15/12/2023 01:28:57

HV Battery Air Leak Test (Structural Pack)

Correction code 16102120 0.65 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.

Open all four doors
Lower all four windows
Open hood
Remove rear apron

Note
14x clips
Remove bolt securing frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Release washer tank neck from washer tank and set aside

Note
1x O-ring, No need to remove hose from neck
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
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
Raise and support vehicle

Note
Ensure vehicle is not charging, Note the MYSP lifting points are more narrow than the MY
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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 push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Remove mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
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, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Install amp clamp to RDU HV harness

Note
Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
Release RDU HV harness from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Verify no high voltage at RDU HV header

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
Remove HV insulating gloves
Remove breather plugs from thermal vents

Note
4x plugs, 3x tabs per plug, Discard after removal
Install air splitter hoses onto thermal vents

Note
5x hoses, Splitter still in development
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Cut away insulation covering pyro cover

Note
If insulation is present then cut away
Remove breather from pyro cover

Note
1x breather, Discard after removal
Install air splitter hose onto pyro cover

Note
1x hose, Splitter still in development
Close both valves on the regulator test tool
Connect regulator to air supply
Turn right side regulator valve to the open position

Note
By turning the valve knob to a horizontal position, The valve is fully open
Set regulator to 0.3 psi
Open left side regulator valve to inject air into ancillary bay

Note
Allow 50 seconds fill time, Close right side regulator valve when pressure reaches 0.3 psi
Wait 30 seconds for pressure to settle
Record value of starting pressure
Wait 60 seconds to test pressure
Record value of end pressure

Note
Subtract ending pressure from starting pressure, If difference is greater than 0.08143 psi then inspect tools and retest, If difference is still greater than 0.08143 psi then escalate a Toolbox session, If difference is 0.08143 psi or less then proceed with current procedure
Disconnect air supply from regulator tool
Remove air splitter hose from pyro cover

Note
1x hose, Splitter still in development
Install breather onto pyro cover

Note
1x breather, Install new breather
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
Disconnect enclosure leak tester from air splitter
Remove air splitter hoses from thermal vents

Note
5x hoses, Splitter still in development
Install breather plugs onto thermal vents

Note
4x plugs, 3x tabs per plug, Install new plugs, Press plug evenly, Make sure tabs are fully engaged and plug is flush with vent
Secure RDU HV harness onto HV battery

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
Install push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
Secure washer tank neck onto washer tank

Note
1x O-ring, Ensure washer hose is properly routed
Install bolt securing frunk to washer fluid reservoir neck

Note
1x bolt, 10mm, 5 Nm
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
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
Move LH front seat to original position
Move RH front seat to original position
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Raise all four windows
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing