13/03/2024 03:53:17

HV Battery (RWD/AWD) (Remove and Replace)

Correction Code 16010102 (RWD), 16010202 (AWD)

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.

Special tools required for this procedure:


Supplier	Part Number	Description
Tesla	1020566-00-E	BATT MAN LIFT TABLE - MDLS

2024-02-02: Fixed reference error.
2023-11-10: Replaced steps with link to 12V Disconnect procedure.
2023-06-07: Service Engineering updates to the touchscreen steps.
2023-05-22: Updated pack configuration steps.
2023-05-22: Added conspicuous discharge warning table.
2023-03-16: Updated Discharge section and added steps to configure the HV battery.

Discharge


	WARNING: To conform with local laws, High Voltage Lithium Batteries must be discharged before packing for shipment. Additionally, HV batteries must be discharged before being put into storage. HV batteries to be surface shipped must have a State of Charge (SoC) of less than 50%. HV batteries to be air shipped must have a SoC of less than 30%. If the method of shipment is unknown or uncertain, or the battery is to be stored, it is recommended to discharge the HV battery to less than 30%. WARNING: Do not ship or store an HV battery that has a loss of high voltage isolation. Verify HV battery isolation before packing for shipment or storage. Use the HV Battery Communication Tool, described in Toolbox article #41977, to determine if the HV battery parameters are within safe limits for shipment or storage.

Note

If possible, perform the discharge procedure before HV battery removal. This method requires less time and user interaction than to use the Battery Discharge Tool after the battery has been removed. The Battery Discharge Tool can only be used by certified technicians.

Note

The steps of the discharge procedure are mostly touch time, and can be performed by the Service Advisors/Front of House team as well as Service Technicians.

Identify the vehicle SOC.
- If the SOC is less than the specified values, proceed with removal. See Removal.
- If the SOC is greater than the specified values, lower all of the vehicle windows and turn on the climate control system to maximum defrost. This setting will discharge the battery by approximately 10% SOC every hour.
Move the vehicle to a location where it can safely continue to discharge the battery unattended.
Identify the vehicle SOC every half-hour.
When the SOC is below 50% for surface transport, or below 30% for air transport, turn off the climate control system, raise the windows, and then move the vehicle to the service bay.

Removal

Open LH front door.
Lower LH front window.
Raise and support vehicle.

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads.
Disconnect 12V power. See Disconnect 12V Power.
Raise vehicle fully and lower lift onto locks.

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.
Remove clips securing LH shear plate to wheel fairing.

Note
2x push clips.
Remove LH shear plate.

Note
1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal.
Remove clips securing RH shear plate to wheel fairing.

Note
2x push clips.
Remove RH shear plate.

Note
1x nyloc nut, 15mm, 35 Nm, 3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal.
Remove clips securing mid aero shield to vehicle.

Note
7x push clips.
Remove bolts securing mid aero shield to vehicle.

Note
7x bolts, 10mm, 4 Nm.
Remove mid aero shield from vehicle.
Remove ski side covers on RH side.

Note
14x clips, 3x covers.
Remove ski side covers on LH side.

Note
14x clips, 3x covers.
Remove front lower bash plate extrusion.

Note
2x bolts, T30, 16 Nm.
Loosen four center bolts securing HV battery.

Note
4x patch bolts, E12, 38 Nm, Discard after removal.
Remove four center bolts securing HV battery with battery powered drill.

Note
4x patch bolts, E12, 38 Nm, Discard after removal.
Position battery table beneath vehicle.
Lower vehicle to table.

Note
Recommend assistance, Align table to vehicle and raise casters to level table if necessary.
Loosen remaining eight center bolts securing HV battery.

Note
8x patch bolts, E12, 38 Nm, Discard after removal.
Remove remaining eight center bolts securing HV battery with battery powered drill.

Note
8x patch bolts, E12, 38 Nm, Discard after removal.
Loosen front four HV battery bolts.

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal.
Remove front four HV battery bolts with battery powered drill.

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal.
Loosen 21mm bolts securing front of HV battery.

Note
2x bolts, 21mm, 115 Nm, Discard after removal.
Remove 21mm bolts securing front of HV battery with battery powered drill.

Note
2x bolts, 21mm, 115 Nm, Discard after removal.
Loosen LH rocker bolts.

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal.
Remove LH rocker bolts with battery powered drill.

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal.
Loosen RH rocker bolts.

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal.
Remove RH rocker bolts with battery powered drill.

Note
8x patch bolts, 13mm, 55 Nm, Discard after removal.
Raise vehicle off of HV battery.
Move battery away from vehicle.
Remove all items from pockets and ensure not wearing metal items.
Inspect HV insulating gloves.

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.
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-
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.
Check voltage on HV rapid mate.

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.
Insert the high voltage RapidMate cover (1038478-00-A) and the low voltage RapidMate cover (1028325-00-A) into the high and low voltage RapidMates.

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 RapidMates.
Remove leather over gloves and HV insulating gloves.
Install battery coolant service fixture onto coolant rapid mate.

Note
Hand tighten nuts while holding fixture down on rapid mate.
Connect the coolant hoses.

Note
Drain hose goes into coolant container, Pressure hose connects to regulator.
Connect shop air to regulator.

Note
Make sure regulator valve is closed prior to connecting shop air.
Slowly open valve on pressure regulator and allow coolant to drain out of HV battery return hose.

Note
Close valve on pressure regulator once no coolant is draining from HV battery return hose into coolant container.
Remove shop air and pressure hose from regulator.
Attach HV battery H-frame to gantry and raise into position.
Position HV battery under gantry.

Note
Recommend assistance.
Lower H-frame onto HV battery and secure H-frame to battery.

Note
4x hooks.
Raise HV battery off of battery table.
Position gantry over pallet.

Note
Recommend assistance.
Lower HV battery onto pallet.
Remove H-frame from old HV battery.

Note
4x hooks.
Raise gantry and H-frame from old HV battery.

Installation

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:
  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.
Open the crate top housing the new HV battery pack.

Note
Recommend assistance.
Position gantry over new HV battery crate and secure H-frame to battery.

Note
4x hooks, Recommend assistance.
Lift new HV battery out of crate.
Move gantry away from HV battery crate and over HV battery table.

Note
Recommend assistance.
Lower HV battery onto battery table.

Note
Recommend assistance, Make sure to align HV battery center to battery table.
Release H-frame from HV battery and raise gantry.

Note
4x hooks.
Remove HV battery from under gantry.

Note
Recommend assistance.
Position gantry over old HV battery.

Note
Recommend assistance .
Lower H-frame onto old HV battery and secure H-frame to battery.

Note
4x hooks.
Raise old HV battery above height of HV battery crate.
Position HV battery crate underneath old HV battery.
Lower old HV battery into crate.

Note
Use caution to align HV battery into crate and not damage the battery, Recommend assistance.
Remove H-frame from old HV battery.

Note
4x hooks.
Raise gantry and H-frame from old HV battery.
Lower gantry and remove HV battery H-frame from gantry.
Close crate top housing old HV battery.

Note
Recommend assistance.
Install battery coolant service fixture onto coolant rapid mate.

Note
Hand tighten nuts while holding fixture down on rapid mate.
Fill the fluid evacuator with coolant.

Note
Fill 8L of coolant.
Connect air hose to fluid evacuator and set the tool to vacuum hose position.

Note
Verify both the pressure and relief valves are closed.
Pressurize and fill battery.

Note
Open pressure valve and hand pump pressure using Mityvac.
Close the pressure valve on the evacuator.
Disconnect air hose from fluid evacuator .
Remove tool from battery pack.
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.

Warning
There may be residual high voltage at the RapidMate connector which might arc when inspecting the connection there.

Note
Align Rapid Mate connections before lowering fully, Recommend assistance.
Remove leather over gloves and HV insulating gloves.
Install front bolts for HV battery with battery powered drill .

Note
4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
Install 21mm bolts at front of HV battery with battery powered drill .

Note
2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step.
Install eight outer center bolts with battery powered drill .

Note
8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
Install LH rocker bolts with battery powered drill .

Note
8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
Install RH rocker bolts with battery powered drill.

Note
8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
Torque rocker HV battery bolts on both sides.

Note
16x patch bolts, 13mm, 55 Nm.
Torque remaining HV battery bolts.

Note
8x patch bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x patch bolts, 13mm, 30 Nm.
Raise vehicle and remove battery table.

Note
Recommend assistance.
Install inner center HV battery bolts with battery powered drill.

Note
4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts.
Torque the inner center HV battery bolts.

Note
4x patch bolts, E12, 38 Nm.
Install front lower bash plate extrusion.

Note
2x patch bolts, T30, 16 Nm.
Install ski side covers onto RH side of HV battery.

Note
14x clips, 3x covers.
Install ski side covers onto LH side of HV battery.

Note
14x clips, 3x covers.
Position mid aero shield and install bolts securing mid aero shield to vehicle.

Note
7x bolts, 10mm, 4 Nm.
Install clips securing mid aero shield to vehicle.

Note
7x push clips.
Install screws, bolt, and nut securing RH shear plate to vehicle.

Note
3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 1x nut, 15mm, 35 Nm, Install new nut.
Install clips securing RH shear plate to wheel fairing.

Note
2x push clips.
Install screws, bolt, and nut securing LH shear plate to vehicle.

Note
3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 1x nut, 15mm, 35 Nm, Install new nut.
Install clips securing LH shear plate to wheel fairing.

Note
2x push clips.
Lower vehicle partially.
Reconnect First Responder Loop and 12V negative terminal.

Note
1x nut, 10mm, 5 Nm, 1x connector.
Connect 12V charger.

Note
The vehicle 12V system must remain supported until vehicle firmware is completed.
Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
If the vehicle is equipped with an Intel Atom MCU and vehicle software 2023.20 or newer, go to step 59. Otherwise, continue to the the next step.
In Toolbox 3, click the Actions tab, type "Service Redeploy" into the search field, click UPDATE_CAN-REDEPLOY, click Run, and allow the routine to complete.
Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
In Toolbox 3, click the Actions tab, type "Pack Replacement" into the search field, click PROC_BMS_X_PACK-REPLACEMENT, click Run, and allow the routine to complete.
In Toolbox 3, click the Actions tab, type "Standby Reboot Gtw" into the search field, click PROC_ICE_X_STANDBY-REBOOT-GTW, click Run, and allow the routine to complete.
In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGE, click Run, and allow the routine to complete.
Go to step 66.
Enable Service Mode Plus. See Service Mode Plus.
On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, in the window that opens, touch Run, and then wait for completion.
Disconnect the First Responder Loop.
Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
In the High Voltage Battery Replacement window, under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, in the window that opens, touch Run, and then wait for completion.
Disable Service Mode Plus. See Service Mode Plus.
Connect the First Responder Loop.
Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
Disconnect 12V charger from vehicle.
Perform a steering wheel scroll wheel reset.
Install HEPA filter outlet duct.
Install HEPA filter inlet duct.

Note
2x tabs, One on each side.
Install clips securing HEPA filter inlet duct to cowl panel.

Note
3x push clips.
Secure drainage hoses to HEPA filter inlet duct.

Note
2x hoses.
Install LH underhood apron.

Note
9x clips.
Install RH underhood apron.

Note
9x clips.
Install rear underhood apron.

Note
8x clips.
Close hood .

Note
Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood.
Remove vehicle from lift.

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode" via Controls > Service > '' JACK MODE'' .
Raise LH front window.
Close LH front door.