2024-05-23

Harness - Pyrotechnic - HV Battery (Remove and Replace)

Correction code 16300062 5.10 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  4. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  5. Position the 2 post lift pads for HV battery removal.
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Remove the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  11. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  12. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain).
  13. Remove the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  14. Remove the power conversion system. See Power Conversion System (Remove and Replace).
  15. Remove the bolts (x6) that attach the power conversion system mounting tray to the HV battery, and then remove the tray from the HV battery.
  16. Peel the Kapton tape, and then remove the mica shielding from the busbar and insulator.
  17. Release the HV battery pyrotechnic harness clip and patch anchor from the high voltage controller.
  18. Disconnect the HV battery pyrotechnic harness from the high voltage controller connector.
  19. Disconnect the electrical harness from the high voltage controller connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Disconnecting the electrical harness permits easier removal of the HV battery pyrotechnic harness.
  20. Carefully release the HV battery pyrotechnic harness connector from the front tray housing.
  21. Release the clips (x2) that attach the HV battery pyrotechnic harness to the front tray housing on either side of the busbar.
  22. Remove the HV battery pyrotechnic harness out from under the busbar, and out of the HV battery.

Install

  1. Install the HV battery pyrotechnic harness in under the busbar.
  2. Fasten the clips (x2) that attach the HV battery pyrotechnic harness to the front tray housing on either side of the busbar.
  3. Carefully fasten the HV battery pyrotechnic harness connector into the front tray housing.
  4. Connect the electrical harness to the high voltage controller connector.
  5. Connect the HV battery pyrotechnic harness to the high voltage controller connector.
  6. Use an alcohol wipe to clean the adhesive patch area on top of the high voltage controller, and allow at least 1 minute to dry.
  7. Fasten the HV battery pyrotechnic harness clip, peel the backing and apply the patch anchor to the high voltage controller.
  8. Install the mica shielding onto the busbar and insulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply new Kapton tape if necessary.
  9. Install the power conversion system mounting tray into the HV battery, and then install the bolts (x6) that attach the tray to the HV battery.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that no wires are pinched beneath the tray.
  10. Install the power conversion system. See Power Conversion System (Remove and Replace).
  11. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  12. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  13. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  14. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  15. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  16. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  17. Connect LV power. See LV Power (Disconnect and Connect).
  18. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  19. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  20. Install the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  21. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.