2025-01-23

HV Battery (AWD) (Remove and Replace)

Correction Code 16010202

  • 2025-01-23: Added step to determine if HV battery parameters are within safe limits before removing the pyro disconnect. Added pyro disconnect removal step.
  • 2024-10-31: Updated HV battery discharge steps.
  • 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 IconA warning icon, calling your attention to a possibly risky situation
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.
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Warning
If the vehicle has air suspension, activate "Jack" mode on the touchscreen before raising and supporting the vehicle.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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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.
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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 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits for shipment or storage.
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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.
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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.
  1. Enable Service Mode Plus. See .
  2. Identify the vehicle's current SOC Max: In the Service Mode Plus menu, touch High Voltage > HV Battery, and then touch the large HV battery diagram to display the HV Battery information window.
    • If the SOC Max is less than the SOC shipping threshold, skip to the Remove section in this procedure.
    • If the SOC Max is greater than the SOC shipping threshold, continue to the next step.
  3. Move the vehicle to a location where the battery can be safely discharged unattended.
  4. In the Service Mode Plus menu, touch High Voltage > HV Battery.
  5. In the Tools section, touch Start HV Discharge, and then in the window that opens, touch Run.
    Informational PurposesAn informational icon, calling your attention
    Note
    The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
  6. After discharge is complete, move the vehicle to the service bay.

Removal

  1. Open LH front door and lower the window.
  2. Raise and support vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Set air suspension to "Jack Mode" Via Controls > Service > ''Jack Mode''.
  3. Open the front trunk.
  4. Remove underhood aprons.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x aprons.
  5. Remove underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  6. Remove HEPA filter. See Filter - HEPA (Remove and Replace).
  7. Disconnect 12V power. See Disconnect 12V Power.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not perform HV disablement. It is not required when performing an HV battery remove and install.
  8. Raise vehicle fully and lower onto locks.
  9. Remove the bolts (x3)LH and RH rear shear plates.
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    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
  10. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace)
  11. Remove the bolts (x2) that attach the front bash plate extrusion.
  12. Remove LH and RH ski side covers.
    Informational PurposesAn informational icon, calling your attention
    Note
    14x push clips, 3x covers per side.
    Figure 2. LH side shown, RH side similar
  13. Remove the center bolts (x4) that attach the HV battery to the vehicle.
  14. Position the battery table under the vehicle.
  15. Lower the vehicle to the table.
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    Note
    Align table to the vehicle and raise casters to level the table if necessary.
  16. Remove the remaining center bolts (x8) that attach the HV battery to the vehicle.
  17. Remove the front HV battery bolts (x4) that attach the HV battery to the vehicle.
  18. Remove the front bolts (x2) that attach the HV battery to the vehicle.
  19. Remove the LH and RH rocker bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts per side. Discard after removal.
    Figure 3. LH side shown, RH side similar
  20. Raise the vehicle and remove the battery table from under the vehicle.
  21. Remove all items from pockets and ensure not wearing metal items.
  22. Inspect HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  23. Put on HV insulating gloves and leather over gloves.
  24. Measure the voltage at the HV rapid mate
    Informational PurposesAn informational icon, calling your attention
    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.
  25. 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.
    Informational PurposesAn informational icon, calling your attention
    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.
  26. Remove leather over gloves and HV insulating gloves.
  27. Install the battery coolant service fixture onto the coolant rapid mate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand tighten nuts while holding the fixture down on the rapid mate.
  28. Connect the coolant hoses.
    Informational PurposesAn informational icon, calling your attention
    Note
    Drain hose goes into coolant container, Pressure hose connects to regulator.
  29. Connect pressurized air to the regulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure regulator valve is closed prior to connecting pressurized air.
  30. Slowly open the valve on the pressure regulator and allow the coolant to drain out of the HV battery return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Close valve on pressure regulator once no more coolant is draining from the HV battery return hose into the coolant container.
  31. Remove pressurized air and pressure hose from regulator.
  32. Use the HV Battery Communication Tool, described in Toolbox article #41977 or Customer Document CD-21-16-003, to determine if the HV battery parameters are within safe limits before proceeding.
  33. Remove the pyrotechnic battery disconnect prior to shipping the HV battery. See Pyrotechnic Battery Disconnect (Remove and Replace).
  34. Attach the HV battery H-frame to the gantry and raise it into position.
  35. Position the HV battery under the gantry.
  36. Lower the H-frame onto the HV battery and attach the H-frame to the battery.
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    Note
    4x hooks.
  37. Raise the HV battery off the battery table.
  38. Position the gantry over a pallet.
  39. Lower the HV battery onto the pallet.
  40. Remove H-frame from the old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x hooks.
  41. Raise the gantry and H-frame from the old HV battery.

Installation

  1. Open the crate top of the crate that contains the new HV battery pack.
  2. Position the gantry over the new HV battery crate and secure the H-frame to the battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x hooks.
  3. Lift the new HV battery out of the crate.
  4. Move the gantry away from the HV battery crate and move it over the HV battery table.
  5. Lower the HV battery onto the battery table.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to align the HV battery center to battery table.
  6. Release the H-frame from the HV battery, and then raise the gantry.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x hooks.
  7. Remove the HV battery from under the gantry.
  8. Position the gantry over the old HV battery.
  9. Lower the H-frame onto the old HV battery and attach the H-frame to the battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x hooks.
  10. Raise the old HV battery above the height of the HV battery crate.
  11. Position the HV battery crate underneath the old HV battery.
  12. Lower the old HV battery into the crate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution to align the HV battery into the crate and not damage the battery.
  13. Remove the H-frame from the old HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x hooks.
  14. Raise gantry and H-frame from the old HV battery.
  15. Lower the gantry and remove the H-frame from the gantry.
  16. Close the crate top of the crate that housed the old HV battery.
  17. Install the battery coolant service fixture onto the coolant rapid mate of the new HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand tighten the nuts while holding the fixture down on the rapid mate.
  18. Fill the fluid evacuator with 8 liters of coolant.
  19. Connect the air hose to the fluid evacuator and set the tool to vacuum hose position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that both the pressure and relief valves are closed.
  20. Pressurize and fill the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Open the pressure valve and hand prime pressure using Mityvac.
  21. Close the pressure valve on the evacuator.
  22. Disconnect the air hose from the fluid evacuator.
  23. Remove the tool from the HV battery pack.
  24. Raise the vehicle for positioning of the HV battery.
  25. Put on HV insulating gloves and leather over gloves, and do not remove them until the HV battery is mated with the vehicle.
  26. Align HV battery inner floating nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    14x nuts, Perform before pack installation
  27. Align the HV battery inner floating nuts (x14).
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform before pack installation.
  28. Remove the HV and LV RapidMate covers or tape.
  29. Position the HV battery underneath vehicle.
  30. Lower the vehicle onto the HV battery pack.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    There may be residual high voltage at the RapidMate connector which might arc when inspecting the connection there.
    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 the HV and LV rapid mates.
  31. Remove leather over gloves and HV insulating gloves.
  32. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque to 30 Nm at a later step.
  33. Install new outer front bolts (x2) that attach the HV battery to the body with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque to 115 Nm at a later step.
  34. Install new outer center bolts (x8) that attach the HV battery to the body with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    8x patch bolts. E12, 38 Nm. Install new patch bolts. Do not over tighten bolts. Torque at later step.
  35. Install new bolts (8x per side) that attach the LH and RH side of HV battery to the body with a battery powered drill.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque to 55 Nm at a later step.
  36. Torque the bolts (8x per side) that attach the HV battery to the body on both sides to 55 Nm.
  37. Torque the remaining HV battery bolts.
    Informational PurposesAn informational icon, calling your attention
    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
  38. Raise the vehicle and remove the battery table.
  39. Install new inner center HV battery bolts (x4) with battery powered drill, and then torque the bolts to 38 Nm.
  40. Install the clips that attach the LH and RH ski side covers.
    Informational PurposesAn informational icon, calling your attention
    Note
    14x clips per side.
    Figure 7. LH side shown, RH side similar
  41. Install the bolts (x2) that attach the front bash plate extrusion (torque 16 Nm).
  42. Install the mid aero shield. See Panel - Aero Shield - Mid (Remove and Replace).
  43. Install the LH and RH shear plate.
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    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
  44. Fully lower the vehicle.
  45. Connect the First Responder Loop.
  46. Connect the 12V negative terminal, and then tighten the nut that attaches the terminal to the auxiliary battery.
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    Note
    10mm, 5 Nm.
  47. Connect a 12V charger to the auxiliary battery.
  48. Remove the coolant reservoir cap from the coolant reservoir.
  49. 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).
  50. 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 next step.
  51. In Toolbox 3, click the Actions tab, type "Service Redeploy" into the search field, click UPDATE_CAN-REDEPLOYvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
    • Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
    , click Run, and allow the routine to complete.
  52. Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
  53. In Toolbox 3, click the Actions tab, type "Pack Replacement" into the search field, click PROC_BMS_X_PACK-REPLACEMENTvia Toolbox: (link), click Run, and allow the routine to complete.
  54. In Toolbox 3, click the Actions tab, type "Standby Reboot Gtw" into the search field, click PROC_ICE_X_STANDBY-REBOOT-GTWvia Toolbox: (link), click Run, and allow the routine to complete.
  55. In Toolbox 3, click the Actions tab, type "Coolant air purge" into the search field, click PROC_THC_X_COOLANT-AIR-PURGEvia Toolbox: (link), click Run, and allow the routine to complete.
  56. Go to step 65.
  57. Enable Service Mode Plus. See Service Mode Plus.
  58. On the vehicle touchscreen, touch Lightning Bolt icon > Procedures.
  59. Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, in the window that opens, touch Run, and then wait for completion.
  60. Disconnect the First Responder Loop.
  61. Unlock the vehicle gateway for diagnostic communication, if not already unlocked. See Gateway Unlock.
  62. 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.
  63. Disable Service Mode Plus. See Service Mode Plus.
  64. Connect the First Responder Loop.
  65. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  66. Disconnect the 12V charger from the vehicle.
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    Note
    After firmware update has completed, the vehicle does no longer need auxiliary 12V support.
  67. Install the coolant reservoir cap onto the coolant reservoir.
  68. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  69. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  70. Remove the vehicle from the lift.
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    Note
    Lower rack arms fully and move them from under the vehicle. Disable "Jack Mode" via Controls > Service > Jack Mode.