23/05/2024 08:41:45

Cover - Front Access - HV Battery (Remove and Install)

Correction code 16101011 5.05 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.

  • 2023-04-07: Added conditional steps for when there is a doubler around the front access cover.
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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.
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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.
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Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
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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 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 glove and safety information.

Torque Specifications

Table 1. Torque Specifications: Cover - Front Access - HV Battery (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts that attach the HV battery front access cover to the HV battery
4.5 Nm (3.3 lbs-ft)
  • Torx T25 socket
Replace

Remove

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  4. Position the 2 post lift pads for HV battery removal.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  7. Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  8. Remove the 2nd row mid floor panel. See:
  9. Remove the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  10. Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  11. Remove the 2nd row rear floor panel. See:
  12. Remove the bolts (x2) that attach the busbar duct to the body, and then remove the busbar duct from the vehicle.
  13. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the trunk side trim bracket. See:
  16. Disconnect LV power. See LV Power (Disconnect and Connect).
  17. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  18. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  19. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  20. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  21. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  22. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  23. Release the clip that attaches the power conversion system outlet hose to the HV battery.
  24. Release the clip that attaches the power conversion system outlet hose to the to the HV battery fitting, and then disconnect the hose from the HV battery.
  25. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain) (On Table).
  26. Remove and discard the bolts (x17) that attach the HV battery front access cover to HV battery.
    Tip: Use of the following tool(s) is recommended:
    • 7 mm socket
  27. If installed, remove the doubler from around the front access cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift the doubler from the rear, and slide forward and out from under the coolant fittings.
  28. Use non-conductive plastic chisels to break the seal and separate the HV battery front access cover from the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful not to severely bend or deform the access cover, nor damage the internal components therein.
    Informational PurposesAn informational icon, calling your attention
    Note
    If there is no sealant present, the gasket can be reused and no sealant needs to be applied.
  29. Wrap a clean shop towel around the power conversion system inlet and outlet fitting to catch excess coolant.
  30. Use a clean shop towel as a wedge to keep the HV batter front access cover elevated for the next steps.
  31. Use the coolant hose special tool to release the clips and disconnect the power conversion system inlet tube from the power conversion system.
  32. Disconnect the power conversion inlet tube from the power conversion system and immediately install plugs into each fitting.
  33. Use the coolant hose special tool to release the clips and disconnect the power conversion system outlet tube from the power conversion system.
  34. Disconnect the power conversion outlet tube from the power conversion system and immediately install plugs into each fitting.
  35. Remove the HV battery front access cover from the HV battery.

Install

  1. Remove the shop towels from the front access cover area of the HV battery.
  2. Use non-conductive plastic chisels or other non-marring tools to remove the sealant from the HV battery and HV battery front access cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    If there is no sealant present, the gasket can be reused and no sealant needs to be applied. Skip to step 6 to proceed with installation.
  3. Use an ESD-safe vacuum to remove debris, wipe the sealing surfaces with an alcohol wipe, and then allow to dry.
  4. Load a cartridge of sealant into the caulking gun and cut the tip of the sealant to make a triangle of X mm by Y mm.
  5. Apply the sealant onto the sealing surface of the HV battery in a continuous smooth bead.
  6. With the help of an assistant, position the HV battery front access cover for installation, remove the plugs from the power conversion system outlet tube and immediately connect the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that both clips on the power conversion system outlet tube securely attach to the power conversion system outlet fitting.
  7. Remove the plugs from the power conversion system inlet tube and immediately connect the fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify that both clips on the power conversion system inlet tube securely attach to the power conversion system inlet fitting.
  8. Carefully set the HV battery front access cover onto the HV battery.
  9. If removed earlier, install the doubler around the front access cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the doubler at an angle, slide the front under the coolant fittings, and then lower the rear of the doubler onto the front access cover.
  10. Install new bolts (x17) to attach the HV battery front access cover to the HV battery.
    4.5 Nm (3.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 7 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolts in a criss-cross pattern.
  11. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  12. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  13. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  14. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  15. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  16. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  17. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  18. Connect LV power. See LV Power (Disconnect and Connect).
  19. Install the trunk side trim bracket. See:
  20. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  21. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  22. Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
    2.5 Nm (1.8 lbs-ft)
  23. Install the 2nd row rear floor panel. See:
  24. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  25. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  26. Install the 2nd row mid floor panel. See:
  27. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  28. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  29. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  30. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  31. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  32. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.