04/06/2024 21:11:49

HV Battery Revision -F to Revision -H (Retrofit)

注意：除非本程序中另有明确规定，否则上述校正代码和 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。 注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。要提供有关 FRT 值的反馈，请发送电子邮件至LaborTimeFeedback@tesla.com。 注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。

Informational PurposesAn informational icon, calling your attention
注
This procedure applies to 2021+ Model S vehicles built before August 15, 2022, and 2021+ Model S vehicles built from August 15, 2022 to September 29, 2022.
Consumables required:
  • 1896854-S0-A: 3 PHASE HEADER PLATE - (1)
  • 1086834-00-A: 3M Impact Resistant Structural Adhesive, 200 mL Cartridge, 07333 - (1)
  • 1457828-00-A: 3M Manual Cartridge Applicator Gun (200 mL), 08571 - (1)
  • 1111111-00-H: ASY,HV BATTERY,P2,MSX ROW PACK (3PHASE) - (1)
  • 1019168-00-A: Electrical Joint Compound,Penetrox A-13 - (1)
  • 1567101-20-A: HVCON,HEADER,0DEG,DU,SX,P2 - (1)
  • 1567101-10-A: HVCON,HEADER,90DEG,DU,SX,P2 - (2)
  • 1588001-00-A: HVCON,PLG,6P,ASY,JUMPER,SX,P2 - (1)
  • 1054785-00-A: Shop Supply, Primer (Grey) - (1)
  • 000-0474-001: THREADLOCKER, LOCTITE 222, PURPLE - (1)
  • 2023-05-22: Added note to cut inside the taped template.
Warning IconA warning icon, calling your attention to a possibly risky situation
警告
仅适用于欧洲：只有接受过二异氰酸酯操作培训并完成所有必修认证课程的技术人员才允许执行使用聚氨酯和含有二异氰酸酯的其他产品的程序。处理含有二异氰酸酯的产品时必须穿戴适当的个人防护装备 (PPE)。

Procedure

重要： Rework vehicle will need 24 hours to fully cure. Do not move rework vehicle during curing.
  1. Ask the customer to remove all personal belongings from the vehicle before proceeding.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Debris from the rework will damage items left inside vehicle.
  2. Cover all neighboring vehicles.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Debris from rework will damage paint on any surrounding vehicles.
  3. Spray primer onto the 3 phase header plate. If the plate is already e-coated, skip this step.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear the proper PPE for using aerosol cans.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not breathe in fumes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Use a cardboard box to prevent overspray onto other vehicles.
  4. Open all the doors and lower the LH front window.
  5. Remove the LH and RH rocker panel moldings. See 饰条 - 门槛板 - LH（拆卸和更换）.
  6. Remove the LH and RH 2nd row seat outer bolsters. See 承梁 - 外 - 座椅 - 第二排 - LH（拆卸和更换）.
  7. Wrap the LH 2nd row seatback, tuck the LH 2nd row seat belt behind the seat back, and move the seat back to the upright position.
    Informational PurposesAn informational icon, calling your attention
    注
    Do not cover the latch.
    Informational PurposesAn informational icon, calling your attention
    注
    The wrap will protect the interior components from debris.
  8. Wrap the RH 2nd row seatback, tuck the RH 2nd row seat belt behind the seat back, and then move the seat back to the upright position.
    Informational PurposesAn informational icon, calling your attention
    注
    Do not cover the latch.
    Informational PurposesAn informational icon, calling your attention
    注
    The wrap will protect the interior components from debris.
  9. Position the 2 post lift pads for HV battery removal.
  10. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3（连接和断开）.
  11. Enable Service Mode through the vehicle touchscreen. See 维护模式（启用和禁用）
  12. Unlock the vehicle Gateway. See 网关（解锁）.
  13. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Diagnostics > Thermal to access thermal system routines.
  14. Authorize thermal routines by holding the right turn signal, and then pressing the brake pedal for 10 seconds with the key on the phone dock.
  15. Touch the Start button next to "Start Thermal Fill Drain (Coolant only)", and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    注
    A window displaying PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTSearch for routine in ToolboxStart Thermal Fluid Fill/Drain (Coolant only)Thermal / Coolant System - Start Thermal Fill/Drainhv / Rear Drive Inverter Replacement - Start Fluid Fill/Drainhv / Rear Left Drive Inverter Replacement - Start Fluid Fill/Drainhv / Rear Right Drive Inverter Replacement - Start Fluid Fill/Drainhv / Front Drive Unit Replacement - Start Coolant Fill/Drainhv / Rear Drive Unit Replacement - Start Coolant Fill/DrainThermal / Actions - Start Coolant Fill/Drainhv / Front Drive Inverter Replacement - Start Fluid Fill/Drain will appear.
    Informational PurposesAn informational icon, calling your attention
    注
    Verify the coolant status is green for "Ready for Fill/Drain".
    Informational PurposesAn informational icon, calling your attention
    注
    The routine has a 5 hour limit. After 5 hours, the routine must be performed again.
    Informational PurposesAn informational icon, calling your attention
    注
    Touch the X in the top left of the window to close once the routine is completed.
  16. Move the driver seat fully forward.
  17. Move the front passenger seat fully rearward.
  18. Remove the rear underhood apron. See 前备箱挡板 - 后部（拆卸和更换）.
  19. 断开低压电源。请参阅低压电源（断开和连接）。
  20. 执行车辆高压禁用程序。请参阅车辆高压禁用程序。
  21. Remove leather glove protectors and HV insulating gloves.
  22. Lower the vehicle until the tires are touching the ground.
  23. Remove the 2nd row lower seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
  24. Remove the DC input HV header foam block.
  25. Remove the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  26. Remove the bolts (x2) that attach the charge port busbar connector to the DC input HV header.
    9 Nm (6.6 lbs-ft)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  27. Lift the charge port busbar connector to remove the connector from the DC input HV header.
  28. Remove the LH and RH rear subframe shear plates. See 剪力板 - 后副车架 - LH（拆卸和更换）.
  29. 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.
  30. Remove the front aero shield panel. See 面板 - 流线型护板 - 前（拆卸和更换）.
  31. Remove the front skid plate. See 车底护板 - 前（拆卸和更换）.
  32. Release the locking tab, and then disconnect the logic connector to the HV battery.
  33. Release the locking tab, and then disconnect the power connector to the HV battery.
  34. Position a coolant drain collector under the front of the vehicle to catch the vehicle coolant.
  35. Release the clip and disconnect the 3 way valve to HV battery hose from the HV battery, and then immediately plug the fittings.
  36. Release the clip and disconnect the HV battery coolant supply hose from the HV battery, and then immediately plug the fittings.
  37. Release the clip and disconnect the power conversion system coolant supply hose from the HV battery, and then immediately plug the fittings.
  38. Release the clips (x2) on the LH front wheel arch liner, and then move the liner aside for access.
  39. Release the clips (x2) that attach the power conversion system coolant return to LH sill hose to the body.
  40. 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.
  41. 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.
  42. 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.
  43. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.
  44. Remove the bolt that attaches the ground strap to the body, and then remove the ground strap from the body.
    10 Nm (7.4 lbs-ft)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  45. Remove coolant drain collector out from underneath the vehicle.
  46. Remove the bolt that attaches the front drive unit HV harness to the HV battery.
    5.5 Nm (4.1 lbs-ft)
    提示： 推荐使用以下工具：
    • 8 毫米套筒
  47. 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.
  48. 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.
  49. First loosen with a ratchet, and then use a power tool to remove the center bolts (x4) securing the HV battery.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • External Torx Plus EP16
  50. Position the battery table underneath the vehicle.
  51. With assistance, align the table to the vehicle, and then lower the vehicle to the table.
    Informational PurposesAn informational icon, calling your attention
    注
    Adjust casters to level table if necessary.
  52. 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.
    20 Nm (14.7 lbs-ft)
    提示： 推荐使用以下工具：
    • 外梅花套筒 Plus EP14
  53. 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.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • External Torx Plus EP16
  54. 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.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  55. 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.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  56. Raise the vehicle off of the HV battery.
  57. With the help of an assistant, move the HV battery and table away from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    注
    Battery will be moved to shipping container at a later step. Proceed with the rework steps to allow required curing time.
  58. Lower the vehicle until the tires are touching the ground.
  59. Release the clips (x2) that attach the LH 2nd row buckle harness to the body.
  60. Release the LH side of the front motor bay insulator from underneath the charge port busbar.
  61. Wrap the rear half of cabin across the B-pillars.
  62. Wrap the cabin carpet.
    Informational PurposesAn informational icon, calling your attention
    注
    Secure with tape as needed.
  63. Wrap the rear half of the cabin across the C-pillars.
  64. Wrap the LH and RH lower C-pillar trims.
  65. Wrap the top of the rear half of the cabin.
  66. Cut a cardboard box to fit the rework area.
    Informational PurposesAn informational icon, calling your attention
    注
    The box needs to fit inside the 2nd row floor panel. The box will act as a shield and prevent debris from spreading.
  67. Install the cardboard box onto the 2nd row floor panel.
    Informational PurposesAn informational icon, calling your attention
    注
    Secure the insulator away from the panel.
  68. Position a section of the cardboard over the body harness.
    Informational PurposesAn informational icon, calling your attention
    注
    The section will guard the harness from the cut-off tool.
  69. Position the 3 phase header plate onto the 2nd row floor panel.
    Informational PurposesAn informational icon, calling your attention
    注
    Note the plate placement on the floor panel.
  70. Apply masking tape to the floor panel on the LH and RH side of the 3 phase header plate to mark the position.
    Informational PurposesAn informational icon, calling your attention
    注
    Do not tape the header plate to the floor panel.
  71. Remove the 3 phase header plate from the 2nd row floor panel.
  72. Apply masking tape 1 inch inward of the 3 phase header plate placement.
  73. Apply masking tape along the 2nd row floor panel seams.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Apply the tape inside the front seam and outside the rear seam.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Reference the image closely to avoid cutting into incorrect panel.
  74. Drill 4 holes into the 2nd row floor panel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for drilling.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Drill inside the templated corners.
  75. Vacuum all debris produced by the drill.
  76. Connect shop air to the cut-off tool.
  77. Use the cutting tool to cut a square out of the 2nd row floor panel along the inside of the masking tape template, and then discard the cutout after removal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    DO NOT cut the extruded aluminum.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Only cut the area inside the taped section.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for cutting.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not breathe in fumes.
  78. Vacuum all debris produced by the cut-off tool.
  79. Remove the front tape from 3 phase header plate template.
  80. Drill 2 holes into the 2nd row floor panel inside and mid-level with rivets.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for cutting.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not drill out rivets.
  81. Vacuum all debris produced by the drill.
  82. Apply masking tape along outside edge of the drilled holes.
  83. Cut a rectangle out of the 2nd row floor panel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for cutting.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not breathe in fumes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not drill the rivets.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Only cut inside and mid-level with the rivets. Discard rectangle after removal.
  84. Vacuum all debris produced by the cut-off tool.
  85. Remove the masking tape, position the 3 phase header plate onto the floor panel, reapply masking tape on the outside of the header plate to create a new template, and then remove the header plate from the floor panel.
  86. Use a heat gun to heat the NVH material inside the 3 phase header plate template on the floor panel, and then use a scraper to remove the material from the floor panel.
  87. Use IPA wipes to clean the 2nd row floor panel mating surface.
    Informational PurposesAn informational icon, calling your attention
    注
    Allow 1 minute of dry time.
  88. Prepare a caulking gun and structural adhesive.
  89. Apply structural adhesive onto the 2nd row floor panel along the inside of the template, and then spread the adhesive evenly with a brush.
  90. Install the 3 phase header plate onto the 2nd row floor panel.
    Informational PurposesAn informational icon, calling your attention
    注
    Apply equal pressure and ensure the panel and plate are flush.
  91. Remove the masking tape from the 2nd row floor panel.
  92. Apply cardboard over the 3 phase header plate edges.
    Informational PurposesAn informational icon, calling your attention
    注
    This will protect sand bag from adhesive squeeze out.
  93. Position a sand bag onto the 3 phase header plate.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure the weight is evenly distributed and holding the plate down.
    重要： Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.
  94. Raise the vehicle fully and lower lift onto locks.
    Informational PurposesAn informational icon, calling your attention
    注
    Set the vehicle to comfortable working height. Make sure there is an audible click from the locks on both sides before lowering, otherwise the vehicle may tilt to the side.
  95. Apply structural adhesive underneath the 2nd row floor panel, and then spread the adhesive evenly with a brush.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Avoid dripping adhesive onto skin or hair.
    重要： Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.
  96. Lower vehicle until the tires are touching the ground.
  97. Perform a power conversion system coolant drain on the old HV battery. See 功率转换系统冷却液（排放） （工作台）.
  98. Perform a platter enclosure coolant drain on the old HV battery. See 磁盘外壳冷却液（排放） （工作台）.
  99. Release the clip that attaches the power conversion system coolant return hose to the HV battery.
  100. Release the clip, and then disconnect the power conversion system coolant return hose from the HV battery.
    图 1. Long Range hose shown, Plaid hose similar
  101. Attach the HV battery H-frame to the gantry and raise the H-frame into position.
  102. Use shackles (x4) to attach the P2 battery sling adapter to the H-frame.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure that the shackles are tight, secure, and the sling will not bind or twist when lifting the HV battery.
  103. With the help of an assistant, remove the top from the HV battery shipping crate.
  104. With the help of an assistant, position the gantry over the HV battery shipping crate.
  105. Lower the H-frame to the new HV battery.
  106. Install the P2 sling adapter onto the new HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Insert the lifting pin into the lifting hole of the HV battery.
    3. Install the collar over the end of the lifting pin, and then release the button.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      警告
      Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.
    4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
    5. Repeat substeps 34.a through 34.d for the other 5 lifting pins.
  107. Lift the new HV battery out of the shipping crate.
  108. With the help of an assistant, move the gantry away from the HV battery shipping crate and over a battery table.
  109. Position an unused HV battery table under the gantry.
  110. Lower the new HV battery onto the battery table.
  111. Remove the P2 battery sling adapter from the new HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
      Informational PurposesAn informational icon, calling your attention
      注
      The collar will fall free, but is tethered to the lifting pin.
    3. Repeat substeps 38.a through 38.b for the other 5 lifting pins.
  112. With the help of an assistant, remove HV battery and table from under the gantry.
  113. With the help of an assistant, position the old HV battery and battery table under the gantry.
  114. Install the P2 sling adapter onto the old HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Insert the lifting pin into the lifting hole of the HV battery.
    3. Install the collar over the end of the lifting pin, and then release the button.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      警告
      Make sure that the collar is fully seated against the underside of the HV battery, the balls are extended from the body of the lifting pin, and the button returns to the up position.
    4. Pull up on the sling adapter to verify that the lifting pin is secure in the HV battery.
    5. Repeat substeps 2.a through 2.d for the other 5 lifting pins.
  115. Raise the old HV battery off of the battery table.
  116. Move the HV battery table out from under the gantry.
  117. With the help of an assistant, position the gantry over the HV battery shipping crate.
  118. With the help of an assistant, align the old HV battery to the shipping crate, then lower the battery into the crate.
  119. Remove the P2 battery sling adapter from the old HV battery.
    1. Press and hold down the button at the top of the lifting pin, so that the balls retract into the body of the pin.
    2. Remove the lifting pin from the lifting hole of the HV battery, and then release the button.
      Informational PurposesAn informational icon, calling your attention
      注
      The collar will fall free, but is tethered to the lifting pin.
    3. Repeat substeps 7.a through 7.b for the other 5 lifting pins.
  120. Raise the gantry and H-frame from the shipping crate.
  121. With the help of an assistant, install the top onto the HV battery shipping crate, and return the battery to MRB.
  122. Return the gantry to position and remove the HV battery H-frame from the gantry.
  123. 重要：
    If performing retrofit procedure for vehicles built before August 15, 2022, continue to the next step. If performing retrofit procedure for vehicles built between August 15, 2022 to September 29, 2022, skip to step 126.
  124. Use a cut-off tool to cut the bottom of the HV battery pack bolts (x2).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for cutting.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not breathe in fumes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not cut the top of the bolts. Only remove the bottom of the two bolts shown in image.
  125. Spray primer onto the bottom of HV battery pack bolts (x2).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure to wear proper PPE for using aerosol cans. Do not breathe in fumes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Spray away from connectors and ground strap.
  126. Secure the PCS outlet hose to the HV battery, and then install the spring clip.
    Informational PurposesAn informational icon, calling your attention
    注
    Perform a push-pull-push test to ensure the hose is fully seated.
  127. Install the clip that attaches the PCS outlet hose to the HV battery.
  128. After 24 hours, remove the sand bag from the 3 phase header plate.
    重要： Allow 24hr for adhesive to fully cure. Any movement before curing will compromise adhesion.
  129. Remove the cardboard from the 2nd row floor panel.
  130. Clean the 2nd row floor panel area.
    Informational PurposesAn informational icon, calling your attention
    注
    Vacuum all debris from interior components before continuing. Wipe wrap as needed. Allow 1 minute of dry time.
  131. Remove the wrap from the vehicle.
  132. Vacuum the 2nd row interior components.
    Informational PurposesAn informational icon, calling your attention
    注
    All debris MUST be removed.
  133. Secure the LH side of the front motor bay insulator underneath charge port busbar.
  134. Secure the clips (x2) that attach the LH 2nd row buckle harness to the body.
  135. With the help of an assistant, move the HV battery and table to underneath the vehicle.
  136. Carefully lower the vehicle onto the HV battery.
    Informational PurposesAn informational icon, calling your attention
    注
    Verify that the liftpads will not contact the battery, and that hoses and harness are not compressed or damaged while lowering.
  137. 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
    注
    Final torque is applied in a later step.
    提示： 推荐使用以下工具：
    • 外梅花套筒 Plus EP14
  138. 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
    注
    Final torque is applied in a later step.
    提示： 推荐使用以下工具：
    • External Torx Plus EP16
  139. First hand start, and then use a power tool to install the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    注
    Final torque is applied in a later step.
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  140. 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
    注
    Final torque is applied in a later step.
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  141. Tighten the LH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  142. Tighten the RH rocker panel bolts (x8) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • 15 毫米套筒
  143. Tighten the outer center bolts (x4) that attach the HV battery to the vehicle.
    20 Nm (14.7 lbs-ft)
    提示： 推荐使用以下工具：
    • 外梅花套筒 Plus EP14
  144. Tighten the outer bolts (x12) that attach the HV battery to the vehicle.
    35 Nm (25.8 lbs-ft)
    提示： 推荐使用以下工具：
    • External Torx Plus EP16
  145. With assistance, raise the vehicle, and then remove battery table from underneath the vehicle.
  146. 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)
    提示： 推荐使用以下工具：
    • External Torx Plus EP16
  147. 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.
  148. Remove all items from pockets and make sure not to wear any metal items.
  149. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    注
    Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  150. Put on the HV insulating gloves and then leather over gloves.
  151. Remove the bolts (x2) that attach the front drive unit HV header to the HV battery, and then gently separate the header to remove it from the HV battery.
    10 Nm (7.4 lbs-ft)
    提示： 推荐使用以下工具：
    • 外梅花套筒 Plus EP10
  152. Position the new front drive unit HV header (PN: 1567101-20-A) onto the HV battery, and then install the bolts (x2) that attach the header to the HV battery.
    10 Nm (7.4 lbs-ft)
    提示： 推荐使用以下工具：
    • 外梅花套筒 Plus EP10
  153. Remove the bolts (x2) that attach the rear drive unit HV battery LH HV header to the HV battery.
    10 Nm (7.4 lbs-ft)
    提示： 推荐使用以下工具：
    • E10 5-lobe socket
  154. Release the tabs (x2) that secure the rear drive unit HV battery LH HV header to the HV battery, and then use a plastic trim tool to gently remove the header from the HV battery.
  155. Secure the new rear drive unit HV battery LH HV header (PN: 1567101-10-A) to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    注
    Verify the header is fully seated.
  156. Install the bolts (x2) that attach the rear drive unit HV battery LH HV header to the HV battery.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    注
    Tighten the bolts evenly.
    提示： 推荐使用以下工具：
    • E10 5-lobe socket
  157. Repeat step 150 through step 153 for the rear drive unit HV battery RH HV header.
    Informational PurposesAn informational icon, calling your attention
    注
    Replace the RH HV header with the same new part - PN: 1567101-10-A.
  158. Remove the leather glove protectors and the HV insulating gloves.
  159. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector square to the HV battery front drive unit header, secure the release lever to the closed position, and then slide the red connector locking tab.
  160. Install the bolt that attaches the front drive unit HV harness to the HV battery.
    5.5 Nm (4.1 lbs-ft)
    提示： 推荐使用以下工具：
    • 8 毫米套筒
  161. Position the coolant drain collector under the front of the vehicle to catch the vehicle coolant.
  162. 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.
  163. Fasten the clips (x2) that attach the power conversion system coolant return to LH sill hose to the body.
  164. 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.
  165. 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.
  166. Plaid vehicles only - Remove the foldable funnel and absorbent material from under the power conversion system coolant return hose.
  167. 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)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  168. 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.
  169. 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.
  170. 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.
  171. 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.
  172. Connect the power connector to the HV battery, and then secure the locking tab.
  173. Connect the logic connector to the HV battery, and then secure the locking tab.
  174. Install the front skid plate. See 车底护板 - 前（拆卸和更换）.
  175. Install the front aero shield panel. See 面板 - 流线型护板 - 前（拆卸和更换）.
  176. Remove the gore breathers (x4) from rear breather assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Be careful not to damage the breathers during removal.
    Informational PurposesAn informational icon, calling your attention
    注
    The breathers will be re-used. The breathers are located at the rear of the pack.
  177. Install tapered plugs (x3) into indicated breather holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Do not push the plugs too far inside.
  178. Install the leak test adapter into the fourth breather hole.
  179. Close both valves on the regulator test tool.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure the valves are closed.
  180. Connect the enclosure leak tester fitting to the leak test adapter.
    Informational PurposesAn informational icon, calling your attention
    注
    If required, safely secure the leak tester air line in a manner where it will not tug the adapter off.
  181. Connect the regulator to air supply.
  182. Turn the RH side regulator valve to the open position.
    Informational PurposesAn informational icon, calling your attention
    注
    Open the valve closest to the air line by turning the valve knob to the horizontal position.
  183. Set the regulator to 0.3 psi, and then allow the regulator to stabilize.
  184. Open the LH side regulator valve to allow air into the HV battery, allow the pressure to stabilize at 0.3 psi, and then close the RH side regulator valve.
    Informational PurposesAn informational icon, calling your attention
    注
    It will take approximately 60 seconds to reach 0.3 psi.
  185. Wait 60 seconds to allow pressure to stabilize.
  186. Record the start pressure value.
  187. Wait 30 seconds for test.
  188. Record the end pressure value.
    Informational PurposesAn informational icon, calling your attention
    注
    If pressure did not drop more than 0.026 psi, continue to next step, If pressure dropped more than 0.026 psi, then inspect HV battery enclosure for leaks
  189. Disconnect the air supply from the leak tester.
  190. Disconnect the enclosure leak tester fitting from the leak test adapter.
    Informational PurposesAn informational icon, calling your attention
    注
    Release the leak tester air line if previously secured.
  191. Remove the leak test adapter from the breather hole.
  192. Remove the tapered plugs (x3) from the breather holes.
  193. Install the gore breathers (x4) onto the rear breather assembly.
    Informational PurposesAn informational icon, calling your attention
    注
    If the breathers were damaged, replace as needed.
  194. 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 RH HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
    Informational PurposesAn informational icon, calling your attention
    注
    Long Range configuration vehicles will have a dummy plug.
  195. Install the LH and RH rear subframe shear plates. See 剪力板 - 后副车架 - LH（拆卸和更换）.
  196. Install the mid aero shield panel. See 面板 - 流线型护板 - 中间（拆卸和更换）.
  197. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    注
    Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  198. Put on the HV insulating gloves and then leather over gloves.
  199. 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.
  200. 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.
  201. Apply two small drops of Penetrox onto each DC input HV header terminal contact surface, and spread evenly.
  202. 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)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  203. 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
    注
    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), escalate to Service Engineering.
    Informational PurposesAn informational icon, calling your attention
    注
    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.
  204. Install the bolt that secures the charge port busbar connector access door.
    9 Nm (6.6 lbs-ft)
    提示： 推荐使用以下工具：
    • 10 毫米套筒
  205. Verify that the black release lever of the HV 6 pin jumper plug is in the open position, install the jumper plug flat and square to the 3 phase header, secure the release lever to the closed position, and then slide the red connector locking tab.
    Informational PurposesAn informational icon, calling your attention
    注
    Only applicable to revision H and later for North America packs.
  206. Install the DC input HV header foam block.
  207. Remove the leather glove protectors and HV insulating gloves
  208. Remove the wrap from the RH 2nd row seatback, and return the seatback and seatbelt to the original positions.
    Informational PurposesAn informational icon, calling your attention
    注
    Clean debris off wrap before removal. Allow 1 minute dry time.
  209. Remove the wrap from the LH 2nd row seatback, and then return the seatback and seatbelt to the original positions.
    Informational PurposesAn informational icon, calling your attention
    注
    Clean debris off wrap before removal. Allow 1 minute dry time.
  210. Install the 2nd row lower seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
  211. Install the LH and RH 2nd row seat side bolsters. See 承梁 - 外 - 座椅 - 第二排 - LH（拆卸和更换）.
  212. Put an empty coolant container in the underhood storage unit.
  213. Fill another container with at least 15L of coolant.
  214. Place the filled coolant container into the front storage area.
  215. Remove the coolant bottle cap.
  216. Install the vacuum refill cap onto the coolant bottle assembly.
  217. Setup the coolant refill tool.
    Informational PurposesAn informational icon, calling your attention
    注
    Verify all valves on the refill tool are in the closed position.
  218. Install the vacuum refill hose into the refill cap on the coolant bottle.
    Informational PurposesAn informational icon, calling your attention
    注
    Perform a push-pull-push test to verify that the hose is fully installed.
  219. Put the refill hose inside the filled coolant container.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure the hose end is fully submerged in coolant.
  220. Position the overflow hose in the empty container.
  221. Connect shop air supply to the coolant refill tool.
    Informational PurposesAn informational icon, calling your attention
    注
    If not already done, verify that the refill valve is set to off.
  222. Open the air inlet valve to draw a vacuum. Once the gauge stabilizes, close the valve fully.
    Informational PurposesAn informational icon, calling your attention
    注
    The gauge stabilizes roughly at 60-70 cmHg. Vacuum should not drop after the valves are closed.
  223. Slowly open the refill valve to allow coolant to be drawn into the cooling system.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure the hose end of refill hose is fully submerged during entire process.
  224. Once the gauge reads zero, close the coolant refill valve.
  225. Remove the coolant refill hose from the coolant container.
  226. Remove the coolant overflow hose from the coolant container.
  227. Remove the vacuum refill hose from the refill cap on the coolant bottle.
  228. Remove the vacuum refill tool cap.
  229. Remove the coolant refill tool from the vehicle.
  230. Remove both coolant containers from the underhood storage unit area.
  231. Secure the First Responder Loop and then secure a 12v maintainer. Leave the LV battery disconnected.
    Informational PurposesAn informational icon, calling your attention
    注
    Place fender cover over multi-system beam. Connect first responder loop then secure 12v maintainer to positive jump post and chassis ground. Vehicle will power on with 0% Low Voltage message at UI.
  232. Move the front seats to original position.
  233. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Diagnostics > Thermal to access thermal system routines.
  234. Authorize thermal routines by holding the right turn signal, and then pressing the brake pedal for 10 seconds with the key on the phone dock.
  235. Touch the Start button next to "Start Coolant Air Purge", and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    注
    A window displaying "TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start - SUCCESS" will appear.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    警告
    Make sure the vehicle is not in drive. The test runs for approximately 10 minutes. Putting vehicle into a drive state will stop this routine. Monitor the coolant level and add more coolant as needed.
    Informational PurposesAn informational icon, calling your attention
    注
    Touch the X in the top left of the window to close once the routine is completed.
  236. Check the coolant level and top off as needed.
    Informational PurposesAn informational icon, calling your attention
    注
    Use a mirror to aid visually.
    Informational PurposesAn informational icon, calling your attention
    注
    Make sure the coolant fluid level is at the Max line and top off as needed.
  237. Install the coolant bottle cap.
  238. On the vehicle touchscreen, touch Quick Controls (vehicle icon) > Service Mode > Software Reinstall.
  239. Touch the Request button in the "Software Reinstall" dialogue box.
    Informational PurposesAn informational icon, calling your attention
    注
    Confirm that a successful request message appears.
    Informational PurposesAn informational icon, calling your attention
    注
    Touch the X in the top left of the window to close once the routine is completed.
  240. On the vehicle touchscreen, touch the clock, and then touch the Install Now button to start the software update.
  241. Secure the LV battery, and then remove the maintainer.
  242. Install the rear underhood apron. See 前备箱挡板 - 后部（拆卸和更换）.
  243. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3（连接和断开）.
  244. Remove the vehicle from the 2 post lift. See 举升车辆 - 双柱举升机.
  245. Install the LH and RH rocker panel moldings. See 饰条 - 门槛板 - LH（拆卸和更换）.
  246. Raise the LH front window and close the all the doors.