01/04/2024 13:57:55

Cover - Pyrotechnic - HV Battery (Remove and Replace)

Correction code 16300052 3.00 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 wearing proper PPE when performing the below procedure.

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.

Raise and support vehicle

Note
Ensure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
Open all four doors

Note
Latch rear doors to prevent accidental closing when vehicle is powered down
Lower all windows
Move LH front seat forward
Move RH front seat forward
Remove 2nd row seat cushion

Note
1x connector, Lift front edge of seat cushion upward to release foam from frame
Partially remove LH rear door seal
Remove LH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of LH rear sill trim working your way back towards rear of sill trim
Partially remove RH rear door seal

Note
Pillar and sill trim have tabs seated underneath seal
Remove RH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Release clips at the front of RH rear sill trim working your way back towards rear of sill trim
Remove clips securing rear main cabin carpet to vehicle

Note
3x push clips
Remove fasteners securing 40 seat frame to body

Note
4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
Fold the 40 seat in down position

Note
Protect the seat cushion, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
Disconnect 40 frame connector

Note
1x connector
Remove 2R 40 seat assembly from vehicle

Note
Recommend assistance
Remove fasteners securing 60 seat frame to body

Note
5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
Fold the 60 seat in down position

Note
Protect the seat back upholstery if necessary, Do not put weight on seat in folded position without cushion present due to risk of bending the locator tab on the frame
Disconnect logic connector at LH seat frame

Note
1x connector
Remove 2nd row 60 seat assembly from vehicle

Note
Recommend assistance
Open hood
Remove rear apron

Note
14x clips
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off
Disconnect 12V negative terminal and first responders loop

Note
1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
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 R1
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove the ancillary bay probe lid cover from the ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present, Replace gasket if damage is found
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
Remove HV insulating gloves
Disconnect the HVC logic connector and install logic cap

Note
1x connector, 1x cap, Release locking tab then push the handle downward to release connector
Remove HVC logic cap

Note
1x cap
Remove fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Discard after removal, Newer vehicles may be equipped with 3x bolts
Remove bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover
Remove ancillary bay cover from HV battery

Note
Inspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
Install fuses access insulator

Note
3x clips
Install the battery pyro and shunt insulators

Note
2x insulators
Install the HV joint insulators onto positive pack contactor

Note
2x insulators
Install the HV joint insulators to negative pack contactor

Note
2x insulators
Install the insulator for DC input assembly to both fastcharge busbars inlet side

Note
1x insulator
Install the negative AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Install the positive AC inlet terminal cover

Note
1x cover, 3x clips, Use caution as the clips are very easy to damage
Install HVC logic cap

Note
1x cap
Raise vehicle fully and lower lift onto locks

Note
Set 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 mid aero shield

Note
11x bolts, 10mm, 5 Nm
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate

Note
2x fir tree clips
Remove lower bolts securing rear battery enclosure skid plate

Note
2x bolts, EP10, 13 Nm
Remove upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Remove upper bolts securing rear battery enclosure skid plate from HV battery

Note
4x bolts, 13mm, 35 Nm
Remove rear battery enclosure skid plate from HV battery pack
Position coolant drain container underneath LH rear of HV battery
Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends

Note
1x spring clip, 2x plugs
Attach coolant drain hose adapter to PCS outlet hose coupling

Note
90 degree angle, Make sure the locking tab is fully seated
Attach coolant drain hose adapter to coolant hose extension
Attach coolant hose extension to coolant drain hose
Position coolant drain underneath RH rear of HV battery
Disconnect rear PT supply hose from rear of HV battery and plug hose

Note
1x spring clip
Attach coolant pressure tester to PCS inlet hose coupling

Note
This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Attach coolant pressure tester to compressed air line

Note
Make sure valves are closed on pressure regulator
Open the regulator valve then slowly adjust regulator to 50 psi

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open the 2nd valve slowly
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Close the regulator valve
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Open the regulator valve slowly
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Close both valves
Remove coolant pressure tester from pressure fitting adapter
Remove coolant pressure tester from PCS inlet hose coupling
Position coolant drain container underneath LH rear of HV battery
Disconnect coolant drain hose adapter from coolant hose extension
Remove coolant drain hose adapter from PCS outlet hose coupling
Position coolant drain underneath RH rear of HV battery
Attach coolant drain hose adapter to PCS inlet hose coupling

Note
Hose connects to coolant cart drain hose, Make sure the locking tab is fully seated
Attach coolant drain hose adapter to coolant hose extension
Position coolant drain container underneath LH rear of HV battery
Attach coolant pressure tester to PCS outlet hose coupling

Note
This adapter connected to regulated air line adapter, Rotate lower hose for more access, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Open the regulator valve then slowly adjust regulator to 50 psi

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open the 2nd valve slowly
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Close the regulator valve
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Open the regulator valve slowly
Set timer for 1 minute and select start

Note
Once timer is complete, select Stop Reset
Close the regulator valve
Disconnect compressed air from coolant pressure tester
Remove coolant pressure tester from pressure fitting adapter
Remove coolant pressure tester from PCS outlet hose coupling

Note
Install plug to coupling
Close the 2nd valve
Position coolant drain underneath RH rear of HV battery
Disconnect coolant hose extension from coolant drain hose
Disconnect coolant drain hose adapter from coolant hose extension
Remove coolant drain hose adapter from PCS inlet hose coupling

Note
Install plug to coupling
Remove coolant drain container from underneath vehicle
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
Disconnect HV controller connectors

Note
7x connectors
Remove the megaharness clips from HV controller hinge tray

Note
5x harness clips
Remove screws securing HVC tray assembly to ancillary bay

Note
2x screws, T25, 2 Nm, 3x wires routed through RH hinge, Pull slightly forward on HVC at ~45 degree angle to access fastener between hinge and tray
Remove the HVC and tray assembly from ancillary bay
Position absorbent sheets below and around the PCS coolant inlet hose to avoid excess coolant dripping
Disconnect PCS coolant inlet hose from PCS and install plugs

Note
1x hose, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers
Position absorbent sheets below and around the PCS coolant outlet hose to avoid excess coolant dripping
Disconnect PCS coolant outlet hose from PCS and install plugs

Note
1x hose, Use the special tool to release the 2x clips
Disconnect PCS to DC bus HV connector

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Disconnect PCS logic connector from PCS

Note
1x connector
Disconnect PCS LV connector from PCS

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Disconnect PCS to fastcharge contactor HV harness connector

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Remove bolts securing PCS to HV battery

Note
5x bolts, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners
Secure suction cups to PCS

Note
Continue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss
Lift PCS up and out of ancillary bay area and remove from vehicle

Note
Recommend assistance, Slightly tilt front of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary
Install HV joint insulator for negative busbar module 3 to shunt

Note
1x insulator
Install HV joint insulator for positive DC link to module 4

Note
1x insulator
Install HV joint insulator for positive busbar module 2 to pyro disconnect

Note
1x insulator
Remove HV joint insulator for positive busbar module 2 to pyro disconnect

Note
1x insulator
Remove Pyro Cover

Note
4xclips
Install Pyro Cover

Note
4xclips
Install HV joint insulator for positive busbar module 2 to pyro disconnect

Note
1x insulator
Position the PCS into ancillary bay

Note
Recommend assistance, Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS downward and lower into position, Align datum into PCS holes, Inspect for any coolant residue inside ancillary bay and clean with absorbent sheets if necessary
Remove suction cups from PCS
Install bolts securing PCS to HV battery

Note
5x bolts, 8mm, 18 Nm
Connect PCS to fastcharge contactor HV harness connector

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Connect PCS LV connector to PCS

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Connect PCS logic connector to PCS

Note
1x connector
Connect PCS to DC bus HV connector

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Remove plug from PCS inlet hose
Replace o-rings on PCS inlet hose

Note
2x o-rings, Apply light amount of Krytox 203
Secure inlet hose to PCS

Note
1x hose, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated
Remove plug from PCS outlet hose
Replace o-rings on PCS outlet hose

Note
2x o-rings, Apply light amount of Krytox 203
Secure PCS outlet hose to PCS

Note
1x hose, Place absorbent sheet under hose to catch excess coolant, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Visually inspect area for any coolant residue, Clean with shop towel if necessary
Remove HV insulating gloves
Raise vehicle fully and lower lift onto locks

Note
Set 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
Position coolant drain container underneath LH rear of HV battery
Install coolant pressure test plug adapter to PCS outlet hose coupling

Note
Remove plug from coupling, Make sure the locking tab is fully seated
Position coolant drain underneath RH rear of HV battery
Install coolant pressure adapter to PCS inlet hose coupling

Note
Remove plug from coupling, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Attach coolant pressure tester to compressed air line

Note
Make sure valves are closed on pressure regulator
Set pressure regulator to specified pressure value

Note
Set pressure to 50 psi
Slowly open valve on pressure regulator and allow pressure to reach specification
Close the valve and let pressure settle

Note
Wait 2 minutes for pressure to settle, Record the reading
Perform the coolant pressure leak test

Note
Wait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not if pressure test fails
Disconnect compressed air from coolant pressure tester
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS inlet hose coupling
Connect rear PT supply hose to rear of HV battery

Note
1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated, Perform push-pull-push test
Remove coolant pressure test plug adapter from PCS outlet hose coupling
Connect RDU inverter inlet hose to rear of HV battery

Note
1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated, , Perform push-pull-push test
Remove coolant drain container from underneath vehicle
Position rear battery enclosure skid plate to HV battery for installation
Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing rear battery enclosure skid plate hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Torque bolts securing HV battery and rear skid plate to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing rear battery enclosure skid plate

Note
1x nut, 10mm, 13 Nm
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
Install RH side hose clips to rear battery skid plate

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
9x bolts, 10mm, 5 Nm
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install 12V negative terminal

Note
1x nut, 10mm, 6 Nm, DO NOT install FRL, You will be performing a toolbox routines with the ancillary bay lid removed, HV power will be connected at a later step
Hook up 12V charger to 12V battery
Connect to vehicle using Toolbox 3.0
Remove coolant bottle cap
Fill coolant to the proper level

Note
Ensure that the fluid level filled to the Max line
Select "Actions/Autodiag" tab and search for "vcfront"
Select TEST-RESET_VCFRONT, click 'Run', and allow routine to complete

Note
Select 'X' at top right window to close once complete
Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE ’, click ‘Run’, and allow routine to complete

Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
Fill coolant to the proper level

Note
Ensure that the fluid level filled to the Max line
Install coolant bottle cap
Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Power off vehicle from center display

Note
via Controls > Safety & Security > Vehicle Power > Power Off
Remove 12V charger from 12V battery
Disconnect 12V negative terminal

Note
1x nut, 10mm, 6 Nm, Ensure the climate control system is off and vehicle is not charging before disconnecting 12V
Drill marked points for access to hinge fasteners

Note
Step up drill bit size, Use 2mm bit first, Use 4mm bit second, Use 6mm bit last, Use caution
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Position HVC tray assembly in ancillary bay

Note
4x locating pins, 3x wires routed through RH hinge
Secure HVC tray assembly to ancillary bay

Note
2x screws, T25, 2 Nm
Connect HV controller connectors

Note
7x connectors
Install the megharness clips to HV controller hinge tray

Note
5x clips
Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
Clean HVC studs and ancillary bay cover underside with isopropyl alcohol

Note
4x studs
Inspect ancillary bay walls for damage

Note
Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, Any paint that comes off the ancillary bay wall, whether or not it sticks to the seal, will require enclosure leak test when reassembled, It can still be reused
Inspect ancillary bay cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Remove HVC logic cap

Note
1x cap
Position the ancillary bay cover to HV battery for installation

Note
Ensure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
Install HVC logic cap

Note
1x cap
Install bolts securing ancillary bay cover to HV battery

Note
18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
Install fasteners securing ancillary bay cover to high voltage controller (HVC)

Note
4x bolts, E10, 5 Nm + 30 degrees, Install new bolts, Newer vehicles may be equipped with 3x bolts
Remove HV insulating gloves
Remove logic cap and connect the HVC logic connector

Note
1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
Install 2R 40 seat assembly into vehicle

Note
Recommend assistance
Connect 40 seat frame connector to body harness

Note
1x connector
Fold the 40 seat into vertical position

Note
Remove seat cushion protection
Secure 40 seat frame to vehicle

Note
4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
Install RH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips
Reseat RH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Install 2nd row 60 seat assembly

Note
Recommend assistance
Connect logic connector at LH seat frame

Note
1x connector
Fold the 60 seat into vertical position

Note
Remove seat back protection if necessary
Install fasteners securing 60 seat frame to body

Note
5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Both inboard rear -> Outboard rear -> Inboard front
Install LH rear sill trim

Note
5x clips, Rear edge is mated with groove in trunk side trim, Install rear edge of LH rear sill trim into trunk side trim and work your way forward securing clips
Reseat LH rear door seal

Note
Seat pillar and sill trim tabs underneath seal
Install clips securing rear main cabin carpet to vehicle

Note
3x push clips
Install 2nd row seat cushion

Note
1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move LH front seat to original position
Move RH front seat to original position
Raise all windows
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped

Model Y Service Manual

Cover - Pyrotechnic - HV Battery (Remove and Replace)

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