16/08/2024 12:48:34
HV Battery (RWD/AWD) (Remove and Install)
Correction Code 16010101 (RWD), 16010201 (AWD)
- 2024-08-16: Added note stating it is not necessary to perform HV disablement.
- 2024-03-06: Added steps of removing and installing vent covers for the vehicles equipped with the covers.
- 1020566-00-E - BATT MAN LIFT TABLE - MDLS
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 any time a high voltage cable is handled. Refer to
Tech Note TN-15-92-003, "High Voltage Awareness Care Points"
for additional safety information.
Warning
If the vehicle has air
suspension, activate "Jack" mode on the touchscreen before raising and
supporting the vehicle.
Warning
Before starting this
procedure, make sure that all bolts that attach the battery to the vehicle are installed
on the vehicle. Failure to check for missing bolts might result in the battery pack to
become loose unexpectedly, and might injure a technician.
Note
Use a cordless electric drill with a
3/8 in drive adapter and an 3/8 in drive air ratchet wrench to perform this procedure.
Do not use an impact wrench to remove battery fasteners.
Note
This procedure is intended to be
performed by 2 technicians.
Removal
- Open LH front door.
- Lower LH front window.
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
- Remove the inlet HEPA filter duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
- Remove the outlet HEPA filter duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
-
Disconnect 12V power. See Disconnect 12V Power.
NoteDo not perform HV disablement. It is not required when performing an HV battery remove and install.
-
Raise the vehicle fully and lower
lift onto locks.
NoteSet vehicle to comfortable working height. Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
- If equipped, remove the vent covers (x2) from the HV battery.
-
Remove the clips (x2) that attach
the LH shear plate to the wheel fairing.
-
Remove the fasteners that attach
the LH shear plate to the vehicle, and then remove the shear plate from the
vehicle.
NoteDiscard the nyloc nut after removal.Tip: Use of the following tool(s) is recommended:
- 15mm socket
- T25 socket
- 10mm socket
- Repeat steps 11 and 12 for the RH shear plate.
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Remove the clips (x14) that attach the RH ski side covers (x3) to the vehicle, and then remove the covers from the vehicle. Repeat this step for the LH side of the vehicle.
-
Remove the bolts (x2) that attach
the front lower bash plate extrusion to the vehicle, and then remove the bash
plate extrusion from the vehicle.Tip: Use of the following tool(s) is recommended:
- T30 socket
-
Loosen all 4 center bolts
securing the HV battery. After all 4 bolts have been loosened, use a battery
powered drill to remove and discard the bolts.Tip: Use of the following tool(s) is recommended:
- E12 socket
-
Position battery table underneath
vehicle.
-
With assistance, lower the
vehicle onto the table.
NoteAlign the table to the vehicle and raise the casters to level table if necessary.
-
Loosen the 8 center bolts
securing the HV battery. After all 8 bolts have been loosened, use a battery power
drill to remove and discard the bolts.Tip: Use of the following tool(s) is recommended:
- E12 socket
-
Loosen the front 4 HV battery
bolts. After all 4 bolts have been loosened, use a battery powered drill to remove
and discard the bolts.Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Loosen the 21mm bolts (x2)
securing the front of HV battery. After both bolts have been loosened, use a
battery powered drill to remove and discard the bolts.Tip: Use of the following tool(s) is recommended:
- 21mm socket
-
Loosen the LH rocker bolts (x8).
After all 8 bolts have been loosened, use a battery powered drill to remove and
discard the bolts.Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Loosen the RH rocker bolts (x8). After all 8 bolts have been loosened, use a
battery powered drill to remove and discard the bolts.Tip: Use of the following tool(s) is recommended:
- 13mm socket
- Raise the vehicle off of the HV battery.
- Move the HV battery away from the vehicle.
- Place an HV Danger placard on top of the HV battery and place a barrier around the working area.
- Remove all items from pockets and ensure not wearing metal items.
-
Inspect HV insulating
gloves.
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves, https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC.
- Put on HV insulating gloves and leather over gloves.
-
Use a multimeter to check
voltages at the Rapid Splitter.
- B+ to ground
- B- to ground
- B+ to B-
WarningIf any voltage reading is more than 10V, continue to hold the probes to the test points to drop the voltage to 10V. If the voltage does not drop, contact a Field Service Engineer before performing any further work. -
Check voltage on HV rapid
mate.
NoteB+ to ground, B- to ground, and B+ to B-, If any voltage reading is more than 10V, the pack contactors are not fully opened, Contact Engineering for support.
-
Insert the high voltage Rapid
Mate cover (1038478-00-A) and the low voltage Rapid Mate cover (1028325-00-A) into
the high and low voltage Rapid Mates.
NoteIf the covers are not available, use 3M 2480S Masking Tape (2" wide) or 3M 471 Red Vinyl Tape (2” wide) to seal the Rapid Mates.
- Remove leather over gloves and HV insulating gloves.
Installation
Warning
Wear proper PPE when
interacting with high voltage components, such as the Rapid Mate, even if those
components were not serviced.
Note
Heed the following
conditions when installing the replacement HV battery, particularly for vehicles
built before April 10, 2016:
-
- If the replacement HV battery
part number is 1014116-00-xxx or later, inspect both upper rear suspension
links:
- If the part numbers are 1027426-00-C (Dual Motor) or later, or 1027421-00-E (RWD) or later, the links are up-to-date and do NOT need to be replaced.
- If the part numbers are earlier than 1027426-00-C (Dual Motor), or 1027421-00-E (RWD), replace the links with part numbers 1027426-00-C (Dual Motor) or 1027421-00-E (RWD) or later. See Link - Suspension - Rear - Upper - LH (Remove and Replace).
- Model S Built Before April 10,
2016: Perform a visual inspection of the HV Rapid Mate:NoteRefer to TN-13-16-001, "Rapid Mate Inspection" for more information.
- Visually inspect the skirt seal on the vehicle-side HV Rapid Mate for damage or deformation. If there is damage or deformation, replace the Rapid Mate seal (refer to procedure).
- Visually inspect the blades, pins, and plastic insulator on the vehicle-side HV Rapid Mate for corrosion or damage. If there is damage or deformation, replace the vehicle-side HV Rapid Mate (refer to procedure).
- If necessary, clean the blades, pins, and plastic insulator on the vehicle-side HV Rapid Mate with alcohol wipes, and allow the alcohol to completely dry.
- Use a swab to apply P-80 emulsion to the outside of the main seal and the inside of the skirt seal on the vehicle-side HV Rapid Mate.
- If the replacement HV battery
part number is 1014116-00-xxx or later, inspect both upper rear suspension
links:
-
Position HV battery underneath
vehicle.
- Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
- Remove covers or tape from LV and HV Rapid Mates.
-
Lower vehicle onto pack.
WarningThere may be residual high voltage at the Rapid Mate connector which might arc when inspecting the connection there.NoteAlign Rapid Mate connections before lowering fully, Recommend assistance.
- Remove leather over gloves and HV insulating gloves.
-
Use a battery powered drill to
install new front HV battery bolts, but do not torque the bolts.
Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Use a battery powered drill to
install new 21mm bolts (x2) securing the front of HV battery, but do not torque
the bolts.
Tip: Use of the following tool(s) is recommended:
- 21mm socket
-
Use a battery powered drill to
install new center bolts (x8) securing the HV battery, but do not torque the
bolts.
Tip: Use of the following tool(s) is recommended:
- E12 socket
-
Use a battery powered drill to
install new LH rocker bolts (x8), but do not torque the bolts.
Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Use a battery powered drill to install new RH rocker bolts (x8), but do not
torque the bolts.
Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Torque the LH and RH rocker bolts (x16).Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Torque the 8 center bolts securing the HV battery.Tip: Use of the following tool(s) is recommended:
- E12 socket
-
Torque the front HV battery bolts (x4).Tip: Use of the following tool(s) is recommended:
- 13mm socket
-
Torque the 21mm bolts (x2) securing the front of HV battery.Tip: Use of the following tool(s) is recommended:
- 21mm socket
- With assistance, raise the vehicle and remove the battery table.
-
Install new center bolts (x4)
securing the HV battery. After all the bolts have been installed, torque the
bolts.Tip: Use of the following tool(s) is recommended:
- E12 socket
-
Position the front lower bash
plate extrusion into the vehicle, and then install the bolts (x2) that attach the
bash plate extrusion to the vehicle.Tip: Use of the following tool(s) is recommended:
- T30 socket
- Position the RH ski side covers (x3) into the vehicle, and then install the clips (x14) that attach the covers to the vehicle. Repeat this step for the LH side of the vehicle.
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
-
Install the fasteners that attach
the LH shear plate to the vehicle.
NoteInstall a new nyloc nut.NoteSee torque specification for each fastener:
- 15mm socket - 35 Nm
- T25 socket - 6 Nm
- 10mm socket - 4 Nm
-
Install the clips (x2) that
attach the LH shear plate to the wheel fairing.
- Repeat steps 20 and 21 for the RH shear plate.
- If equipped, install the vent covers (x2) to the HV battery.
- Lower vehicle partially.
- Connect 12V power. See Disconnect 12V Power.
- Install the outlet HEPA filter duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
- Install the inlet HEPA filter duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
- Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
- Raise the LH front window and close the LH front door.