08/10/2024 17:33:19

BMS PCBA - High Voltage Battery Assembly (HV Battery 1.0/1.5) (Remove & Replace)

Correction code 16012112

  • 2024-06-24: Added alternative sealants to replace Threebond 1216E due to non availability of Threebond in certain markets.
  • 2024-03-26: Updated note regarding required software versions.
  • 2024-02-29: Added step for software reinstall before unlocking vehicle Gateway during installation.
  • 2024-02-20: Added part number 1108645-00-A for EMEA Torx Bit T20 Ball End.
  • 1126456-00-A - Battery Powered Drill
  • 1107312-00-A - Torx Bit T20 Ball End (for NA and APAC)
  • 1108645-00-A - Torx Bit T20 Ball End (for EMEA)
  • 1028325-00-A - LV Rapid Mate Cover
  • 1038478-00-A - HV Rapid Mate Cover
Sealant required for this procedure:
  • Threebond 1216E (1089956-00-A), Permatex Right Stuff (1031099-00-A), or Dowsil 7091 (1962594-00-A)
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Informational PurposesAn informational icon, calling your attention
Note
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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.
Informational PurposesAn informational icon, calling your attention
Note
Ensure the vehicle software is updated to 2022.8.10.17 or above for Tegra or 2023.38 or above for Intel vehicles before performing the procedure. If this is not possible, refer to Toolbox Article 31039 for further information.

Remove

  1. Open the LH front door and lower both front windows.
  2. Place the vehicle in Service Mode with the touchscreen. See Service Mode.
  3. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  4. Unlock the vehicle gateway. See Gateway Unlock.
  5. Perform a backup of the BMS data.
    • If the MCU is based on Tegra: Make sure the laptop is connected to network. Then on the laptop, select the Actions tab and search for ‘PROC_BMS_X_ECU-REPLACEMENT-BACKUP’, select PROC_BMS_X_ECU-REPLACEMENT-BACKUPSearch for routine in ToolboxBMS ECU Backuphv / Battery Management System (BMS) Replacement - Backup Old BMS, click Run, and allow the routine to complete. Ensure the routine is successful, and select 'X' at the top right of window to close once the routine is complete.
    • If the MCU is based on Intel: On the touchscreen, tap Service > High Voltage > Procedures > BMS Replacement > Backup Old BMS to perform the BMS data backup.
  6. Disconnect the laptop.
  7. Place the vehicle on a 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Prepare to raise the vehicle. Set the air suspension to "Jack Mode", then position the lift arm pads on the vehicle jack pads.
  8. Remove the RH underhood apron. See Underhood Apron - LH (Remove and Replace).
  9. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  10. Release the tabs (x2) and push clips (x2) that secure the cabin filter cover and the RH side of the cowl screen panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the cowl onto the strut.
  11. Remove the bolts (x2) that secure the front HVAC filter housing.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 6 in extension
    • 10 mm socket
  12. Release the tabs (x2) to remove the front HVAC filter housing.
  13. Disconnect the LV battery power. See Disconnect 12V Power.
  14. Release the push clips (x2) that secure the RH side of the cowl screen panel.
  15. Raise the vehicle to a comfortable working height, and lower the lift onto locks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

    Make sure that the doors are clear of surrounding objects.

  16. Inspect the HV battery for damage.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Check for dents, fluid leaks, or other signs of instability. If any damage is found, escalate a Toolbox session.
  17. Remove the vent covers (x2) from the HV battery.
  18. Remove the push clips (x2) that attach the LH shear plate to the wheel fairing.
  19. 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.
    Tip: Use of the following tool(s) is recommended:
    • 15mm socket
    • T25 socket
    • 10mm socket
  20. Repeat step 18 and 19 for the RH shear plate.
  21. Remove the push clips (x2) and bolts (x3) that secure the LH outer diffuser rail.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
    • Clip pry tool
  22. Remove the bolts (x3) that secure the LH inner diffuser rail.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
  23. Repeat step 21 and 22 for the RH side.
  24. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  25. Remove the front bash plate extrusion. See Bash Plate - Front - Extrusion (Remove and Replace).
  26. Loosen the center bolts (x4) that secure 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:
    • External Torx E12
    • 3 in extension
    • ¼ in to 3/8 in adapter
    • Battery Powered Drill - 1126456-00-A
  27. Position a battery table beneath the vehicle, then lower the vehicle to table.
  28. Loosen the center bolts (x8) that secure 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:
    • 3 in extension
    • External Torx E12
    • ¼ in to 3/8 in adapter
    • Battery Powered Drill - 1126456-00-A
  29. Loosen the front HV battery bolts (x4). 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:
    • 3 in extension
    • 13 mm socket
    • ¼ in to 3/8 in adapter
    • Battery Powered Drill - 1126456-00-A
  30. Loosen the bolts (x2) that secure 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:
    • 6 in extension
    • 21 mm deep socket
    • 3/8 in to ½ in adapter
    • Battery Powered Drill - 1126456-00-A
  31. 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:
    • 3 in extension
    • 13 mm socket
    • ¼ in to 3/8 in adapter
    • Battery Powered Drill - 1126456-00-A
  32. 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:
    • 3 in extension
    • 13 mm socket
    • ¼ in to 3/8 in adapter
    • Battery Powered Drill - 1126456-00-A
  33. Raise the vehicle off the HV battery, and then move the battery away from the vehicle.
  34. Remove all items from pockets and ensure not wearing metal items.
  35. Inspect the condition of the HV rubber gloves and protective outer gloves. Do not use any PPE that is out of date, leaking, or otherwise compromised.
  36. Put on HV insulating gloves and leather over gloves.
  37. Use a multimeter to check voltages at the HV rapid mate.
    • B+ to ground
    • B- to ground
    • B+ to B-
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component. If the voltage is greater than 10V, the pack contactors are not open or welded, stop work and escalate a Toolbox session.
  38. Use a Fluke insulation meter to check for isolation.
    • B+ to ground
    • B- to ground
    Informational PurposesAn informational icon, calling your attention
    Note
    If the isolation reading is less than 3 MΩ, escalate a Toolbox session.
  39. Install the HV and LV rapid mate covers.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the covers are not available, use masking tape to protect the rapid mate from debris.
  40. Ensure the entire work area, including above and below the battery, is clear, and then place the HV Danger placard on the top of the battery.
  41. Place barricades around the work area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Note the location of extinguishers and the HV rescue hook.
  42. Verify the operation of Hioki test meter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow meter to warm up for 60 minutes
  43. Remove the pyrotechnic fuse. See Fuse - Pyrotechnic - HV Battery 1.0/1.5 (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Minor arcing is possible. Reuse the fuse unless it is blown.
  44. Put a piece of 3M vinyl tape 471 across the rear of the HV battery to cover the crossmember bolts.
  45. Remove the screws that secure the rapid mate plate, the screws at the rear edge of the HV battery top cover, and the rearmost side screws.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the forward side screws that should be covered by the tape. Put these screws into the designated container so that they can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
    • Electrical Protective Gloves
  46. Use the non-marring scraper and a dead blow hammer to separate the sealant at the LH and RH rear corners where the HV battery cover contacts the rapid mate plate.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Deform the HV battery cover as little as possible. Do not insert the scraper more than 20 mm into the battery to avoid damaging internal components.
  47. Use the non-marring scraper and the dead blow hammer to separate the sealant across the rear of the HV battery cover where it contacts the rapid mate plate.
  48. Center the plastic wedge between the HV battery cover and the rapid mate plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    The notch on the plastic wedge should be toward the right side of the HV battery.
  49. Gently tap the wedge with a mallet to make sure that the wedge is fully seated.
  50. Carefully bend the cover up to approximately 80 degrees.
  51. Put on the HV-safe static control wrist strap. Clip the strap’s ground connection to a threaded hole on the edge of the HV battery enclosure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Put the static control wrist strap on as soon as the cover is opened. Otherwise, damage to sensitive electrical components might result.
  52. Pull back the pack contactor paper insulator, and then tape it to the rapid mate plate to keep it out of the work area.
  53. Use the insulation multimeter to measure the voltage between the yellow terminal (negative) and the purple terminal (positive) on the pack contactors.
    • If the voltage is less than 50V, continue with this procedure.
    • If the voltage is 50V or greater, make sure that the HV battery fuse has been removed. If the fuse has been removed, escalate a Toolbox session, as appropriate.
  54. Remove the orange insulating cap from the leftmost white contactor stud.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove only 1 insulating cap at a time to reduce the risk of a high voltage short circuit.
  55. Remove the nut and the washer of the white contactor harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place the hardware into the designated container so that they can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated 13 mm socket
    • Insulated Ratchet/torque wrench
    • Electrical Protective Gloves
  56. Repeat step 54 and 55 for the yellow, purple and orange contactor studs in turn.
  57. Remove the bolt from the ground strap on the left side of the pack contactors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Put this bolt into the designated container so that it can be accounted for before reinstalling components.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Extension 1/4 Dr. Wobble 10.5"
    • Insulated Ratchet/torque wrench
    • Insulated 10 mm 12-point deep socket
  58. Use an insulated blade to score the sealant between the battery enclosure and the rapid mate plate.
  59. Use the non-marring scraper to separate the sealant at the rear edge of the rapid mate plate, and then separate the rapid mate plate from the ancillary bay.
  60. Release the rightmost fir tree clip at right rear edge of the ancillary bay.
  61. Release the HV sense harness fir tree clip.
  62. Lift up the rapid mate plate and release the edge clip.
  63. Move the rapid mate plate back and remove the edge clips (x2).
  64. Disconnect the connectors (x6) from the battery management system (BMS) circuit board.
  65. Remove the rapid mate plate from the HV battery.
  66. Use the non-marring scraper to clean the old sealant from the rapid mate plate and the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    The sealing surface should be smooth and consistent. The sealant does not need to be completely removed.
  67. Use a small pick to remove any old sealant from screw holes, if necessary.
  68. Use an ESD-safe vacuum to clean the areas that were covered by sealant, the rapid mate plate, and inside the ancillary bay.
  69. Remove the screws (x8) that attach the BMS PCBA to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The top-left corner screw is underneath the bus bar and next to the shunt. It can be tricky to access and remove. It is necessary to use a special ball-head T20 bit for this purpose, which is more convenient to use in combination with insulating tools.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Torx Bit T20 Ball End - 1107312-00-A (for NA and APAC)
    • Torx Bit T20 Ball End - 1108645-00-A (for EMEA)
    • Insulated Extension 1/4 Dr. Wobble 10.5"
    • Electrical Protective Gloves

Install

  1. Install the screws (x8) to attach the BMS PCBA to the HV battery.
    1.9 Nm (1.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The top-left corner screw is underneath the bus bar and next to the shunt. It can be tricky to access and remove. It is necessary to use a special ball-head T20 bit for this purpose, which is more convenient to use in combination with insulating tools.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Torx Bit T20 Ball End - 1107312-00-A (for NA and APAC)
    • Torx Bit T20 Ball End - 1108645-00-A (for EMEA)
    • Insulated Extension 1/4 Dr. Wobble 10.5"
    • Electrical Protective Gloves
  2. Use an ESD-safe vacuum to clean the inside of the ancillary bay.
  3. Use an alcohol wipe to clean the rapid mate plate to ancillary bay surfaces.
    Informational PurposesAn informational icon, calling your attention
    Note
    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. Allow alcohol to dry for 1 minute.
  4. Use an alcohol wipe to firmly wipe the top and bottom of the busbars to remove any loose debris.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to clean both busbars at the same time. Allow alcohol to dry for 1 minute.
  5. Use an alcohol wipe to wipe the top and bottom of the white insulation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to clean both busbars at the same time. Allow alcohol to dry for 1 minute.
  6. Use a new alcohol wipe to firmly wipe the top and bottom of the busbars again to remove any loose debris.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to clean both busbars at the same time. Allow alcohol to dry for 1 minute.
  7. Use an alcohol wipe to wipe the top and bottom of the white insulation again.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to clean both busbars at the same time. Allow alcohol to dry for 1 minute.
  8. Use the insulated mirror to check the bottom of the busbar for any remaining debris or lint from the alcohol wipe.
  9. Use an ESD-safe vacuum to remove all debris.
  10. If the busbar insulation is damaged or peeled back less than 5 mm beyond the first bend of the busbar, continue to the next step.
    Informational PurposesAn informational icon, calling your attention
    Note
    If all busbar insulation is in good condition, skip to step 12 to inspect the busbar mica.
  11. Tightly wrap the damaged insulation with polyimide tape. Wrap the insulation 2-3 times, pressing firmly on the end of the tape for proper adhesion.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the busbar insulation is completely dry. The tape must not extend onto the nut and washer area on the top and the bottom of the busbar.
  12. Inspect the busbar mica, replace the mica if it is broken or damaged.
  13. Use an ESD-safe vacuum to remove all debris. Make sure that there are no metal shavings inside the ancillary bay or on the top of the BMS circuit board.
  14. Remove the ESD wrist strap and the HV insulating gloves.
  15. Scrape off any large chunks or beads of sealant from the rapid mate plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform this procedure away from the HV battery, but still within the designated safe area.
  16. Remove the covers or tape from the high voltage and low voltage rapid mate connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform this procedure away from the HV battery, but still within the designated safe area.
  17. Vacuum the rapid mate plate to remove any debris.
  18. Use an alcohol wipe to clean the rapid mate plate.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Allow the rapid mate plate to fully dry before continuing. 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. Allow alcohol to dry for 1 minute.
  19. Check the high voltage and low voltage rapid mate connector jacks on the rapid mate plate for damage or excessive wear.
    Informational PurposesAn informational icon, calling your attention
    Note
    If either connector is damaged, replace the rapid mate plate.
  20. Install protective covers on (or apply tape to) the high voltage and low voltage rapid mate connectors.
  21. Remove the white contactor insulator sheet from the rapid mate plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure all of the old adhesive is removed.
  22. Remove the output busbar insulator and check the insulator for damage.
    Informational PurposesAn informational icon, calling your attention
    Note
    New insulator is required if there is any evidence of damage.
  23. Use the Hioki resistance tester to measure the impedance between the busbars and the rapid mate studs. The acceptable impedance is between 0.080 mΩ (80 μΩ) and 0.150 mΩ (150μΩ).
    • If the impedance is lower than 0.080 mΩ (80 μΩ), reposition the probes and measure again.
    • If the impedance is greater than 0.150 mΩ (150μΩ), stop work and escalate the Toolbox session.
  24. Install the output busbar insulator.
  25. Install a new contactor insulator sheet, and then gently tape the sheet out of the way.
  26. Inspect the condition of the HV rubber gloves and protective outer gloves. Do not use any PPE that is out of date, leaking, or otherwise compromised.
  27. Put on the HV insulating gloves and the leather over gloves.
  28. Wear an ESD wrist strap and ground the strap to the HV battery enclosure.
  29. Position the rapid mate plate slightly above its normal location at the rear of the HV battery.
  30. Secure the clips (x3) to connect the contactor harness to the rapid mate plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Route the pack contactor control harness above the output busbar, then above the input HV busbar, in front of the rapid mate assembly.
  31. Starting from the outside and working inwards, connect the BMS harness connectors (x6).
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the daisy chain connector is still properly installed, and was not accidentally disconnected. Perform a “push-pull-push” test on all harnesses to make sure that they are properly secured.
  32. Connect the low voltage communications harness fir tree clip on the right side of ancillary bay.
  33. Install a new ground strap bolt.
    4.5 Nm (3.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the torque wrench is not pressed against the HV battery enclosure while the ground strap bolt is being tightened. This can cause an inaccurately high torque reading, leading to an under-torqued bolt. Use a pink paint pen to mark the head of the bolt after it is torqued.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated Extension 1/4 Dr. Wobble 10.5"
    • Insulated Ratchet/torque wrench
    • Insulated 10 mm 12-point deep socket
    • Electronic Torque Wrench
  34. Loosely reinstall the old screws (x2) that attach the LH and RH ends of the rapid mate plate to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install new fasteners at this time.
  35. Install the nut that attaches the orange sense harness to the rightmost contactor stud, and then install the other 3 nuts that attach the purple, yellow and white harnesses to the other 3 studs in turn.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the orange, purple and yellow terminals are oriented properly in the 11 o’clock position and the white terminal is in the 10 o'clock position. Use a pink paint pen to mark only the nuts after they are torqued. Do not mark the studs.
    Tip: Use of the following tool(s) is recommended:
    • Electronic Torque Wrench
    • Insulated 13 mm socket
    • Insulated Extension 1/4 Dr. Wobble 10.5"
    • Insulated Ratchet/torque wrench
  36. Connect the 3+1 probe leads to the Hioki resistance meter.
    Informational PurposesAn informational icon, calling your attention
    Note
    The probes must contact bare metal surfaces. Avoid contacting paint marks.
  37. Measure the impedance value at the white, yellow, purple and orange terminals in turn.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable impedance is 0.050 mΩ (50 μΩ) or less. If the impedance is greater than 0.050 mΩ (50μΩ), stop work and escalate the Toolbox session. The upper probe must be pressed against the top of the pack contactor stud, not on top of the nut. The lower probes must be pressed against the busbar, not on the cable ring terminal. The curved edge of the L-shaped probe must be pressed against the side of the stud shoulder.
  38. Use an ESD-safe vacuum to clean the inside of the ancillary bay.
  39. Install a new orange insulating cap on each pack contactor terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the top of each cap with a pink paint pen.
  40. Remove the tape that held the pack contactor insulator sheet out of the way.
  41. Remove and discard the old screws that loosely attached the rapid mate plate to the ancillary bay.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated Torx T25 socket
  42. Remove the ESD strap and disconnect it from the HV battery enclosure.
  43. Use alcohol wipes to clean all sealing surfaces.
  44. Bend the HV battery top cover down smoothly and evenly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Center the long plastic wedge against the HV battery cover on the fold side. Do not use a hammer to bend the HV battery cover. Make sure that the bend radius is fully worked out of the HV battery top cover so it sits flat when in position. Do not allow a large downward dent to remain in the section of the HV battery cover, as this might press down onto the pack contactor studs.
  45. Loosely install new screws (x6) along the rear of the rapid mate plate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage no more than approximately 2 threads.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated Torx T25 socket
    • Electronic Torque Wrench
  46. Load the sealant in the caulking gun, and then cut the nozzle approximately 15 mm from the tip.
  47. Holding the rapid mate plate up slightly with a non-conductive wedge tool, then apply a bead of sealant inside the gap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the sealant bleeds out of the LH and RH ends of the rapid mate plate. Use a flashlight or shop light to check the sealing area for complete coverage. Apply additional sealant as needed.
  48. Working from the center outward, tighten the screws (x6) to secure the rapid mate plate.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an orange paint pen to mark the heads of the screws after they are torqued.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
    • Electronic Torque Wrench
  49. Use the non-marring scraper to smooth any sealant along the rear of the HV battery enclosure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wipe off any sealant that gets on top of the HV warning label.
  50. Apply a thick bead of sealant to the forward flange on the rapid mate plate and along the LH and RH sides of the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    The surfaces near where the HV battery top cover bends up are the most prone to leakage. Make sure that adequate sealant is applied to these areas. Do not loosen the adjacent screw in an attempt to inject more sealant into this area.
  51. Bend the HV battery top cover down. Working from the center outward, hold the HV battery top cover down while loosely installing the HV battery top cover mounting screws (x12).
    Informational PurposesAn informational icon, calling your attention
    Note
    The HV battery top cover does not need to be perfectly flat or smooth at this time.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
  52. Partially tighten the HV battery top cover mounting screws (x12) from the center outward, and then torque the screws in the same order.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark each bolt with an orange paint pen as it is torqued.
    Tip: Use of the following tool(s) is recommended:
    • Insulated Torx T25 socket
    • Insulated Ratchet/torque wrench
    • Electronic Torque Wrench
  53. If any part of the battery top cover is not flat, gently press it down with the handle of a mallet or other heavy tools.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is especially important to flatten the HV battery top cover where it was bent.
  54. If sealant touches any part of either rapid mate connector, use isopropanol on a lint-free cloth to remove the sealant.
  55. Use a flashlight or a shop light to check the HV battery sealing area for complete coverage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply additional sealant as needed.
  56. Remove the tape from across the rear of the HV battery.
  57. Connect the ESD ground strap to the new HV battery fuse case.
  58. Perform Hioki impedance test on the new HV battery hybrid pyro fuse with a properly-zeroed Hioki tester.
    • If the impedance is between 0.080 mΩ (80 μΩ) and 0.150 mΩ (150 μΩ), continue to the next step.
    • If the impedance is less than 0.080 mΩ (80 μΩ) or more than 0.150 mΩ (150 μΩ), escalate a toolbox session for assistance and return the new fuse via MRB.
  59. Record the part number and the serial number of the HV battery pyro fuse.
  60. Put on the HV-safe static control wrist strap and clip the strap’s ground connection to a suitable ground.
  61. Install the pyrotechnic fuse. See Fuse - Pyrotechnic - HV Battery 1.0/1.5 (Remove and Replace).
  62. Inspect the sealant between the HV battery and the fuse cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a flashlight or shop light to check the Right Stuff sealing area for complete coverage.
  63. Inspect the vehicle-side HV rapid mate seal, the blade, the pins, and the plastic insulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Replace the seal if damaged. Use IPA to clean the blades, pins, and plastic insulator if necessary. If damage is found on these components, rapid mate must be replaced. Allow 1 minute dry time.
  64. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    See yellow highlighted areas in the image. This will ease the installation of the seal.
  65. Position the HV battery underneath the vehicle.
  66. Remove the HV and LV rapid mate covers.
  67. Position HV battery underneath the vehicle, then lower the vehicle onto the HV battery pack.
    Informational PurposesAn informational icon, calling your attention
    Note
    Before lowering fully, use assistance to align the pack using the alignment rods and guide via the borescope camera or a flexible inspection mirror checking HV and LV rapid mates.
  68. Loosely install new front HV battery bolts (x4) with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not over tighten the bolts. Torque at later step.
  69. Loosely install new LH rocker bolts (x8) with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at later step.
  70. Loosely install new RH rocker bolts (x8) with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at later step.
  71. Loosely install new bolts (x2) at the front of the HV battery with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at later step.
  72. Loosely install new outer center bolts (x8) with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque at later step.
  73. Torque the HV battery rocker bolts (x16) on both sides.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
  74. Torque the outer center bolts (x8).
    38 Nm (28.0 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E12
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  75. Torque the bolts (x2) that secure the front of the HV battery.
    115 Nm (84.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 6 in extension
    • 21 mm deep socket
    • Ratchet/torque wrench
  76. Torque the front HV battery bolts (x4).
    30 Nm (22.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 3 in extension
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
  77. With assistance, raise the vehicle and remove the battery table.
  78. Loosely install new inner center HV battery bolts (x4) with a battery powered drill, and then torque the bolts.
    38 Nm (28.0 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not over tighten the bolts.
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 3 in extension
    • External Torx E12
  79. Install the front bash plate extrusion. See Bash Plate - Front - Extrusion (Remove and Replace).
  80. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  81. Install the clips (x2) and bolts (x3) that secure the RH outer diffuser rail.
    3 Nm (2.2 lbs-ft)
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt in the middle needs to be torqued to 4 Nm while the others need to be torqued to 3 Nm.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
  82. Install the bolts (x3) that secure the RH inner diffuser rail.
    3 Nm (2.2 lbs-ft)
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt in the middle needs to be torqued to 4 Nm while the others need to be torqued to 3 Nm.
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • 2 in extension
    • 10 mm socket
  83. Repeat step 81 and 82 for the LH diffuser rails.
  84. Install the fasteners (x5) that attach the RH shear plate to the wheel fairing.
    35 Nm (25.8 lbs-ft)
    6 Nm (4.4 lbs-ft)
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Install a new nyloc nut. The nyloc nut should be torqued to 35 Nm, the three T25 screws should be torqued to 6 Nm, and the 10mm bolt should be torqued to 4 Nm.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Cordless Ratchet/Impact Driver
    • 4 in extension
    • Torx T25 socket
    • 10 mm socket
    • 15 mm deep socket
  85. Install the push clips (x2) that attach the RH shear plate to the wheel fairing.
  86. Repeat step 84 and 85 for the LH shear plate.
  87. Lower the vehicle until the tires are touching ground.
  88. Secure the RH side of the cowl screen panel.
  89. Connect the LV battery power. See Disconnect 12V Power.
  90. Connect a 12V charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    The vehicle 12V system must remain supported until the vehicle firmware is completed.
  91. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  92. Reinstall the vehicle firmware. See Firmware Reinstall - Touchscreen.
  93. Unlock the vehicle gateway. See Gateway Unlock.
  94. Restore the BMS data.
    • If the MCU is based on Tegra: Make sure the vehicle is connected to network. Then on the laptop, select the Actions tab and search for ‘PROC_BMS_X_ECU-REPLACEMENT-RESTORE’, select PROC_BMS_X_ECU-REPLACEMENT-RESTORESearch for routine in ToolboxBMS ECU Restorehv / Battery Management System (BMS) Replacement - Restore New BMS, click Run, and allow the routine to complete. Ensure the routine is successful, and select 'X' at the top right of window to close once the routine is complete.
    • If the MCU is based on Intel: On the touchscreen, tap Service > High Voltage > Procedures > BMS Replacement > Restore New BMS to perform the BMS data recovery.
  95. Search for "Coolant Air Purge", select PROC_THC_X_COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Actions - Coolant Air Purge, click Run, and allow the routine to complete.
  96. Disconnect the laptop.
  97. Remove the coolant bottle cap, inspect the coolant level and top off to the MAX line, and then install the coolant bottle cap.
  98. Reinstall the vehicle firmware. See Firmware Reinstall - Touchscreen.
  99. Disconnect the 12V charger from the vehicle.
  100. Secure the tabs (x2) to install the front HVAC filter housing.
  101. Install the bolts (x2) that secure the front HVAC filter housing.
    1.5 Nm (1.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Cordless Ratchet/Impact Driver
    • 6 in extension
    • 10 mm socket
    • Ratchet/torque wrench
  102. Install the tabs (x2) and push clips (x2) to secure the cabin filter cover and the RH side of the cowl screen panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the cowl from the strut.
  103. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  104. Install the RH underhood apron. See Underhood Apron - LH (Remove and Replace).
  105. Lower the rack arms fully and remove them from under the vehicle. Tap Controls > Service > Jack Mode on the touchscreen to remove the air suspension from "Jack Mode".
  106. Charge the vehicle for at least 10 minutes.
  107. Perform a vehicle test drive.