09/09/2022 15:31:40

HV Header - 6 Pin - HV Battery (Remove and Replace)

Correction code 16300082 0.90 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Raise and support vehicle.
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    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads, DO NOT position the lift arm pads under the battery or side rails, as shown in red.
  2. Open hood.
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    Note
    Via center display > Controls > Frunk Open.
  3. Remove rear underhood apron.
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    Note
    11x clips, 2x datums.
  4. Power off vehicle via center display.
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    Note
    Controls > Safety & Security > Power Off.
  5. Disconnect LV battery connector and First Responder Loop.
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL.
  6. Verify operation of multimeter.
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals.
  7. Raise vehicle fully and lower lift onto locks.
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    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.
  8. Remove clips securing front aero shield.
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    Note
    5x push clips.
  9. Remove bolts securing front aero shield and remove from vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  10. Release clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  11. Remove bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  12. Remove bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  13. Remove bolts securing front skid plate to front subframe and remove skid plate.
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    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
  14. Remove clips securing mid aeroshield.
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    Note
    4x push clips.
  15. Remove bolts securing mid aeroshield and remove from vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  16. Install amp clamp to LH RDU HV harness.
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    Note
    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down.If current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
  17. Remove all items from pockets and ensure not wearing metal items.
  18. Inspect HV insulating gloves.
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  19. Put on HV insulating gloves and leather over gloves.
  20. Release LH RDU HV harness from HV battery.
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    Note
    1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up.
  21. Verify no high voltage at LH rear RDU HV header.
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
  22. Release HV compressor connection to HV battery.
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    Note
    1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up.
  23. Release HV connector 6P header.
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    Note
    2x bolts, EP10, 10 Nm, Gently separate HV header.

Install

  1. Secure HV connector 6P header.
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    Note
    2x bolts, EP10, 10 Nm, Align connector casing to header, Verify the fitment as this header will secure at a slight angle, Take time to line them up and then begin threads.
  2. Secure HV compressor connection to battery pack.
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    Note
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked.
  3. Secure LH RDU HV harness to battery pack.
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    Note
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins.
  4. Remove the leather glove protectors and HV insulating gloves.
  5. Remove gore breathers from rear breather assembly.
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    Note
    4x breathers, Breathers are to be re-used, Be cautious during removal and do not incur damage, If damaged proceed to replacement, Located at rear of pack.
  6. Secure tapered plugs into the three indicated breather holes.
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    Note
    3x tapered plugs, Do not push plugs too far inside.
  7. Secure the leak test adapter onto the fourth breather hole.
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    Note
    1x leak test adapter.
  8. Close both valves on the regulator test tool.
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    Note
    Verify valves are closed.
  9. Secure enclosure leak tester fitting to the leak test adapter.
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    Note
    If required, safely secure the leak tester air line in a manner where it will not tug the adapter off.
  10. Connect regulator to air supply.
  11. Turn right side regulator valve to the open position.
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    Note
    Open valve closest to the air line, By turning the valve knob to a horizontal position, The valve is fully open.
  12. Set regulator to 0.3 psi.
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    Note
    Allow regulator to stablize.
  13. Open the left side regulator valve to allow air into the HV battery.
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    Note
    Close right side regulator valve when the pressure reaches 0.3 psi and stabilizes, It will take roughly 60 seconds to reach 0.3 psi.
  14. Wait 60 seconds to allow pressure to stabilize.
  15. Record start pressure value.
  16. Wait 30 seconds for test.
  17. Record end pressure value.
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    Note
    If pressure did not drop more than 0.026 psi, continue to next step, If pressure dropped more than 0.026 psi, then inspect HV battery enclosure for leaks.
  18. Disconnect air supply from leak tester.
  19. Release enclosure leak tester fitting from the leak test adapter.
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    Note
    Release the leak tester air line if previously secured.
  20. Release leak test adapter from breather hole.
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    Note
    1x leak test adapter.
  21. Release tapered plugs from the breather holes.
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    Note
    3x tapered plugs.
  22. Secure gore breathers onto rear breather assembly.
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    Note
    4x gore breathers, If breathers were damaged replace as required.
  23. Apply Loctite 222 onto mid aeroshield bolts and install fasteners securing mid aeroshield to vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  24. Install clips securing mid aeroshield.
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    Note
    4x push clips.
  25. Position front skid plate for installation and thread in all bolts .
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    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 15mm, 60 Nm, 2x bolts, 15mm, 30 Nm, 2x bolts, 10mm, 10 Nm, Torque at later step.
  26. Torque bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  27. Torque bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  28. Torque bolts securing front skid plate to front subframe.
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    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
  29. Secure clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  30. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  31. Install clips securing front aero shield.
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    Note
    5x push clips.
  32. Lower vehicle fully.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  33. Connect First Responder Loop and LV battery connector.
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    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated.
  34. Install rear underhood apron.
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    Note
    11x clips, 2x datums.
  35. Close hood.
  36. Calibrate the rear doors.
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    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  37. Remove vehicle from lift.
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".