16/08/2024 12:48:34
HV Battery (AWD) (Remove and Install)
Correction Code 16010201
- 2024-08-16: Added note stating it is not necessary to perform HV disablement.
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 rachet 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 |
Removal
-
Open LH front door.
-
Raise and support
vehicle.
NoteSet air suspension to "Jack Mode" Via Controls > Service > ''Jack Mode''.
-
Open hood.
NoteVia center display > Controls > Front Trunk.
-
Remove underhood
aprons.
Note4x aprons.
-
Remove frunk carpet.
Note2x connectors.
-
Remove underhood storage
unit.
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
-
Remove HEPA filter.
NoteLift up from bottom and pull out.
-
Power down vehicle using
MCU.
NoteVia Controls > Safety > ''Power off".
-
Disconnect 12V negative
terminal.
Note1x nut, 10mm, 5 Nm.
-
Disconnect first responder
loop.
NoteDo not perform HV disablement. It is not required when performing an HV battery remove and install.Note1x connector, push to release.
-
Raise vehicle fully and
lower onto locks.
NoteSet 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.
-
Remove LH rear shear
plate.
Note3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nylon nut, 15mm, Discard nylon nut after removal.
-
Remove RH shear plate.
Note3x screws, T25, 6 Nm, 1x nyloc nut, 15mm, 35 Nm, Discard after removal, 1x bolt, 10mm, 4 Nm, 2x push clips.
-
Remove mid aero
shield.
Note20x bolts, 10mm, 4 Nm, 2x push clips.
-
Remove front bash plate
extrusion.
Note2x patch bolts, T30, 16 Nm.
-
Remove LH ski side
covers.
Note14x push clips, 3x covers.
-
Remove RH ski side
covers.
Note14x push clips, 3x covers.
-
Loosen four center bolts
securing HV battery.
Note4x patch bolts, E12, 38 Nm, Discard after removal.
-
Remove four center bolts
securing HV battery.
Note4x patch bolts, E12, 38 Nm, Discard after removal.
-
Position battery table
beneath vehicle.
-
Lower vehicle to
table.
NoteRecommend assistance, Align table to vehicle and raise casters to level table if necessary.
-
Loosen remaining eight
center bolts securing HV battery.
Note8x patch bolts, E12, 38 Nm, Discard after removal.
-
Remove remaining eight
center bolts securing HV battery.
Note8x patch bolts, E12, 38 Nm, Discard after removal.
-
Loosen front four HV battery
bolts.
Note4x patch bolts, 13mm, 30 Nm, Discard after removal.
-
Remove front four HV battery
bolts.
Note4x patch bolts, 13mm, 30 Nm, Discard after removal.
-
Loosen 21mm bolts securing
front of HV battery.
Note2x bolts, 21mm, 115 Nm, Discard after removal.
-
Remove 21mm bolts securing
front of HV battery.
Note2x bolts, 21mm, 115 Nm, Discard after removal.
-
Loosen LH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Remove LH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Loosen RH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Remove RH rocker
bolts.
Note8x patch bolts, 13mm, 55 Nm, Discard after removal.
-
Raise vehicle and remove
battery table.
NoteRecommend assistance.
-
Move battery away from
vehicle.
- Place an HV Danger placard on top of the HV battery and place a barrier around the working area.
-
Remove all items from
pockets and ensure not wearing metal items.
-
Inspect HV insulating
gloves.
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R1.pdf.
-
Put on HV insulating gloves
and leather over gloves.
-
Use a multimeter to check
voltages at the Rapid Splitter.
- B+ to ground
- B- to ground
- B+ to B-
WarningIf any voltage reading is more than 10V, continue to hold the probes to the test points to drop the voltage to 10V. If the voltage does not drop, contact a Field Service Engineer before performing any further work. -
Check voltage on HV Rapid
Mate.
NoteB+ to ground, B- to ground, and B+ to B-, If any voltage reading is more than 10V, the pack contactors are not fully opened, Contact Engineering for support.
-
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.
NoteIf 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.
Installation
-
Raise vehicle for
positioning of HV battery.
NoteSet 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.
-
Put on HV insulating gloves
and leather over gloves, and do not remove them until the HV battery is
mated with the vehicle.
-
Remove covers or tape from
LV and HV Rapid Mates.
-
Position HV battery
underneath vehicle.
-
Lower vehicle onto
pack.
WarningThere may be residual high voltage at the RapidMate connector which might arc when inspecting the connection there.NoteAlign Rapid Mate connections before lowering fully, Recommend assistance.
-
Remove leather over gloves
and HV insulating gloves.
-
Install front bolts securing
HV battery to body with battery powered drill .
Note4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
-
Install outer front bolts
securing HV battery to body with battery powered drill .
Note2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step.
-
Install outer center bolts
securing HV battery to body with battery powered drill .
Note8x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
-
Install bolts securing LH
side of HV battery to body with battery powered drill .
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
-
Install bolts securing RH
side of HV battery to body with battery powered drill .
Note8x patch bolts, 13mm, 55 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step.
-
Torque bolts securing HV
battery to body on both side.
Note16x patch bolts, 13mm, 55 Nm.
-
Torque remaining HV battery
bolts.
Note8x bolts, E12, 38 Nm, 2x bolts, 21mm, 115 Nm, 4x bolts, 13mm, 30 Nm.
-
Raise vehicle off of HV
battery.
-
Install inner center HV
battery bolts with battery powered drill .
Note4x patch bolts, E12, 38 Nm, Install new patch bolts, Do not over tighten bolts.
-
Torque the inner center HV
battery bolts.
Note4x patch bolts, E12, 38 Nm.
-
Install LH ski side
covers.
Note14x clips, 3x covers.
-
Install RH ski side
covers.
Note14x clips, 3x covers.
-
Install front bash plate
extrusion.
Note2x bolts, T30, 16 Nm.
-
Install mid aero
shield.
Note20x bolts, 10mm, 4 Nm, 2x push clips.
-
Install LH shear
plate.
Note3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push pins, Install new nyloc nut 15mm, 35 Nm.
-
Install RH shear
plate.
Note3x screws, T25, 6 Nm, 1x bolt, 10mm, 4 Nm, 2x push pins, Install new nyloc nut 15mm, 35 Nm.
-
Lower vehicle fully.
-
Connect first responder loop
and then 12V negative terminal.
Note1x connector, 1x nut, 10mm, 5 Nm.
-
Connect first responder
loop.
Note1x connector.
-
Install HEPA filter
housing.
-
Install underhood storage
unit.
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm.
-
Install frunk carpet.
Note2x connectors.
-
Install under hood
aprons.
Note4x aprons.
-
Close hood.
-
Calibrate falcon doors using
MCU.
NoteRequired after 12V and FRL disconnect.
-
Close LH front door.
-
Remove vehicle from
lift.
NoteLower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode".