16/08/2024 12:48:35

HV Battery (AWD) (Remove and Replace)

Correction Code 16010202

2024-08-16: Added note stating it is not necessary to perform HV disablement.
2023-06-07: Service Engineering updates to the touchscreen steps.
2023-06-02: Updated torque specifications in installation step 34.
2023-06-01: Updated procedure to latest GSD validation including replacement of Toolbox 3 routines by routines run from the touchscreen.
2023-05-22: Updated pack configuration steps.
2023-05-22: Added conspicuous discharge warning table.
2023-04-23: Deleted duplicated installation step of the first responder loop.
2023-03-16: Updated Discharge section and added steps to configure the HV battery.

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

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 shipped must have a State of Charge (SoC) of less than 30% or 50%, depending on the region. 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 and lower the window.
Raise and support vehicle.

Note
Set air suspension to "Jack Mode" Via Controls > Service > ''Jack Mode''.
Open the front trunk.
Remove underhood aprons.

Note
4x aprons.
Remove underhood storage unit. See Underhood Storage Unit (Remove and Replace).
Remove HEPA filter. See Filter - HEPA (Remove and Replace).
Disconnect 12V power. See Disconnect 12V Power.

Note
Do not perform HV disablement. It is not required when performing an HV battery remove and install.
Raise vehicle fully and lower onto locks.
Remove the bolts (x3)LH and RH rear shear plates.

Note
3x screws, 1x bolt, 2x push clips and 1x nyloc nut. Discard nyloc nut after removal.

Figure 1. LH side shown, RH side similar
Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace)
Remove the bolts (x2) that attach the front bash plate extrusion.
Remove LH and RH ski side covers.

Note
14x push clips, 3x covers per side.

Figure 2. LH side shown, RH side similar
Remove the center bolts (x4) that attach the HV battery to the vehicle.
Position the battery table under the vehicle.
Lower the vehicle to the table.

Note
Align table to the vehicle and raise casters to level the table if necessary.
Remove the remaining center bolts (x8) that attach the HV battery to the vehicle.
Remove the front HV battery bolts (x4) that attach the HV battery to the vehicle.
Remove the front bolts (x2) that attach the HV battery to the vehicle.
Remove the LH and RH rocker bolts.

Note
8x patch bolts per side. Discard after removal.

Figure 3. LH side shown, RH side similar
Raise the vehicle and remove the battery table from under the 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.
Put on HV insulating gloves and leather over gloves.
Measure the voltage at the HV rapid mate

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage components. Measure B+ to Ground, B- to Ground, and B+ to B-. If any voltage measured is greater than 10V, the pack contactors are not open or welded. Stop work and reach out to Service Engineering.
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 the battery coolant service fixture onto the coolant rapid mate.

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

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

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

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

Note
4x hooks.
Raise the HV battery off the battery table.
Position the gantry over a pallet.
Lower the HV battery onto the pallet.
Remove H-frame from the old HV battery.

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

Installation

Open the crate top of the crate that contains the new HV battery pack.
Position the gantry over the new HV battery crate and secure the H-frame to the battery.

Note
4x hooks.
Lift the new HV battery out of the crate.
Move the gantry away from the HV battery crate and move it over the HV battery table.
Lower the HV battery onto the battery table.

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

Note
4x hooks.
Remove the HV battery from under the gantry.
Position the gantry over the old HV battery.
Lower the H-frame onto the old HV battery and attach the H-frame to the battery.

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

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

Note
4x hooks.
Raise gantry and H-frame from the old HV battery.
Lower the gantry and remove the H-frame from the gantry.
Close the crate top of the crate that housed the old HV battery.
Install the battery coolant service fixture onto the coolant rapid mate of the new HV battery.

Note
Hand tighten the nuts while holding the fixture down on the rapid mate.
Fill the fluid evacuator with 8 liters of coolant.
Connect the air hose to the fluid evacuator and set the tool to vacuum hose position.

Note
Make sure that both the pressure and relief valves are closed.
Pressurize and fill the HV battery.

Note
Open the pressure valve and hand prime pressure using Mityvac.
Close the pressure valve on the evacuator.
Disconnect the air hose from the fluid evacuator.
Remove the tool from the HV battery pack.
Raise the vehicle for positioning of the HV battery.
Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
Align HV battery inner floating nuts

Note
14x nuts, Perform before pack installation
Align the HV battery inner floating nuts (x14).

Note
Perform before pack installation.
Remove the HV and LV RapidMate covers or tape.
Position the HV battery underneath vehicle.
Lower the vehicle onto the HV battery pack.

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

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 the HV and LV rapid mates.
Remove leather over gloves and HV insulating gloves.
Install new front bolts (x4) that attach the HV battery to the body with a battery powered drill. Torque to 30 Nm at a alter step.

Note
Torque to 30 Nm at a later step.
Install new outer front bolts (x2) that attach the HV battery to the body with a battery powered drill.

Note
Torque to 115 Nm at a later step.
Install new outer center bolts (x8) that attach the HV battery to the body with a battery powered drill.

Note
8x patch bolts. E12, 38 Nm. Install new patch bolts. Do not over tighten bolts. Torque at later step.
Install new bolts (8x per side) that attach the LH and RH side of HV battery to the body with a battery powered drill.

Note
Torque to 55 Nm at a later step.
Torque the bolts (8x per side) that attach the HV battery to the body on both sides to 55 Nm.
Torque the remaining HV battery bolts.

Note
8x bolts, E12, 38 Nm. 2x bolts, 21mm, 115 Nm. 4x bolts, 13mm, 30 Nm.

Figure 4. Torque these bolts to 38 Nm

Figure 5. Torque these bolts to 30 Nm

Figure 6. Torque these bolts to 115 Nm
Raise the vehicle and remove the battery table.
Install new inner center HV battery bolts (x4) with battery powered drill, and then torque the bolts to 38 Nm.
Install the clips that attach the LH and RH ski side covers.

Note
14x clips per side.

Figure 7. LH side shown, RH side similar
Install the bolts (x2) that attach the front bash plate extrusion (torque 16 Nm).
Install the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace).
Install the LH and RH shear plate.

Note
3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push pins. Install new nyloc nut 15mm, 35 Nm.

Figure 8. LH side shown, RH side similar
Fully lower the vehicle.
Connect the First Responder Loop.
Connect the 12V negative terminal, and then tighten the nut that attaches the terminal to the auxiliary battery.

Note
10mm, 5 Nm.
Connect a 12V charger to the auxiliary battery.
Remove the coolant reservoir cap from the coolant reservoir.
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 57. 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 65.
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 the 12V charger from the vehicle.

Note
After firmware update has completed, the vehicle does no longer need auxiliary 12V support.
Install the coolant reservoir cap onto the coolant reservoir.
Install the HEPA filter. See Filter - HEPA (Remove and Replace).
Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
Remove the vehicle from the lift.

Note
Lower rack arms fully and move them from under the vehicle. Disable "Jack Mode" via Controls > Service > Jack Mode.