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.
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Raise and support vehicle
NoteEnsure vehicle is not charging before lifting it off the ground, Set air suspension to "Jack Mode" if equipped
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Open all four doors
NoteLatch rear doors to prevent accidental closing when vehicle is powered down
- Lower all windows
- Move LH front seat forward
- Move RH front seat forward
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Remove 2nd row seat cushion
Note1x connector, Lift front edge of seat cushion upward to release foam from frame
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Partially remove LH rear door seal
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Remove LH rear sill trim
Note5x 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
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Partially remove RH rear door seal
NotePillar and sill trim have tabs seated underneath seal
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Remove RH rear sill trim
Note5x 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
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Remove clips securing rear main cabin carpet to vehicle
Note3x push clips
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Remove fasteners securing 40 seat frame to body
Note4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
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Fold the 40 seat in down position
NoteProtect 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
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Disconnect 40 frame connector
Note1x connector
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Remove 2R 40 seat assembly from vehicle
NoteRecommend assistance
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Remove fasteners securing 60 seat frame to body
Note5x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet
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Fold the 60 seat in down position
NoteProtect 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
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Disconnect logic connector at LH seat frame
Note1x connector
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Remove 2nd row 60 seat assembly from vehicle
NoteRecommend assistance
- Open hood
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Remove rear apron
Note14x clips
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Power off vehicle from center display
NoteVia Controls > Safety & Security > Vehicle Power > Power Off
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Disconnect 12V negative terminal and first responders loop
Note1x 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
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
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Remove the ancillary bay probe lid cover from the ancillary bay cover
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Verify no high voltage
NoteMake 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
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Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
NoteConfirm no visual damage present, Replace gasket if damage is found
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Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts
- Remove HV insulating gloves
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Disconnect the HVC logic connector and install logic cap
Note1x connector, 1x cap, Release locking tab then push the handle downward to release connector
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Remove HVC logic cap
Note1x cap
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Remove fasteners securing ancillary bay cover to high voltage controller (HVC)
Note4x bolts, E10, 5 Nm + 30 degrees, Discard after removal, Newer vehicles may be equipped with 3x bolts
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Remove bolts securing ancillary bay cover to HV battery
Note18x 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
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Remove ancillary bay cover from HV battery
NoteInspect the ancillary bay for any missing insulators, Install any missing insulators that are accessible before continuing to next step
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Install fuses access insulator
Note3x clips
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Install the battery pyro and shunt insulators
Note2x insulators
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Install the HV joint insulators onto positive pack contactor
Note2x insulators
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Install the HV joint insulators to negative pack contactor
Note2x insulators
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Install the insulator for DC input assembly to both fastcharge busbars inlet side
Note1x insulator
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Install the negative AC inlet terminal cover
Note1x cover, 3x clips, Use caution as the clips are very easy to damage
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Install the positive AC inlet terminal cover
Note1x cover, 3x clips, Use caution as the clips are very easy to damage
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Install HVC logic cap
Note1x cap
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Raise vehicle fully and lower lift 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
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Remove mid aero shield
Note11x bolts, 10mm, 5 Nm
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Release clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Release LH side hose clip from rear battery skid plate
Note2x clips, Clip quantity may vary on older vehicles
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Release RH side hose clips from rear battery skid plate
Note2x fir tree clips
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Remove lower bolts securing rear battery enclosure skid plate
Note2x bolts, EP10, 13 Nm
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Remove upper nut securing rear battery enclosure skid plate
Note1x nut, 10mm, 13 Nm
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Remove upper bolts securing rear battery enclosure skid plate from HV battery
Note4x bolts, 13mm, 35 Nm
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Remove rear battery enclosure skid plate from HV battery pack
- Position coolant drain container underneath LH rear of HV battery
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Disconnect RDU inverter inlet hose from rear of HV battery and plug both ends
Note1x spring clip, 2x plugs
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Attach coolant drain hose adapter to PCS outlet hose coupling
Note90 degree angle, Make sure the locking tab is fully seated
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Attach coolant drain hose adapter to coolant hose extension
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Attach coolant hose extension to coolant drain hose
- Position coolant drain underneath RH rear of HV battery
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Disconnect rear PT supply hose from rear of HV battery and plug hose
Note1x spring clip
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Attach coolant pressure tester to PCS inlet hose coupling
NoteThis adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
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Attach coolant pressure tester to pressure fitting adapter
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Attach coolant pressure tester to compressed air line
NoteMake sure valves are closed on pressure regulator
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Open the regulator valve then slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Open the 2nd valve slowly
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Close the regulator valve
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Open the regulator valve slowly
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Close both valves
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Remove coolant pressure tester from pressure fitting adapter
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Remove coolant pressure tester from PCS inlet hose coupling
- Position coolant drain container underneath LH rear of HV battery
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Disconnect coolant drain hose adapter from coolant hose extension
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Remove coolant drain hose adapter from PCS outlet hose coupling
- Position coolant drain underneath RH rear of HV battery
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Attach coolant drain hose adapter to PCS inlet hose coupling
NoteHose connects to coolant cart drain hose, Make sure the locking tab is fully seated
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Attach coolant drain hose adapter to coolant hose extension
- Position coolant drain container underneath LH rear of HV battery
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Attach coolant pressure tester to PCS outlet hose coupling
NoteThis adapter connected to regulated air line adapter, Rotate lower hose for more access, Make sure the locking tab is fully seated
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Attach coolant pressure tester to pressure fitting adapter
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Open the regulator valve then slowly adjust regulator to 50 psi
NoteUse caution as coolant may spill, Make sure to wear safety glasses
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Open the 2nd valve slowly
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Close the regulator valve
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Open the regulator valve slowly
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Set timer for 1 minute and select start
NoteOnce timer is complete, select Stop Reset
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Close the regulator valve
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Disconnect compressed air from coolant pressure tester
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Remove coolant pressure tester from pressure fitting adapter
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Remove coolant pressure tester from PCS outlet hose coupling
NoteInstall plug to coupling
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Close the 2nd valve
- Position coolant drain underneath RH rear of HV battery
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Disconnect coolant hose extension from coolant drain hose
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Disconnect coolant drain hose adapter from coolant hose extension
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Remove coolant drain hose adapter from PCS inlet hose coupling
NoteInstall plug to coupling
- Remove coolant drain container from underneath vehicle
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Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
- Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
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Disconnect HV controller connectors
Note7x connectors
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Remove the megaharness clips from HV controller hinge tray
Note5x harness clips
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Remove screws securing HVC tray assembly to ancillary bay
Note2x 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
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Remove the HVC and tray assembly from ancillary bay
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Position absorbent sheets below and around the PCS coolant inlet hose to avoid excess coolant dripping
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Disconnect PCS coolant inlet hose from PCS and install plugs
Note1x 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
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Position absorbent sheets below and around the PCS coolant outlet hose to avoid excess coolant dripping
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Disconnect PCS coolant outlet hose from PCS and install plugs
Note1x hose, Use the special tool to release the 2x clips
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Disconnect PCS to DC bus HV connector
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS logic connector from PCS
Note1x connector
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Disconnect PCS LV connector from PCS
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Disconnect PCS to fastcharge contactor HV harness connector
Note1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
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Remove bolts securing PCS to HV battery
Note5x bolts, Ensure ONLY the 8mm fasteners are removed, Do not remove the T30 fasteners
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Secure suction cups to PCS
NoteContinue pressing plunger until red line is no longer visible, Do not install on top of any stickers as this will cause suction loss
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Lift PCS up and out of ancillary bay area and remove from vehicle
NoteRecommend 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
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Install HV joint insulator for negative busbar module 3 to shunt
Note1x insulator
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Install HV joint insulator for positive DC link to module 4
Note1x insulator
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Install HV joint insulator for positive busbar module 2 to pyro disconnect
Note1x insulator
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Remove HV joint insulator for positive busbar module 2 to pyro disconnect
Note1x insulator
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Remove Pyro Cover
Note4xclips
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Install Pyro Cover
Note4xclips
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Install HV joint insulator for positive busbar module 2 to pyro disconnect
Note1x insulator
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Position the PCS into ancillary bay
NoteRecommend 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
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Remove suction cups from PCS
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Install bolts securing PCS to HV battery
Note5x bolts, 8mm, 18 Nm
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Connect PCS to fastcharge contactor HV harness connector
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Connect PCS LV connector to PCS
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Connect PCS logic connector to PCS
Note1x connector
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Connect PCS to DC bus HV connector
Note1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
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Remove plug from PCS inlet hose
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Replace o-rings on PCS inlet hose
Note2x o-rings, Apply light amount of Krytox 203
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Secure inlet hose to PCS
Note1x 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
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Remove plug from PCS outlet hose
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Replace o-rings on PCS outlet hose
Note2x o-rings, Apply light amount of Krytox 203
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Secure PCS outlet hose to PCS
Note1x 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
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Raise vehicle fully and lower lift 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
- Position coolant drain container underneath LH rear of HV battery
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Install coolant pressure test plug adapter to PCS outlet hose coupling
NoteRemove plug from coupling, Make sure the locking tab is fully seated
- Position coolant drain underneath RH rear of HV battery
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Install coolant pressure adapter to PCS inlet hose coupling
NoteRemove plug from coupling, Make sure the locking tab is fully seated
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Attach coolant pressure tester to pressure fitting adapter
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Attach coolant pressure tester to compressed air line
NoteMake sure valves are closed on pressure regulator
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Set pressure regulator to specified pressure value
NoteSet pressure to 50 psi
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Slowly open valve on pressure regulator and allow pressure to reach specification
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Close the valve and let pressure settle
NoteWait 2 minutes for pressure to settle, Record the reading
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Perform the coolant pressure leak test
NoteWait 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
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Disconnect compressed air from coolant pressure tester
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Remove pressure fitting adapter from coolant pressure tester
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Remove coolant pressure tester from PCS inlet hose coupling
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Connect rear PT supply hose to rear of HV battery
Note1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated, Perform push-pull-push test
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Remove coolant pressure test plug adapter from PCS outlet hose coupling
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Connect RDU inverter inlet hose to rear of HV battery
Note1x 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
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Position rear battery enclosure skid plate to HV battery for installation
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Install upper bolts securing rear battery enclosure skid plate to HV battery hand tight
Note4x bolts, 13mm, 35 Nm, Torque at later step
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Install upper nut securing rear battery enclosure skid plate hand tight
Note1x nut, 10mm, 13 Nm, Torque at later step
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Install lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
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Torque bolts securing HV battery and rear skid plate to vehicle
Note4x bolts, 13mm, 35 Nm
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Torque upper nut securing rear battery enclosure skid plate
Note1x nut, 10mm, 13 Nm
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Install lower bolts securing HV battery rear skid plate enclosure
Note2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts
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Install RH side hose clips to rear battery skid plate
Note2x fir tree clips
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Install LH side hose clip to HV battery rear skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
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Install clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Note9x bolts, 10mm, 5 Nm
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Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Install 12V negative terminal
Note1x 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
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Hook up 12V charger to 12V battery
- Connect to vehicle using Toolbox 3.0
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Remove coolant bottle cap
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Fill coolant to the proper level
NoteEnsure that the fluid level filled to the Max line
- Select "Actions/Autodiag" tab and search for "vcfront"
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Select TEST-RESET_VCFRONTSearch for routine in ToolboxLow Voltage / Power Distribution - Reset VCFRONTMid Voltage / Power Distribution - Reset VCFRONT, click 'Run', and allow routine to complete
NoteSelect 'X' at top right window to close once complete
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Select
‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to
complete
NoteMake 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
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Fill coolant to the proper level
NoteEnsure that the fluid level filled to the Max line
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Install coolant bottle cap
- Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
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Power off vehicle from center display
Notevia Controls > Safety & Security > Vehicle Power > Power Off
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Remove 12V charger from 12V battery
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Disconnect 12V negative terminal
Note1x nut, 10mm, 6 Nm, Ensure the climate control system is off and vehicle is not charging before disconnecting 12V
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Drill marked points for access to hinge fasteners
NoteStep up drill bit size, Use 2mm bit first, Use 4mm bit second, Use 6mm bit last, Use caution
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Position HVC tray assembly in ancillary bay
Note4x locating pins, 3x wires routed through RH hinge
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Secure HVC tray assembly to ancillary bay
Note2x screws, T25, 2 Nm
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Connect HV controller connectors
Note7x connectors
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Install the megharness clips to HV controller hinge tray
Note5x 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).
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Clean HVC studs and ancillary bay cover underside with isopropyl alcohol
Note4x studs
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Inspect ancillary bay walls for damage
NoteAny 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
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Inspect ancillary bay cover seal to confirm it has no visual damage
NoteImage up close for clarity, Delaminated and torn seals cannot be reused
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Remove HVC logic cap
Note1x cap
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Position the ancillary bay cover to HV battery for installation
NoteEnsure all accessible insulators are present, wearing Electrical Protective Gloves is not necessary once all HV components are covered.
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Install HVC logic cap
Note1x cap
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Install bolts securing ancillary bay cover to HV battery
Note18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image
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Install fasteners securing ancillary bay cover to high voltage controller (HVC)
Note4x bolts, E10, 5 Nm + 30 degrees, Install new bolts, Newer vehicles may be equipped with 3x bolts
- Remove HV insulating gloves
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Remove logic cap and connect the HVC logic connector
Note1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated
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Install 2R 40 seat assembly into vehicle
NoteRecommend assistance
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Connect 40 seat frame connector to body harness
Note1x connector
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Fold the 40 seat into vertical position
NoteRemove seat cushion protection
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Secure 40 seat frame to vehicle
Note4x bolts, 11mm, 37 Nm, Bottom seat bolts located behind main carpet, Torque in sequence; Outboard front -> Inboard rear -> Outboard rear -> Inboard front
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Install RH rear sill trim
Note5x 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
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Reseat RH rear door seal
NoteSeat pillar and sill trim tabs underneath seal
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Install 2nd row 60 seat assembly
NoteRecommend assistance
-
Connect logic connector at LH seat frame
Note1x connector
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Fold the 60 seat into vertical position
NoteRemove seat back protection if necessary
-
Install fasteners securing 60 seat frame to body
Note5x 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
Note5x 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
NoteSeat pillar and sill trim tabs underneath seal
-
Install clips securing rear main cabin carpet to vehicle
Note3x push clips
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Install 2nd row seat cushion
Note1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
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Connect first responder loop and 12V negative terminal
Note1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
-
Install rear apron
Note14x 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
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Close all four doors
NoteIf 12V is powered up, Unlatch rear doors before closing
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Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped