2024-08-16

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.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
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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.
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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.
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Note
This procedure is intended to be performed by 2 technicians.

Removal

  1. Open LH front door.
  2. Lower LH front window.
  3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  6. Remove the inlet HEPA filter duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  7. Remove the outlet HEPA filter duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  8. Disconnect 12V power. See Disconnect 12V Power.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not perform HV disablement. It is not required when performing an HV battery remove and install.
  9. Raise the vehicle fully and lower lift onto locks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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.
  10. If equipped, remove the vent covers (x2) from the HV battery.
  11. Remove the clips (x2) that attach the LH shear plate to the wheel fairing.
    Figure 1. LH shown; RH similar
  12. Remove the fasteners that attach the LH shear plate to the vehicle, and then remove the shear plate from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the nyloc nut after removal.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15mm socket
    • T25 socket
    • 10mm socket
    Figure 2. LH shown; RH similar
  13. Repeat steps 11 and 12 for the RH shear plate.
  14. Remove the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  15. 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.
  16. 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.
    16 Nm (11.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • T30 socket
  17. 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.
    38 Nm (28.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E12 socket
  18. Position battery table underneath vehicle.
  19. With assistance, lower the vehicle onto the table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the table to the vehicle and raise the casters to level table if necessary.
  20. 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.
    38 Nm (28.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E12 socket
  21. 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.
    30 Nm (22.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  22. 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.
    115 Nm (84.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21mm socket
  23. Loosen the LH rocker bolts (x8). After all 8 bolts have been loosened, use a battery powered drill to remove and discard the bolts.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  24. Loosen the RH rocker bolts (x8). After all 8 bolts have been loosened, use a battery powered drill to remove and discard the bolts.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  25. Raise the vehicle off of the HV battery.
  26. Move the HV battery away from the vehicle.
  27. Place an HV Danger placard on top of the HV battery and place a barrier around the working area.
  28. Remove all items from pockets and ensure not wearing metal items.
  29. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check 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.
  30. Put on HV insulating gloves and leather over gloves.
  31. Use a multimeter to check voltages at the Rapid Splitter.
    • B+ to ground
    • B- to ground
    • B+ to B-
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    If 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.
  32. Check voltage on HV rapid mate.
    Informational PurposesAn informational icon, calling your attention
    Note
    B+ 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.
  33. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If 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.
  34. Remove leather over gloves and HV insulating gloves.

Installation

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Wear proper PPE when interacting with high voltage components, such as the Rapid Mate, even if those components were not serviced.
Informational PurposesAn informational icon, calling your attention
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:
      Informational PurposesAn informational icon, calling your attention
      Note
      Refer to TN-13-16-001, "Rapid Mate Inspection" for more information.
      1. 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).
      2. 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).
      3. 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.
      4. 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.

  2. Position HV battery underneath vehicle.
  3. Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
  4. Remove covers or tape from LV and HV Rapid Mates.
  5. Lower vehicle onto pack.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    There may be residual high voltage at the Rapid Mate connector which might arc when inspecting the connection there.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align Rapid Mate connections before lowering fully, Recommend assistance.
  6. Remove leather over gloves and HV insulating gloves.
  7. Use a battery powered drill to install new front HV battery bolts, but do not torque the bolts.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  8. Use a battery powered drill to install new 21mm bolts (x2) securing the front of HV battery, but do not torque the bolts.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21mm socket
  9. Use a battery powered drill to install new center bolts (x8) securing the HV battery, but do not torque the bolts.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E12 socket
  10. Use a battery powered drill to install new LH rocker bolts (x8), but do not torque the bolts.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  11. Use a battery powered drill to install new RH rocker bolts (x8), but do not torque the bolts.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  12. Torque the LH and RH rocker bolts (x16).
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
    Figure 3. LH shown; RH similar
  13. Torque the 8 center bolts securing the HV battery.
    38 Nm (28.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E12 socket
  14. Torque the front HV battery bolts (x4).
    30 Nm (22.1 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13mm socket
  15. Torque the 21mm bolts (x2) securing the front of HV battery.
    115 Nm (84.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 21mm socket
  16. With assistance, raise the vehicle and remove the battery table.
  17. Install new center bolts (x4) securing the HV battery. After all the bolts have been installed, torque the bolts.
    38 Nm (28.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • E12 socket
  18. 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.
    16 Nm (11.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • T30 socket
  19. 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.
  20. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  21. Install the fasteners that attach the LH shear plate to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install a new nyloc nut.
    Informational PurposesAn informational icon, calling your attention
    Note
    See torque specification for each fastener:
    • 15mm socket - 35 Nm
    • T25 socket - 6 Nm
    • 10mm socket - 4 Nm
    Figure 4. LH shown; RH similar
  22. Install the clips (x2) that attach the LH shear plate to the wheel fairing.
    Figure 5. LH shown; RH similar
  23. Repeat steps 20 and 21 for the RH shear plate.
  24. If equipped, install the vent covers (x2) to the HV battery.
  25. Lower vehicle partially.
  26. Connect 12V power. See Disconnect 12V Power.
  27. Install the outlet HEPA filter duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  28. Install the inlet HEPA filter duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  29. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  30. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  31. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  32. Raise the LH front window and close the LH front door.