04/06/2024 18:01:46

HV Battery (AWD) (Remove and Install)

Correction code 16010201 3.18 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 proper PPE is worn when performing the below procedure.

  • 2023-09-07: Added photos of Model S 3 phase connector/dummy.
  • 2023-08-03: Added notes, cautions, and warnings for releasing and installing charge port busbar connector.
  • 2023-05-23: Reorganized Removal first steps.
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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. 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 glove and safety information.

Remove

  1. Remove the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).
  2. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  3. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  4. Position the 2 post lift pads for HV battery removal.
  5. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts.
  9. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  10. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  11. Remove the leather glove protectors and the HV insulating gloves.
  12. Remove the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  13. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  14. If a 3-phase connector or dummy is present, slide the red connector locking tab, open the black release lever, and then disconnect the 3-phase connector or dummy from the HV battery 3-phase HV header.
    Figure 1. Dummy shown, 3-phase connector similar
    Figure 2. Dummy shown, 3-phase connector similar
  15. Remove the DC input HV header foam block.
  16. Remove the bolt that secures the charge port busbar connector access door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage the cover seal when prying the cover from the assembly.
  17. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header.
    9 Nm (6.6 lbs-ft)
  18. Lift the charge port busbar connector to remove the connector from the DC input HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure to set the busbar aside to prevent unintended remating with the pack port.
  19. Remove the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  20. If the vehicle is equipped with a performance rear drive unit, slide the red connector locking tab, open the black release lever, and then disconnect the rear drive unit HV harness from the HV battery RH HV header.
  21. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  22. Remove the front skid plate. See Skidplate - Front (Remove and Replace).
  23. Position a coolant drain collector under the front of the vehicle to catch the vehicle coolant.
  24. Release the clip and disconnect the 3 way valve to HV battery hose from the HV battery, and then immediately plug the fittings.
  25. Release the clip and disconnect the HV battery coolant supply hose from the HV battery, and then immediately plug the fittings.
  26. Release the clip and disconnect the power conversion system coolant supply hose from the HV battery, and then immediately plug the fittings.
  27. Pull the red locking tab out, and then pull the tab again to disconnect the electrical harness from the HV battery logic connector.
  28. Pull the red locking tab out, and then disconnect the electrical harness from the HV battery LV connector.
  29. Release the clips (x2) on the LH front wheel arch liner, and then move the liner aside for access.
  30. Release the clips (x2) that attach the power conversion system coolant return to LH sill hose to the body.
  31. Release the clip and disconnect the power conversion system coolant return to LH sill hose from the LH sill hose, and then immediately plug the fittings.
  32. Release the clip that attaches the power conversion system coolant return to RH sill hose from the HV battery.
  33. Plaid vehicles only - Place a foldable funnel and absorbent material over the HV harness connectors and under the power conversion system coolant return hose to direct coolant away from the HV battery.
  34. Plaid vehicles only - Release the clip, disconnect the rear drive unit branch of the power conversion system coolant return hose from the coolant return hose, and then immediately plug both fittings.
  35. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.
  36. Remove the bolt that attaches the ground strap to the body, and then remove the ground strap from the body.
  37. Remove coolant drain collector out from underneath the vehicle.
  38. Remove the bolt that attaches the front drive unit HV harness to the HV battery.
  39. Slide the red connector locking tab, open the black release lever, and then disconnect the front drive unit HV harness from the HV battery front drive unit HV header.
  40. Slide the red connector locking tab, open the black release lever, and then disconnect the compressor HV harness from the HV battery compressor HV header.
  41. First loosen with a ratchet, and then use a power tool to remove the center bolts (x4) that attach the HV battery to the vehicle.
  42. Position the battery table underneath the vehicle.
  43. With the help of an assistant, lower the vehicle to just above the battery table, raise and lower table casters as necessary to level the table to the HV battery, and then lower the vehicle onto the table.
  44. First loosen with a ratchet, and then use a power tool to remove the outer center bolts (x4) that attach the HV battery to the vehicle.
  45. First loosen with a ratchet, and then use a power tool to remove the outer bolts (x12) that attach the HV battery to the vehicle.
  46. First loosen with a ratchet, and then use a power tool to remove the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
  47. First loosen with a ratchet, and then use a power tool to remove the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
  48. Raise the vehicle off of the HV battery.
  49. With the help of an assistant, move the HV battery and table away from the vehicle.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. With the help of an assistant, move the HV battery and table to underneath the vehicle.
  3. Carefully lower the vehicle onto the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that the liftpads will not contact the battery, and that hoses and harness are not compressed or damaged while lowering.
  4. First hand start, and then use a power tool to install the outer bolts (x12) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Final torque is applied in a later step.
  5. First hand start, and then use a power tool to install the outer center bolts (x4) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Final torque is applied in a later step.
  6. First hand start, and then use a power tool to install the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Final torque is applied in a later step.
  7. First hand start, use a power tool to install, and after all have been installed, tighten the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
  8. Tighten the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
  9. Tighten the outer bolts (x12) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
  10. Tighten the outer center bolts (x4) that attach the HV battery to the vehicle.
    20 Nm (14.7 lbs-ft)
  11. With the help of an assistant, raise the vehicle, and then remove the battery table out from under the vehicle.
  12. First hand start, use a power tool to install, and after all have been installed, tighten the center bolts (x4) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
  13. Verify that the black release lever of the compressor HV harness connector is in the open position, install the connector square to the HV battery compressor HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  14. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery front drive unit HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  15. Install the bolt that attaches the front drive unit HV harness to the HV battery.
    5.5 Nm (4.1 lbs-ft)
  16. Position the coolant drain collector under the front of the vehicle to catch the vehicle coolant.
  17. Remove the plugs from both fittings and immediately connect the power conversion system coolant return to LH sill hose to the LH sill hose, fasten the clip, and perform a Push-Pull-Push check of the fittings.
  18. Fasten the clips (x2) that attach the power conversion system coolant return to LH sill hose to the body.
  19. Fasten the clip that attaches the power conversion system coolant return to RH sill hose to the HV battery.
  20. Plaid vehicles only - Place a foldable funnel and absorbent material over the HV harness connectors and under the power conversion system coolant return hose to direct coolant away from the HV battery.
  21. Plaid vehicles only - Remove the plugs, immediately connect the rear drive unit branch of the power conversion system coolant return hose to the coolant return hose, fasten the clip, and perform a Push-Pull-Push check of the fittings.
  22. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.
  23. Install the ground strap to the body, and then install the bolt that attaches the ground strap to the body.
    10 Nm (7.4 lbs-ft)
  24. Return the LH front wheel arch liner to the LH front wheel arch, and then fasten the clips (x2) that attach the liner to the wheel arch.
  25. Inspect the HV battery LV connector and logic connector for coolant, and use shop air and a clean dry shop towel to remove any coolant from the connectors.
  26. Connect the electrical harness to the HV battery LV connector, and then push the red locking tab in.
  27. Connect the electrical harness to the HV battery logic connector, and then push the red locking tab in.
  28. Remove the plugs from both fittings and immediately connect the power conversion system coolant supply hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.
  29. Remove the plugs from both fittings and immediately connect the HV battery coolant supply hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.
  30. Remove the plugs from both fittings and immediately connect the 3 way valve to HV battery hose to the HV battery, fasten the clip, and perform a Push-Pull-Push check of the fittings.
  31. Remove the coolant drain collector out from under the vehicle.
  32. Install the front skid plate. See Skidplate - Front (Remove and Replace).
  33. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  34. Verify that the black release lever of the rear drive unit HV harness connector is in the open position, install the connector flat and square to the HV battery LH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  35. Install the LH and RH rear subframe shear plates. See Shear Plate - Rear Subframe - LH (Remove and Replace).
  36. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  37. Use an alcohol wipe to clean the charge port busbar connector lead contact surfaces of residual Penetrox, and allow at least one minute to dry.
  38. Use an alcohol wipe to clean the DC input HV header terminal contact surfaces of residual Penetrox, and allow at least one minute to dry.
  39. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
  40. Install the charge port busbar connector onto the DC input HV header, and then install the bolts (x2) that attach the connector to the header.
    9 Nm (6.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the busbar is seated flush onto pack port to prevent arcing.
  41. Put on the HV insulating gloves and leather over gloves.
  42. Use the Hioki resistance meter to measure the resistance between the charge port busbar connector lead and the DC input HV header bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  43. Repeat step 42 for the other charge port busbar connector lead and DC input HV header bolt head.
  44. Remove the HV insulating gloves and leather over gloves.
  45. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
  46. Install the DC input HV header foam block.
  47. If a 3-phase connector or dummy was disconnected, verify that the black release lever of the 3-phase connector or dummy is in the open position, install the connector square to the HV battery 3-phase HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
    Figure 3. Dummy shown, 3-phase connector similar
    Figure 4. Dummy shown, 3-phase connector similar
  48. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  49. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  50. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  51. Connect LV power. See LV Power (Disconnect and Connect).
  52. Perform a cooling system air purge. See Cooling System (Partial Refill and Bleed).
  53. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  54. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.
  55. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  56. Install the LH and RH rocker panel scuff plates. See Scuff Plate - Rocker Panel - LH (Remove and Replace).