2025-03-26

HV Battery Cover Corrosion (Remove)

Correction Code S019916005, S029916005, S039916005

  • 2025-03-26: Released archived information.
  • 3M P95 PARTICULATE RESPIRATORY MASK OR EQUIVALENT
  • 508107582, RUSTOLEUM GREY PRIMER
  • 508107592, RUSTOLEUM WHITE ENAMEL
  • 508139693, SEM SELF ETCHING PRIMER
  • 1054112-00-A, WIRE BRUSH
  • 1038478-00-A, ASY,COVER,HV RAPID,HVBAT,MDLS
  • 1028325-00-A, ASY,COVER,LV RAPID,HVBAT,MDLS
  • 1005706-00-C, COVER,PORTS,BATT,COOLANT CX
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only Service Technicians that have completed the HV Battery switch replacement training are authorized to perform this service.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn any time a high voltage cable is handled. Refer to service bulletin TN-15-92-003, “High Voltage Awareness Care Points” for additional safety information.
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CAUTION
If the diameter of any portion of the corrosion is 6 inches (152 mm) or larger, or if there is perforation in the HV Battery cover, the HV Battery must be returned to a remanufacturing center.
Informational PurposesAn informational icon, calling your attention
Note
The high voltage (HV) Battery might experience minor corrosion on the top and/or sides of the cover. The corrosion does not affect HV Battery operation and is primarily due to continuous water exposure, and is improved greatly with the inclusion of the 2nd generation Battery blanket.

Procedure

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Warning
Wear protective eyewear while performing this procedure.
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CAUTION
To avoid damage from paint overspray, ensure that the affected HV Battery is located away from vehicles and other objects before performing this procedure.
Informational PurposesAn informational icon, calling your attention
Note
This procedure should be performed on all areas on the HV Battery cover that have corrosion or bare metal.
Informational PurposesAn informational icon, calling your attention
Note
If the HV Battery has the 2nd generation Battery blanket, do not remove the blanket to inspect for corrosion.
  1. If the Battery has the 2nd generation blanket, inspect the plastic top layer. Remove and discard the blanket if the plastic cover is ripped, torn, or has a hole in it and install a new Battery blanket (refer to Service Manual procedure 16014002)
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform SI-14-16-006, “Retrofit Second Generation Battery Blanket on HV Battery 1.0” to retrofit the 2nd generation Battery blanket on Batteries that have the 1st generation blanket.
  2. Cover the HV battery connectors:
    Informational PurposesAn informational icon, calling your attention
    Note
    If any of these covers are not available, cover the connector with masking tape to prevent debris from falling into the HV Battery during this procedure.
    • HV connector with an HV Rapid Mate cover, Tesla P/N 1038478-00-A
    • Low voltage (LV) connector with a LV Rapid Mate cover, Tesla P/N 1028325-00-A
    • Coolant connector with a Coolant Rapid Mate cover, Tesla P/N 1005706-00-C
  3. Use the wire brush to remove loose rust from the affected areas on the cover of the HV Battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only the brush listed in the Special Tools table of this procedure; brushes that have thicker bristles can damage the e-coating on the HV Battery.
  4. Vacuum all loose rust.
  5. Clean the affected areas with alcohol wipes. Allow the alcohol to dry before continuing this procedure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use anything other than isopropyl alcohol (IPA) to clean the HV battery enclosure. Using other chemicals, such as brake cleaner, might corrode the coating on the HV battery enclosure.
  6. If there is corrosion near the sticker on the Battery cover, cover the sticker with a paper or plastic sheet to avoid overspray.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The remainder of this procedure must be performed in a well-ventilated area while wearing a 3M P95 Particulate Respiratory Mask or equivalent. If necessary, move the HV Battery outside of the Service Center. Refer to all product instructions and warnings for proper application method and safety precautions.
  7. Spray the affected areas with a thin coat of grey Rust-Oleum Primer. Allow the primer to dry for approximately 5 minutes before continuing with this procedure.
  8. Repeat the previous step for a total of 3 coats.
  9. Spray the affected areas with a thin coat of white Rust-Oleum Enamel. Allow the coating to dry for approximately 5 minutes before continuing with this procedure.
  10. Spray the affected areas with a thin coat of SEM Self Etching Primer. Allow the SEM Self Etching Primer to dry for approximately 5 minutes before continuing with this procedure.
  11. Remove the cover from the sticker on the Battery cover, if necessary.