04/06/2024 18:01:51

Harness - LV - Front - HV Battery (Remove and Replace)

Correction code 16300022 5.52 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.

  • 2023-08-03: Updated LV DC header bolts torque.
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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.

Remove

  1. Remove the HV battery. See HV Battery (AWD) (Remove and Install).
  2. Secure PCS Flush adapter to PCS inlet hose coupling.
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    Note
    Remove plugs as required, Verify fully seated, Perform push-pull-push test.
  3. Secure coolant cart flush hose to regulator and PCS Flush adapter.
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    Note
    Verify regulator valve is closed, Pressure regulator is not adjustable (set at 20 psi).
  4. Secure PCS Drain adapter to the end of the PCS outlet hose.
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    Note
    Verify valve is closed, Remove plug as required, Verify fully seated, Perform push-pull-push test.
  5. Secure coolant cart drain hose to PCS drain adapter and coolant drain container.
  6. Open valve on PCS Drain adapter.
  7. Connect shop air to regulator.
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    Note
    Make sure regulator valve is closed prior to connecting shop air.
  8. Slowly open valve on pressure regulator and allow coolant to drain out of HV battery.
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    Allow coolant to drain.
  9. Close valve on pressure regulator once no more coolant is draining .
  10. Close valve on PCS Drain adapter.
  11. Remove cart drain hose from PCS Drain adapter.
  12. Remove PCS Drain adapter from end of PCS outlet hose.
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    Note
    1x spring clip.
  13. Remove cart flush hose from PCS Flush adapter.
  14. Remove PCS Flush adapter from PCS inlet coupling.
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    Note
    1x spring clip.
  15. Remove clip securing PCS outlet hose to HV battery.
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    Note
    1x clip.
  16. Release PCS outlet hose from HV battery.
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    Note
    1x spring clip.
  17. Remove all items from pockets and ensure not wearing metal items.
  18. Inspect HV insulating gloves.
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  19. Put on HV insulating gloves and leather over gloves.
  20. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  21. Remove fasteners securing front access cover to HV battery assembly.
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    Note
    17x bolts, T25, 4.5 Nm, Discard after removal.
  22. Separate HV front access cover sealant to allow removal.
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    Note
    Only use non-conductive non-marring tools to break sealant, Be cautious not to severely bend and deform the access cover, Be cautions and do not damage the internal components or HV battery casing.
  23. Disconnect coolant hoses from PCS and install plugs.
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    Note
    2x hoses, Use the special tool to release the 2x clips on each hose, Support front access cover with non-conductive material as needed, Use a shop towel to catch any minimal excess coolant.
  24. Remove front access cover from HV battery.
  25. Disconnect PCS to DC bus HV connector.
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward.
  26. Disconnect PCS logic connector from PCS.
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    1x connector.
  27. Disconnect PCS LV DC power harness connector.
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward.
  28. Disconnect AC filter HV harness connector from PCS.
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    Note
    1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward.
  29. Release AC Filter harness clips.
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    3x clips.
  30. Remove bolts securing PCS to mounting tray.
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    Note
    6x bolts, 8mm, 6 Nm, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners.
  31. Lift PCS up and out of front ancillary bay area and remove from vehicle.
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    Note
    Shift PCS left to clear lip of battery enclosure then straight up to remove.
  32. Remove PCS mounting tray from front ancillary bay area.
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    Note
    6x bolts, 10mm, 8 Nm.
  33. Release HV connector 6 pin carrier connection.
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    1x locking connector, Disengage locking tab and release connector.
  34. Release HV connector FDU carrier connection.
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    1x locking connector, Disengage locking tab and release connector.
  35. Release HV connector 6 pin carrier connection from clipping point.
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    1x clip, Release from clipping location.
  36. Remove FDU HV header.
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    2x bolts, EP10, 10 Nm, Gently separate FDU hv header.
  37. Release bolts securing HV connector 0 degree carrier and remove.
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    Note
    2x bolts, 13mm, 5nm +60 degrees, Discard fasteners after removal.
  38. Release HVcon 6 pin carrier cable from fuse.
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    1x nut, 8mm, 4.5 Nm, Do not drop fastener, Move cable aside.
  39. Release HVcon 6 pin carrier cable from inductor coil.
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    1x nut, 7mm, 2.5 Nm, Do not drop fastener, Move cable aside.
  40. Disconnect HVC logic connector.
  41. Remove nuts securing HVC to front stack tray.
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    Note
    4x nuts, 10mm, 5.1 Nm.
  42. Shift HVC for access to the remaining outboard connector.
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    Lift HVC upward off of studs, then shift HVC inboard and rotate front edge upward to create clearance.
  43. Disconnect outboard HV pack main harness connector to HVC.
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    Note
    1x connector, Depress locking tab and rotate lever arm to release, Be careful as there is very little slack in the harness.
  44. Remove LV DC harness ground bolt.
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    Note
    1x bolt, 10mm, 10 Nm.
  45. Release LV DC header from battery pack.
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    Note
    3x bolts, T20, 2.5 Nm.
  46. Release clips securing LV DC harness and remove assembly.
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    Note
    4x clips, Wear electrical protective gloves, Carefully release clips and guide cable over and out, Be cautious and do not damage any components.

Install

  1. Install LV DC harness into battery pack.
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    4x clips, Carefully guide the harness in and secure the clips, Be cautious and do not damage any components.
  2. Secure LV DC header onto battery pack.
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    Note
    3x bolts, T20, 2.5 Nm.
  3. Secure LV DC harness ground bolt .
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    Note
    1x bolt, 10mm, 10 Nm.
  4. Secure outboard HV pack main harness connector to HVC.
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    Note
    1x connector, Rotate lever arm to secure locking tab, Be careful as there is very little slack in the harness.
  5. Shift HVC down onto studs for installation.
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    Be mindful not to pinch surrounding wiring and connectors, Rotate HVC under DC busbar staying high to clear studs, then lower to install position.
  6. Install nuts securing HVC to front stack tray.
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    Note
    4x nuts, 10mm, 5.1 Nm.
  7. Connect HVC logic connector.
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    Note
    1x connector, Release locking tab then push the handle downward to release connector.
  8. Secure HVcon 6 pin carrier cable onto inductor coil.
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    Note
    1x nut, 7mm, 2.5 Nm, Do not drop fastener.
  9. Secure HVcon 6 pin carrier cable onto fuse.
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    Note
    1x nut, 8mm, 4.5 Nm, Do not drop fastener.
  10. Cleaning mating surfaces of the HV connector 0 degree carrier.
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    Allow 1 min for IPA to dry.
  11. Install bolts securing FDU HV connector 0 degree carrier.
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    Note
    2x bolts, 13mm, 5nm +60 degrees, Install new fasteners.
  12. Install FDU HV header.
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    Note
    2x bolts, EP10, 10 Nm.
  13. Perform Hioki impedance test at the HV joints of the FDU HV connector 0 degree carrier.
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    2x HV joint, Verify meter has been properly zero adjusted prior to usage, The acceptable resistance is below d 0.045 mΩ (45 μΩ), If the resistance is greater than 0.045 mΩ (45 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.
  14. Secure HV connector FDU carrier connection.
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    1x connector, Fully engage locking tab.
  15. Secure HV connector 6 pin carrier connection onto clipping point.
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    1x clip.
  16. Secure HV connector 6 pin carrier connection.
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    1x connector, Fully engage locking tab.
  17. Install PCS mounting tray to front ancillary bay area.
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    Note
    6x bolts, 10mm, 8 Nm, Be mindful not to pinch any wires underneath the tray.
  18. Install PCS to front ancillary bay area.
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    Shift PCS under lip of battery enclosure.
  19. Install fasteners securing PCS to mounting tray.
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    Note
    6x bolts, 8mm, 6 Nm.
  20. Secure AC Filter harness clips.
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    Note
    3x clips.
  21. Connect AC filter HV harness connector to PCS.
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    Note
    1x connector, Push down to secure locking tab.
  22. Connect PCS LV DC power harness connector.
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    Note
    1x connector, Push down to secure locking tab.
  23. Connect PCS logic connector to PCS.
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    1x connector.
  24. Connect PCS to DC bus HV connector.
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    Note
    1x connector, Push down to secure locking tab.
  25. Clean sealing surface of HV battery front access panel.
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    Note
    Clean sealant and allow for re-seal, Only use non-conductive non-marring tools, Use ESD vacuum and remove all debris.
  26. Clean sealing surface of front access cover.
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    Check cover for deformation, Bend cover back to original form, if cover is warped or damaged excessively then proceed to a replacement instead.
  27. Prepare caulking gun and adhesive, Cut the sealant tip.
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    Cut tip at an angle to allow for easier application.
  28. Apply sealant onto the sealing surface of the front access panel.
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    Follow original bead line, Replace seal if originally equipped.
  29. Position front cover for installation and secure hoses to PCS.
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    2x hoses, 2x clips on each hose, Recommend assistance, Secure hoses while holding cover, Remove plugs.
  30. Install front access cover to HV battery.
  31. Install fasteners securing front access cover to HV battery assembly.
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    17x bolts, T25, 4.5 Nm, Install new fasteners, Allow proper time for sealant to cure, Refer to adhesive work instructions.
  32. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  33. Secure coolant leak test adapter to PCS inlet coupling.
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    This adapter is connected to regulated air line adapter, Make sure the locking tab is fully seated, Perform push-pull-push test.
  34. Secure closed ended coolant leak test adapter to PCS outlet coupling.
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    Note
    Perform push-pull-push test.
  35. Secure pressure test fixture hose to leak test adapter.
  36. Secure compressed air line to pressure test fixture.
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    Note
    Make sure valves are closed on pressure regulator.
  37. Open the regulator valve then slowly adjust regulator to 50 psi.
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    Use caution due to high pressure, Make sure to wear safety glasses and personal protection equipment.
  38. Open the 2nd valve slowly.
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    Slowly allow air to enter system.
  39. Allow 1 minutes and 50 seconds for the pressure to stabilize .
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    Allow 1 minutes and 50 seconds (110 seconds) for pressure to stabilize.
  40. Close the regulator valve.
  41. Record start pressure value.
  42. Allow 4 minutes to test.
  43. Record end pressure value.
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    If pressure did not drop more than 0.35 psi, continue to next step, If pressure dropped more than 0.35 psi, then inspect for leaks and retest.
  44. Release compressed air line from pressure test fixture.
  45. Open the regulator valve slowly.
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    Slowly allow air to leave the system.
  46. Release pressure test fixture hose from coolant leak test adapter.
  47. Remove coolant leak test adapter from PCS inlet coupling.
  48. Remove closed ended coolant leak test adapter from PCS outlet coupling.
  49. Secure PCS outlet hose to HV battery.
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    Note
    1x spring clip, Perform push-pull-push test.
  50. Install clip securing PCS outlet hose to HV battery.
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    1x clip.
  51. Install the HV battery. See HV Battery (AWD) (Remove and Install).