19/12/2024 09:04:45

Aero Shield Support Tab - HV Battery 1.0/1.5 (Remove and Replace)

Correction Code 16012022 (HV Battery already removed), 16012032 (HV Battery not yet removed)

Part required for this procedure: 1045662-00-A: AEROSHIELD SUPPORT TAB - 1.5 ENCLOSURE - SERVICE

Special tools required for this procedure:

Part Number Description
1072865-00-A MARKING TEMPLATE, AEROTAB
1038478-00-A ASY,COVER,HV RAPID,HVBAT,MDLS
1028325-00-A ASY,COVER,LV RAPID,HVBAT,MDLS
1005706-00-C COVER,PORTS,BATT,COOLANT CX
1075777-00-A PNEUMATIC ROD GRINDER
1075778-00-A MOUNTING ADAPTER

Procedure

  1. Remove the HV Battery, if not already removed. See GUID-03EE68D7-2B14-44B0-9EA7-D05C67825E50.html.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To avoid damage from paint overspray, ensure that the HV Battery is located away from vehicles and other objects before performing this procedure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the HV, LV, and coolant connectors are covered.
  2. Cover the HV Battery with a blanket or tarp to avoid paint overspray.
  3. Apply protective tape around the damaged aero shield support tab area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the HV Battery warning label is covered with protective tape.
  4. Sand the broken tab and weld so that the affected area is flat.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wear protective eyewear and hearing protection when using the pneumatic grinder.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    : Make sure that no metal shavings get into the HV Battery. The HV and LV ports must be sealed to prevent metal shavings from entering the HV Battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only sanding disks that are 80 grit or finer to avoid damaging the HV Battery.
  5. Clean the affected area with alcohol wipes, and then allow 1 minute to dry.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use anything other than isopropyl alcohol (IPA) to clean the HV battery enclosure. Using other chemicals, such as brake cleaner, might corrode the coating on the HV battery enclosure.
  6. Put the marking template on the HV Battery and mark both drill locations with a marker.
  7. Working from the bottom of the HV Battery, use a punch to indent the HV Battery enclosure at the marked locations.
  8. Working from the bottom of the HV Battery, use a 4 mm (5/32 in) drill to drill holes at both marked locations.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Wear protective eyewear and hearing protection when drilling.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Only drill in the areas marked in the previous step. Do not drill into the bottom of the HV Battery.
  9. Use a 5.5 mm (7/32 in) drill to expand each of the 2 holes.
  10. Clean the affected area with alcohol wipes. Allow the alcohol to dry before continuing this procedure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use anything other than isopropyl alcohol (IPA) to clean the HV battery enclosure. Using other chemicals, such as brake cleaner, might corrode the coating on the HV battery enclosure.
  11. Test fit the new aero shield support tab to ensure that it fits properly, and then remove the aero shield support tab again.
    Informational PurposesAn informational icon, calling your attention
    Note
    The screws are installed from the underside of the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The remainder of this procedure must be performed in a well-ventilated area while wearing a 3M P95 Particulate Respiratory Mask or equivalent. If necessary, move the HV Battery outside of the Service Center. Refer to all product instructions and warnings for proper application method and safety precautions.
  12. Spray the area around the aero shield support tab with a thin coat of Etch Primer.
    Tip: Use a piece of cardboard to minimize overspray.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Exposed metal is susceptible to corrosion. Make sure that the entire affected area, including the bottom area, is coated with the Eych Primer.
  13. Allow the primer to dry for approximately 5 minutes before continuing with this procedure.
  14. Repeat steps 12 and 13 to apply a total of 3 coats.
  15. Apply Loctite Red 271 High Strength Threadlocker or equivalent to the threads of the new screws.
  16. Put the new aero shield support tab in place. From the bottom of the HV Battery, install 2 screws to attach the tab to the HV Battery (torque 6 Nm).
  17. Spray the entire affected area with a thin coat of Etch Primer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the sides of the aero shield support tab are coated as well.
  18. Allow the coating to dry for approximately 5 minutes before continuing with this procedure.
  19. Spray the entire affected area with a thin coat of SEM Self Etching Primer.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the sides of the aero shield support tab and all crevices are coated.
  20. Allow the SEM Self Etching Primer to dry for approximately 5 minutes before continuing with this procedure.
  21. Remove the protective tape and blanket/tarp from the HV Battery.
  22. Reinstall the HV Battery. See GUID-03EE68D7-2B14-44B0-9EA7-D05C67825E50.html.