Model 3
  • 1133843-00-A 冷却液排放和加注适配器套件，M3
  • 1135762-00-A 冷却软管维修堵头套件，Model 3
  • 1065131-00-A 电池冷却液排放和加注套件
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140501-00-A Pack Kit, Enclosure, Leak Test, HV Battery, Complete
  • 1144879-00-A Kit, Encl Leak Test Adapters, HV Battery
  • 1108272-00-B 变流器逻辑连接器盖，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.

Discharge

警告：为遵从当地法律规定，高压锂电池必须在放电后打包运输。此外，高压电池也必须在放电后进行存放。要进行运输的高压电池，其充电状态 (SoC) 必须小于 25% 或 45%（以地区规定为准）。如果运输方式未知或不确定，或者电池需要存放，则建议将高压电池放电至 25% 以下。

警告：放电后，等待 20 分钟，确认充电状态低于目标值。等待 20 分钟后，开路电压 (OCV) 会稳定下来，这对于确保测量准确至关重要。如果充电状态未达到规定水平，请继续放电。

请确保使用高压电池通信工具收集所有高压电池装运数据，且最好是在将高压电池从车辆上拆下之前收集。

警告：切勿运输或存放已失去高压绝缘的高压电池。请先验证高压电池绝缘状况，再打包运输或进行存放。请参阅 Toolbox 文章#41977或客户文档CD-21-16-003中所述的高压电池通信工具，以确定高压电池参数是否处于运输或存放的安全限值范围内。
Note
如果可能，请在拆卸高压电池前执行放电程序并收集高压电池装运数据。与拆下电池后使用电池放电工具相比，此方法用时更短，所需用户交互也较少。只有通过认证的技术人员才能使用电池放电工具。.
Note
放电程序的步骤主要在维修时间进行，可由维修顾问/前台团队以及维修技术人员执行。.
  1. Enable Service Mode Plus. See 维护模式增强版.
  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.

拆卸

  1. Remove the LH and RH lower rocker panel covers. See 盖板 - 门槛板 - 下 - 左侧（拆卸和更换）.
  2. Open all doors and lower the windows.
    Note
    Latch the rear doors to prevent accidental lockout.
  3. Remove the rear underhood apron. See 前备箱挡板 - 后部（拆卸和更换）.
  4. Remove the cabin intake duct. See 槽 - 上部 - 驾驶室进气（拆卸和更换）.
  5. Move the driver seat fully rearwards.
  6. Remove the LH instrument panel end cap. See 端盖 - 仪表板 - 左侧（拆卸和更换）.
  7. Remove the LH middle A-pillar trim. See 饰板 - A 柱 - 中部 - 左侧（拆卸和更换）.
  8. Remove the LH lower A-pillar trim. See 饰板 - A 柱 - 下 - 左侧（拆卸和更换）.
  9. Remove the driver footwell cover. See 盖板 - 脚部空间 - 驾驶位（拆卸和更换）.
  10. Remove the LH front floor mat.
  11. Remove the LH center console side panel carpet. See 侧板 - 中控台 - 左侧（拆卸和更换）.
  12. Remove the clips (x3) that attach the LH front carpet to the vehicle.
  13. Fold the LH front carpet for access, and then release the seat harness from the clip to allow the carpet to fold back further.
    Note
    The driver footrest is part of the LH front carpet.
  14. Remove the LH front footwell HV battery bolts.
  15. Inspect below front end of LH front seat cushion if a HV battery bolt is present. If present, remove the bolt.
    Note
    Newer vehicles may not be equipped with this bolt.
  16. Move the LH front seat fully forward.
  17. Move the RH front seat fully rearwards.
  18. Remove the RH instrument panel end cap. See 端盖 - 仪表板 - 左侧（拆卸和更换）.
  19. Remove the RH middle A-pillar trim. See 饰板 - A 柱 - 中部 - 左侧（拆卸和更换）.
  20. Remove the RH lower A-pillar trim. See 饰板 - A 柱 - 下 - 左侧（拆卸和更换）.
  21. Remove the front passenger footwell cover. See 罩 - 脚部空间 - 副驾位 (LHD)（拆卸和更换）.
  22. Remove the RH front floor mat.
  23. Remove the RH center console side panel carpet. See 侧板 - 中控台 - 左侧（拆卸和更换）.
  24. Remove the clips (x4) that attach the RH front carpet to the vehicle.
  25. Fold the RH front main cabin carpet aside for access.
  26. Release the seat electrical harness from the clips to allow the RH front carpet to fold back more.
  27. Remove the RH front inner bolts (x2) that attach the HV battery to the body.
  28. Inspect below front end of RH front seat cushion if a HV battery bolt is present. If present, remove the bolt.
    Note
    1x bolt, Newer vehicles may not be equipped with this bolt
  29. Move the RH front seat forward.
  30. Remove the 2nd row floor mat from the vehicle.
  31. Remove the 2nd row lower seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
  32. Remove the clips (x4) and hook-and-loop strips that attach the rear carpet to the vehicle.
    Note
    The number of clips on newer vehicles might vary.
  33. Lift up the LH side of the rear carpet and insert a hand to feel if the 4th LH HV battery bolt is present. If the bolt is present, then remove the bolt.
  34. Lift up the RH side of the rear carpet and insert a hand to feel if the 4th RH HV battery bolt is present. If the bolt is present, then remove the bolt.
  35. Inspect the carpet for perforations. If perforations are present, separate the carpet and inspect for a fastener below the RH front seat.
    Note
    This step may vary depending on the build date of the vehicle.
  36. Remove the HV battery bolt below the rear end of the RH front seat.
  37. Move RH front seat to center location and seat back to upright position
    Note
    This step only applies if HV battery is equipped with bolts below RH front seat. Vehicle will be powered down and seat needs to be in this position to allow both bolts to be installed hand tight.
  38. Inspect the LH carpet for perforations. If perforations are present, separate the carpet and inspect for a fastener below the LH front seat.
    Note
    This step may vary depending on the build date of the vehicle.
  39. Remove the HV battery bolt below the rear end of the LH front seat.
  40. Move LH front seat to center location and seat back to upright position
    Note
    This step only applies if HV battery is equipped with bolts below LH front seat. Vehicle will be powered down and the seat needs to be in this position to allow both bolts to be installed hand tight.
  41. Enable Service Mode. See 维护模式.
  42. Unlock the vehicle Gateway. See 网关（解锁）.
  43. 运行 ODIN 例行程序 PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)
    Note
    The 5-way valve is set to Series position, and the coolant pumps are disabled.
  44. Enable EPB Service Mode. See 驻车制动 - 钳 - 后 - 左侧（释放）
  45. Disconnect 12V power. See 12V/低压电源（断开和连接）.
  46. Disconnect HVC logic connector and install logic cap.
  47. Perform Vehicle HV Disablement Procedure. See 车辆高压禁用程序.
  48. Remove the HV cap that covers the HV harness located on the LH side of the ancillary bay.
  49. Remove the bolts that attach the charge port to HV battery harness bracket at the ancillary bay, and then remove the bracket from the vehicle.
  50. Release the clip that attaches the charge port harness to the vehicle at the sill area.
  51. Slide the release to unlock the DC input connector handle of the charge port to HV battery harness from the secured position.
  52. Fully raise the handle on the DC input connector.
  53. Remove the DC input connector from the ancillary bay DC input header.
  54. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
  55. Fully raise the handle on the 3-phase connector.
  56. Remove the 3-phase connector from the ancillary bay 3-phase header.
  57. Remove the bolts that attach the LH and RH inner ancillary bay rails to the ancillary bay cover.
    Note
    Newer built vehicles may be equipped with ancillary covers without volcano brackets and the bolts will not be present.
  58. Remove the DCDC ground busbar. See 母排 - DCDC 接地（拆卸和更换）.
  59. Remove and discard the nut that attaches the positive 12V output cable to the DCDC passthrough, and then remove the cable from the passthrough.
    Note
    Inspect the condition of the rubber boot at the end of the output cable, and replace the boot if it is melted or damaged.
  60. Remove the HVC logic cap.
  61. 请参阅 Toolbox 文章#41977或客户文档CD-21-16-003中所述的高压电池通信工具，以确定高压电池参数是否处于运输或存放的安全限值范围内。
  62. Install the HVC logic cap.
  63. Push the vehicle onto a lift.
  64. Install lift pad adapters.
    • For EMEA only, install 举升机垫适配器，Model 3 (1453419-00-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 举升机垫适配器，Model 3 (1453419-00-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.
  65. Fully raise vehicle.
    Note
    Set the vehicle to a comfortable working height.
  66. Remove the front aero shield panel. See 面板 - 流线型护板 - 前（拆卸和更换）.
  67. Release the clips along the bottom edge of the LH and RH wheel arch liners.
  68. Install bungee straps to pull the LH and RH wheel arch liners away from the HV battery and expose the coolant hoses.
  69. Remove the front HV battery skid plate. See 滑板 - 高压电池 - 前部（拆卸和更换）.
  70. Disconnect the electrical harness from the PTC heater HV connector, and then release the electrical harness from the bracket.
    Note
    The PTC heater HV connector is only for vehicles without a heat pump. For vehicle with a heat pump, skip to the next step.
  71. Disconnect the electrical harness from the A/C HV connector, and then release the electrical harness from the bracket.
  72. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
  73. 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.
  74. Fully raise the handle on the front drive unit HV connector.
  75. Remove the front drive unit HV connector from the front drive unit HV header.
  76. Remove the bolt that attaches the ground strap to the front drive unit.
  77. Release the clip that attaches the front drive unit ground strap to the front drive unit.
  78. Remove the push clip that attaches the LH front wheel liner to the LH rocker panel.
  79. Remove the push clip that attaches the RH front wheel liner to the LH rocker panel.
  80. Use bungee straps to pull back the LH and RH front wheel liner.
    Note
    Attach bungee straps to the subframe.
  81. Perform a rear powertrain coolant drain. See 动力总成冷却液（排空和重新加注）.
  82. Perform a platter enclosure coolant drain. See 磁盘外壳冷却液（排放和重新加注）.
  83. Remove the rear aero shield panel. See 面板 - 流线型护板 - 后部（拆卸和更换）.
  84. Release the fir tree clips that attach the coolant hoses to the LH shear plate.
  85. Remove the smaller bolts that attach the LH shear plate to the body.
  86. Remove the larger bolt that attaches the LH shear plate and rear subframe to the body, and then remove the LH shear plate.
  87. Re-install the larger bolt, and hand-tighten the bolt to the rear subframe.
  88. Repeat steps 84 through 87 for the RH shear plate.
  89. Remove the rear HV battery skid plate. See 滑板 - 高压电池 - 后部（拆卸和更换）.
  90. Release the clip and disconnect the coolant outlet hose from the powertrain return hose, and immediately plug the male and female fittings.
  91. Release the clip and disconnect the rear drive unit inverter inlet hose from the LH underside of the ancillary bay, and immediately plug the male and female fittings.
  92. Disconnect the HV battery return tube from the RH rear of the HV battery.
    Note
    Allow hose to drain, then plug it to avoid spillage during replacement.
  93. Remove the coolant drain container from underneath vehicle
  94. Remove the nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
  95. 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.
  96. Fully raise the handle on the HV battery rear drive unit connector.
  97. Remove the HV battery rear drive unit connector from the HV battery header.
  98. Support front portion of rear subframe
  99. Remove large bolt securing RH shear plate and subframe to body and remove shear plate
    Note
    1x bolt, 21mm, 125 Nm, Discard after removal
  100. Hand tighten the bolt that attaches the RH side of the subframe to the body.
  101. Remove the large bolt that attaches the LH shear plate and subframe to the body and remove the shear plate.
  102. Hand tighten the bolt that attaches the LH side of the subframe to the body.
  103. Remove the support stand from under the vehicle.
  104. Inspect the replacement HV battery assembly.
    Note
    If installing a new battery, then ski removal from the old HV battery is not necessary. If installing a remanufactured battery, then remove battery center ski from the old HV battery.
  105. Disconnect the ancillary harness connector from the RH rear of the HV battery.
  106. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
    Note
    The PTC heater HV connector is only for vehicles without a heat pump.
  107. With an assistant, remove the end bolts that attach the center rail ski to the HV battery, and then remove the rail ski from the battery.
  108. Place HV battery table into position and lower vehicle to support HV battery
    Note
    Line up the table so the center 4 bolts are accessible through the opening in the table. Adjust the final battery table position using the adjustable caster jacks on the table.
  109. Remove the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  110. Remove the front center bolt that attaches the HV battery to the vehicle.
  111. Remove the front bolts that attach the HV battery to the vehicle.
    Note
    The number of fasteners on newer vehicles may vary.
  112. 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.
  113. With an assistant, raise the vehicle and remove the HV battery from underneath the vehicle.
  114. Remove the HV battery from under the vehicle.
  115. Remove the HV battery perimeter seal. See 密封件 - 外围 - 高压电池（拆卸和更换）.
  116. 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.
  117. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  118. Release the clips (x5) that attach the HV battery return hose to the LH side of the HV battery, and then remove the hose from the HV battery.
  119. Release the clip and disconnect the powertrain supply hose fitting from the RH rear underside of the ancillary bay.
  120. 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.
  121. Attach the HV battery H-frame to the gantry and raise it into position.
  122. Remove the logic cap from the old battery pack.
  123. Open the crate top housing of the new HV battery pack.
    Note
    Confirm part number specific to vehicles configuration. See https://epcadmin.teslamotors.com/epcadmin.
  124. Put on HV insulating gloves and leather over gloves.
  125. Remove the bolts that attach the ancillary bay cover to the HVC.
    Note
    Fastener count may vary on newer vehicles. Inspect the bolts for plastisol rubber residue and replace bolts if found. Newer bolts are not equipped with plastisol.
  126. Release the ancillary bay cover bolts from the old HV battery.
  127. Remove the ancillary bay cover from the HV battery.
  128. Inspect the DC input busbar of the new HV battery pack. If new pack is different from the old pack, rework the DC input. See 直流输入母排改直流输入线束（改装）.
    Note
    Add correction code 16302806 as a separate correction to the Service Visit.
  129. Compare the ancillary bay cover from the new to the old HV battery. If the new pack has different mounting points for the second row inner rails, replace the ancillary bay cover from the old to the new pack. See 盖板 - 高压电池仓（互换）（电池置于操作台上）
    Note
    Add correction code 16300107 as a separate correction to the Service Visit.
  130. Install the HVC logic cap.
  131. Inspect the ancillary bay for any missing insulators.
    Note
    Install service insulator kit before continuing to the next step. The number of bolts on newer vehicles may vary.
  132. Lower the HV controller back into place.
  133. Remove the battery pyro and shunt insulators.
    Note
    Make sure to wear proper PPE from this step onwards until the ancillary bay cover has been reinstalled.
  134. Remove the bolts that attach the pyro disconnect to the ancillary bay.
    Note
    Discard the bolts after removal
  135. Remove the pyro disconnect from the ancillary bay.
    Note
    1x connector from the bottom. Lift pyro disconnect straight up and out of the ancillary bay.

安装


  2. Open the crate top housing of the new HV battery pack.
    Note
    Confirm part number specific to vehicles configuration. See https://epcadmin.teslamotors.com/epcadmin.
  3. Put on HV insulating gloves and leather over gloves.
  4. Remove the bolts that attach the ancillary bay cover to the HVC.
    Note
    Fastener count may vary on newer vehicles. Inspect the bolts for plastisol rubber residue and replace bolts if found. Newer bolts are not equipped with plastisol.
  5. Release the ancillary bay cover bolts from the old HV battery.
  6. Remove the ancillary bay cover from the HV battery.
  7. Inspect the DC input busbar of the new HV battery pack. If new pack is different from the old pack, rework the DC input. See 直流输入母排改直流输入线束（改装）.
    Note
    Add correction code 16302806 as a separate correction to the Service Visit.
  8. Compare the ancillary bay cover from the new to the old HV battery. If the new pack has different mounting points for the second row inner rails, replace the ancillary bay cover from the old to the new pack. See 盖板 - 高压电池仓（互换）（电池置于操作台上）
    Note
    Add correction code 16300107 as a separate correction to the Service Visit.
  9. Install the HVC logic cap.
  10. Inspect the ancillary bay for any missing insulators.
    Note
    Install service insulator kit before continuing to the next step. The number of bolts on newer vehicles may vary.
  11. Lower the HV controller back into place.
  12. Remove the battery pyro and shunt insulators.
    Note
    Make sure to wear proper PPE from this step onwards until the ancillary bay cover has been reinstalled.
  13. Remove the bolts that attach the pyro disconnect to the ancillary bay.
    Note
    Discard the bolts after removal
  14. Remove the pyro disconnect from the ancillary bay.
    Note
    1x connector from the bottom. Lift pyro disconnect straight up and out of the ancillary bay.
  15. Remove the HVC logic cap.
  16. Remove the ancillary bay Service Insulator Kit.
  17. Position ancillary bay cover to THE HV battery for installation.
    Note
    Make sure that all accessible insulators are present. Wearing Electrical Protective Gloves is not necessary once all HV components are covered. If the new part does not have the volcano bracket bolt, remove it from the old part and install it on the new part.
  18. Install the ancillary bay cover. See 盖板 - 高压电池仓（拆卸和安装）.
  19. Install the old Pyro Disconnect onto the old HV battery.
    Note
    Attach pyro to ancillary bay cover volcano brackets with zip ties. If ancillary bay cover is not equipped with volcano brackets, then attach pyro to RH rear corner of HV Battery with zip ties and add tape as notification as shown in illustration. Install a piece of paper roll under the pyro disconnect.
  20. Remove the nuts that attach the new HV battery to the crate.
  21. Position the gantry over the new HV battery crate and attach the H-frame to the HV battery.
  22. Lift the new HV battery out of the crate.
  23. Move the gantry away from the HV battery crate and over the second HV battery table.
  24. Lower the HV battery onto the second battery table.
    Note
    Make sure to align the HV battery onto the center ski. If the original pack is RWD and supplied pack is DM, center ski transfer will be required.
  25. Release the H-frame from the HV battery and raise the gantry.
  26. Remove the HV battery from under the gantry.
  27. Position the gantry over the old HV battery.
  28. Lower the H-frame onto the old HV battery and attach the H-frame to the HV battery.
    Note
    8x bolts, 8mm Allen
  29. Raise the old HV battery above the height of the HV battery crate.
  30. Position the HV battery crate underneath the old HV battery.
  31. Lower the old HV battery into the crate.
    Note
    Align the 4 studs and do not damage the battery.
  32. Remove the H-frame from the old HV battery.
    Note
    8x bolts, 8mm Allen, Hand tight
  33. Raise the gantry and H-frame from the old HV battery.
  34. Lower the gantry and remove the HV battery H-frame from the gantry.
  35. Install the nuts (x4) that attach the HV battery to crate hand tight.
  36. Close the crate top housing of the old HV battery.
  37. Install the logic cap onto the new HV battery pack.
  38. Remove the lower bolts (x6) that attach the rear battery enclosure skid plate.
  39. Remove the upper nut that attaches the HV battery rear skid plate.
    Note
    Fastener count may vary on older built vehicles.
  40. Remove the rear battery enclosure skid plate from the HV battery pack.
  41. Verify if the PTC fuse is installed inside the ancillary bay. If the fuse is not installed, proceed with 保险丝 - 驾驶室加热器 - 高压电池（电池置于操作台上）（安装） and add correction code 16304026 as a separate correction to the Service Visit.
    Note
    Measure resistance at the rear HV header for the ancillary harness between PTC B+ and PTC B-, the 2 pins facing the rear of the car are +/- for the PTC. If resistance is OL, the fuse is not installed. If resistance is anything higher than 50 kOhm, then the fuse is installed. Be extra careful when measuring to not widen the female pins on the HV ancillary header during measurement.
  42. Remove the nuts (x2) that attach the RDU HV cable bracket to the HV battery and remove the RDU HV cable.
    Note
    Number of fasteners may vary on newer vehicles.
  43. Disconnect the RDU HV cable from the HV battery.
  44. Install the powertrain supply hose to the upper clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  45. Connect the powertrain supply hose fitting to the RH rear underside of the ancillary bay, and then fasten the clip.
  46. Install the powertrain return hose to the lower clips on the RH side of the HV battery, and then fasten the clips (x5) to attach the hose to the HV battery.
  47. 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 1. 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 Hose - Passthrough - Front Manifold - HV Battery (Male Coupler) (Retrofit).
    Figure 2. HV battery coolant passthrough fittings; Female
  48. Install the front hose assembly onto the HV battery and attach the RH outer coolant hose connection.
    Note
    Use a shop towel to clean any residue coolant if necessary. Make sure that the locking clip is fully seated.
  49. Install the RH manifold tube to the front of the HV battery.
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  50. Connect the LH outer coolant hose to the front of the HV battery.
    Note
    Use a shop towel to clean any residue coolant if necessary. Make sure the locking clip is fully seated.
  51. Connect the LH inner coolant hose to the front of the HV battery.
    Note
    Use a shop towel to clean any residue coolant if necessary. Perform a push-pull-push test to make sure hose is fully seated.
  52. Install a new ancillary perimeter seal onto HV battery pack. See 密封件 - 外围 - 高压电池（拆卸和更换）.
    Note
    This seal is a one time use item and should be replaced each time a HV battery pack is removed from a vehicle or installed onto a new HV battery pack, if not equipped.
  53. Install the HV battery alignment rods.
    Note
    2x rods to body at front of vehicle, 2x rods to battery near ancillary bay.
  54. Position the HV battery under the vehicle.
  55. Lower the vehicle onto the HV battery and align the holes.
    Note
    Use the alignment rods. Make sure that the coolant hoses do not get caught on the alignment rods. Be careful not to damage HV cables. Do not fully lower the vehicle onto the battery (this will help with installing the battery bolts).
  56. Hand-tighten the LH and RH bolts (x16) that attach the HV battery to the body.
  57. Install the center ski cover onto the HV battery.
    Note
    6x bolts. Four long bolts in the middle, two short bolts on the sides.
  58. Install ancillary harness bracket to front of HV battery
    Note
    2x barrel clips
  59. Install the clips that attach the ancillary harness cover at the rear of the HV battery.
  60. Use both hands to firmly connect the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector of the PTC heater (non-heat pump vehicles) and A/C compressor 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.
  61. While pressing the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector onto the HV battery header, fully lower the handle.
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  62. Slide the release to lock the HV battery PTC heater (non-heat pump vehicles) and A/C compressor connector handle in the secured position.
  63. Install front bolts securing HV battery to vehicle hand tight
    Note
    The number of fasteners on newer vehicles may vary. Reinstall fastener unless the body is patched or no hole exists. Patch the body if HV battery doesn't have these holes.
  64. Remove the HV battery alignment rods (x4).
  65. Hand-tighten the bolts (x8) that attach the HV battery LH and RH support brackets to the vehicle.
  66. Install bolts securing HV battery to body at LH shear plate area hand tight.
    Note
    Torque at a later step
  67. Install the bolts that attach the HV battery to body at the RH shear plate area hand tight.
    Note
    Torque at a later step
  68. Fully raise the handle on the HV battery rear drive unit connector of the rear drive unit to HV battery harness.
  69. Install the HV connector special tool onto the HV battery rear drive unit connector.
  70. 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.
  71. Remove the HV connector special tool from the HV battery rear drive unit connector.
  72. 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.
  73. Slide the release to lock the HV battery rear drive unit connector handle in the secured position.
  74. 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.
  75. Install the nut of nuts that attach the rear drive unit HV electrical harness bracket to the HV battery.
    10 Nm (7.4 lbs-ft)
    Note
    Number of nuts may vary.
  76. Position the coolant drain under the rear RH side of the HV battery.
  77. Remove the plugs from the coolant outlet hose and the powertrain return hose, 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.
  78. Position the coolant drain under the rear LH side of the HV battery.
  79. Remove the plugs from the rear drive unit inverter inlet hose and the LH underside of the ancillary bay, 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.
  80. Install the HV battery rear skid plate. See 滑板 - 高压电池 - 后部（拆卸和更换）.
  81. Open the LH rear door.
  82. Set the LH rear HV battery interior bolt using a cordless impact.
    Note
    Lift up carpet for access. Ensure smooth thread engagement and bolts are not cross threaded into the pack. Flush down bolts, do not over tighten the bolts. Fully torque at a later step.
  83. Install the LH middle inner HV battery bolt hand tight.
    Note
    Torque at a later step. The number of bolts on newer vehicles may vary.
  84. Close the LH rear door.
  85. Open the LH front door.
  86. Install the LH front inner HV battery bolt hand tight.
    Note
    Torque at a later step. The number of bolts on newer vehicles may vary. Bolt is located below the LH front seat.
  87. Set the LH front footwell HV battery bolts with a cordless impact.
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into the pack. Flush down bolts. Do not over tighten bolts. Fully torque at a later step.
  88. Close the LH front door.
  89. Open the RH rear door.
  90. Set the RH rear HV battery interior bolt with a cordless impact.
    Note
    Lift up the carpet for access. Ensure smooth thread engagement and bolts are not cross threaded into the pack. Flush down bolts. Do not over tighten bolts. Fully torque at a later step.
  91. Install the RH middle inner HV battery bolt hand tight.
    Note
    Torque at a later step. The number of bolts on newer vehicles may vary.
  92. Close the RH rear door.
  93. Open the RH front door.
  94. Install the RH front inner HV battery bolt hand tight.
    Note
    Torque at a later step. The number of bolts on newer vehicles may vary. Bolt is located below the RH front seat.
  95. Set the RH front footwell HV battery bolts with a cordless impact.
    Note
    Ensure smooth thread engagement and bolts are not cross threaded into the pack. Flush down bolts. Do not over tighten the bolts. Fully torque at a later step.
  96. Close RH front door
  97. Lower the vehicle completely onto the pack.
  98. Torque the LH and RH bolts that attach the HV battery to vehicle.
    35 Nm (25.8 lbs-ft)
  99. Torque the front bolts that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    Note
    The number of fasteners on newer vehicles may vary.
  100. Torque the bolts (x8) that attach the LH and RH front support brackets to the vehicle.
    110 Nm (81.1 lbs-ft)
  101. Torque the bolts that attach the rear skid plate enclosure to the vehicle.
    35 Nm (25.8 lbs-ft)
  102. Torque the upper nut that attaches the HV battery rear skid plate enclosure.
    13 Nm (9.6 lbs-ft)
  103. Torque the lower bolts that attach the HV battery rear skid plate.
    13 Nm (9.6 lbs-ft)
    Note
    Earlier VINs may be equipped with additional bolts.
  104. Install the RH side hose clips to the HV battery rear skid plate enclosure.
    Note
    2x fir tree clips.
  105. Install LH side hoses clip to the HV battery rear skid plate enclosure.
    Note
    Number of clips may vary on older vehicles.
  106. Remove the battery table from under the vehicle.
  107. Remove the smaller fasteners for LH shear plate.
  108. Remove smaller fasteners for the RH shear plate.
  109. Install the LH front bolt and shear plate to the rear subframe hand tight.
    Note
    Install new bolt. Torque at a later step.
  110. Install the smaller bolts that attach the LH shear plate to the HV battery hand tight.
  111. Install the RH front bolt and shear plate to the rear subframe hand tight.
    Note
    Install new bolt. Torque at a later step.
  112. Install the smaller bolts that attach the RH shear plate to the HV battery hand tight.
  113. Torque the smaller bolts that attach the shear plates to vehicle.
    35 Nm (25.8 lbs-ft)
  114. Torque the large bolt that attaches the subframe and LH shear plate to the body.
    125 Nm (92.2 lbs-ft)
    Note
    Mark the bolt after torquing.
  115. Torque the bolt that attaches the subframe and RH shear plate to the body.
    125 Nm (92.2 lbs-ft)
    Note
    Mark the bolt after torquing.
  116. Install the clips that attach the coolant hoses to the RH shear plate.
  117. Install the clips that attach the coolant hoses to the LH shear plate.
  118. Install the rear aero shield. See 面板 - 流线型护板 - 后部（拆卸和更换）.
  119. Position a coolant drain container underneath the LH front of the HV battery.
  120. Install the HV battery front manifold hose clips to the body.
  121. Remove the plugs, and then connect the male side to the female side of the HV battery front manifold hose.
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  122. Remove the plugs, and then connect the female side to the male side of the HV battery return hose.
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  123. Position the coolant drain container underneath the RH front of the HV battery.
  124. Remove the plugs, and then connect the PT return tube.
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  125. Remove the plugs, and then connect the Pt return tube.
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  126. Remove the coolant drain container from underneath the vehicle.
  127. Release the RH front wheel liner from the bungee strap.
  128. Release the LH front wheel liner from the bungee strap.
  129. Install the push clip that attaches the LH front wheel liner to the LH front rocker panel.
  130. Install the push clip that attaches the RH front wheel liner to the RH front rocker panel.
  131. Remove the plastic bracket that attaches the HV connectors to the body.
    Note
    3x clips
  132. Connect the A/C compressor HV harness connector.
    Note
    Apply abrasion tape to harness if it is not present.
  133. Connect the PTC HV connector to the HV cable, and then reinstall the bracket.
    Note
    Apply abrasion tape to the harness if it is not present.
  134. Install the FDU ground strap and bolt to the HV battery.
    10 Nm (7.4 lbs-ft)
  135. Attach the FDU ground strap harness clip to the FDU.
  136. Install the FDU HV harness connector to the FDU.
    Note
    Make sure that the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever.
  137. Install the FDU HV harness connection to the FDU.
    Note
    Verify lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully install the lever and engage the red locking tab. Do not damage the connector or header during installation.
  138. Install the bolt that attaches the FDU HV harness to the FDU.
    10 Nm (7.4 lbs-ft)
  139. Install the front skid plate onto the HV battery. See 滑板 - 高压电池 - 前部（拆卸和更换）.
  140. Install the clips that attach the front LH and RH wheel liners to the front skid plate.
  141. Install the front aero shield panel. See 面板 - 流线型护板 - 前（拆卸和更换）.
  142. Lower the vehicle fully and move the rack arms away from the vehicle.
    Note
    Install plugs back into holes in BIW.
  143. Open all four doors
  144. Install the nut that attaches the positive LV output cable to the HV battery.
    9 Nm (6.6 lbs-ft)
    Note
    Install a new nut. Mark the nut after torquing. Make sure that the rubber boot is not pinched between the cable terminal.
  145. Install the positive LV output cable cover.
  146. Install the DCDC ground busbar. See 母排 - DCDC 接地（拆卸和更换）.
  147. Install the bolts that attach the LH and RH inner penthouse rails to penthouse cover.
    24 Nm (17.7 lbs-ft)
  148. Connect the 3PH chargeport inlet harness to the HV header.
    Note
    Rotate the lever arm and install the locking tab.
  149. Connect the charge port harness to the ancillary bay.
    Note
    Use one hand to support the connector while the other latches the locking tab. Once installed, make sure that the latch is not damaged and fully secured in the latched position.
  150. Install the clip that attaches the charge port harness to the vehicle at the sill area.
  151. Install the sadface bracket into the vehicle.
    Note
    Number of clips may vary on newer vehicles.
  152. Install the bolts that attach the sadface bracket to the vehicle.
    10 Nm (7.4 lbs-ft)
  153. Install the second row ancillary bay high voltage cap.
  154. Remove the HVAC plenum outer duct.
  155. Perform a coolant vacuum refill. See 冷却系统（真空再加注）.
  156. Connect the HVC logic connector.
  157. Install the second row ancillary bay 12V cap.
  158. Connect 12V/LV power. See 12V/低压电源（断开和连接）
  159. Press and hold the park button to release the EPB service mode.
  160. 运行 ODIN 例行程序 PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    via Toolbox:(link)
  161. 运行 ODIN 例行程序 TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
  162. Inspect coolant level and adjust as necessary.
    Note
    Make sure that the fluid level is 5mm above the Max line, top off or remove coolant as needed.
  163. Move LH front seat backward
  164. Torque the HV battery bolt below the front end of the LH front seat.
    66 Nm (48.7 lbs-ft)
    Note
    The number of bolts on newer vehicles may vary.
  165. Torque the LH front footwell HV battery bolts.
    136 Nm (100.3 lbs-ft)
  166. Fold the LH front main cabin carpet back to its original position.
    Note
    Move front edge down and slide back section up to ease positioning. Install the seat harness into the clip.
  167. Install the clips that attach the LH front main cabin carpet to the vehicle.
    Note
    3x push clips. Number of clips on newer vehicles may vary.
  168. Move the RH front seat backward.
  169. Torque the HV battery bolt below the front end of the RH front seat.
    66 Nm (48.7 lbs-ft)
  170. Torque the RH front footwell HV battery bolts.
    136 Nm (100.3 lbs-ft)
  171. Unfold the RH front main cabin carpet back to its original position.
    Note
    Move front edge down and slide back section up to ease positioning. Install the seat harness into the clips.
  172. Install the clips that attach the RH front main cabin carpet to the footwell area.
    Note
    3x push clips. Number of clips may vary on older vehicles.
  173. Install the RH console side panel carpet.
    Note
    1 tab, 12x clips. Position the side panel and align the front tab. Install the console panel from the front towards the rear.
  174. Install the RH front floor mat.
  175. Install the RH footwell cover assembly.
    Note
    2x connectors
  176. Install the RH footwell assembly onto the IP.
    Note
    4x push clips.
  177. Install the RH lower A-pillar trim. See 饰板 - A 柱 - 下 - 左侧（拆卸和更换）.
  178. Install RH mid A-pillar assembly. See 饰板 - A 柱 - 中部 - 左侧（拆卸和更换）.
  179. Install RH IP end cap. See 端盖 - 仪表板 - 左侧（拆卸和更换）.
  180. Move RH front seat forward.
  181. Install the HVAC inlet plenum.
    Note
    2x clips. Align tab at bottom of duct before installing the clips.
  182. Install the cabin intake upper duct assembly.
    Note
    3x clips. Some configurations may come with 4x clips.
  183. Install the rear apron.
    Note
    12x clips
  184. 运行 ODIN 例行程序 TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
    via Toolbox:(link)
  185. Install the LH console side panel carpet.
    Note
    1x tab, 10x clips, Position side panel and align the front tab. Push the console panel from the front towards the rear
  186. Install the LH front floor mat
  187. Install the LH footwell cover. See 盖板 - 脚部空间 - 驾驶位（拆卸和更换）.
  188. Install the LH lower A-pillar trim. See 饰板 - A 柱 - 下 - 左侧（拆卸和更换）.
  189. Install LH mid A-pillar assembly. See 饰板 - A 柱 - 中部 - 左侧（拆卸和更换）.
  190. Install LH IP end cap. See 端盖 - 仪表板 - 左侧（拆卸和更换）.
  191. Exit Service Mode. See 维护模式.
  192. Move the LH front seat forward
  193. Install the clips and Velcro that hold the rear main cabin carpet to the vehicle.
  194. Connect 2nd row seat cushion harness and install 2nd row seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
  195. Install 2nd row floor mat into the vehicle.
  196. Install the LH and RH rocker panels. See 盖板 - 门槛板 - 下 - 左侧（拆卸和更换）.