HV Battery (RWD) (Structural Pack) (3-Phase) (Remove and Install)
Correction code 16010131 4.14 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.
- 2024-06-13: Updated lift pad adapter PNs.
- 2023-11-21: Added new lift pad instructions.
- 2023-11-07: Added references to wade seal procedures.
- 1936724-00-A - Universal Lift Pad Adapters
- 1020566-00-F ASY, Battery Table, Manual Lift
- 1065131-00-A Battery Coolant Drain Kit
- 1108272-00-B Cap, Logic Conn, Inv, 3DU
- 1050448-00-B Coolant Vacuum Refill Tool
- 1754057-00-A Current Probe, Clamp, DC, 600V
- 1076927-00-A Hioki Tester
- 1129166-00-A Hoist, H-Frame EMEA
- 1133787-00-A Key, Seat Belt Release, Model 3
- 1134523-00-B Kit, Alignment Rods, Battery, M3
- 1133843-00-A Kit, Coolant Drain & Fill Adapters, M3
- 1479505-00-A Kit, M3 Vacuum Fill Coolant Adapter
- 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
- 1637160-00-A MYSP and Palladium Pack Lift Attachment
- 1076928-00-A Test Probes - Hioki 9461
- 1080589-00-A Wheel Chocks
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 at all times a high voltage
cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness
Care Points
for additional safety
information.
Remove
- Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Remove and Replace).
-
Remove the butyl patches
(x2) that cover the LH rocker access holes.
-
Install lift pad adapters.
- For EMEA only, install Adapter, Lift Pad, Model Y (1614078-00-A)
- For other regions, install Universal Lift Pad Adapters (1936724-00-A)
WarningDO NOT use any other lift pad adapters.NoteOutside of EMEA, Universal Lift Pad Adapters (1936724-00-A) replace Adapter, Lift Pad, Model Y (1614078-00-A). Discard any other versions of lift pad adapters.NoteIn EMEA, the Universal Lift Pad Adapters are not yet available. Make sure to use the rubber Model Y lift pads on Model Y and the Model 3 lift pads on Model 3.Instructions for Universal Lift Pad Adapters:
- Depending on the lift type, install the correct thread adapter onto the lift adapter.
- Make sure the thread stop washer is installed and tightened to the bottom of the lift adapter. If the thread stop washer is not installed, do not continue using the lift adapter.
- Install the lift adapters onto the
lift arms so that the black lift pad is toward the vehicle.WarningMake sure the adapter is install in the correct orientation.
- Position the lift arms so that the lift adapters align with the datum hole on the vehicle.
- Lift the lift arms to fully seat the lift pads into the vehicle.
- Make sure all 4 adapters are fully seated into the vehicle.
- Open all doors and lower the windows.
- Release the LH and RH parking brake calipers. See Parking Brake - Caliper - Rear - LH (Release).
-
Run the Thermal Fill Drain
(Coolant Only) routine using the touchscreen. See Cooling System (Structural Pack) (Drain and Refill).
NoteSelect Run. Close once the routine is completed., then touch
- Remove the seats and the interior carpet from the vehicle. See Carpet - Interior Complete (Remove and Replace).
- Remove the center console. See Center Console (2.0) (Structural Pack) (Remove and Install).
-
Release the center console
harness from the HV battery.
Note1x clip
-
Remove the bolts (x4) that
attach the LH and RH lower IP carrier brackets.
-
Secure the center seat belt
buckles away from the ancillary bay.
-
Remove the rear inner HV
battery bolts (x4).
-
Push the vehicle onto a
2-post lift.
NoteAssistance recommended. Note that this vehicle can only be safely pushed for a very short distance and at very slow speed.
-
Raise and support the
vehicle. See Raise Vehicle - 2 Post Lift.
NoteVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
- Raise vehicle fully and lower the lift onto locks.
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
-
Pull the RH front wheel
liner away from the HV battery.
-
Pull the LH front wheel
liner away from the HV battery.
- Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Structural Pack).
- Lower the vehicle until the tires are touching the ground.
-
Release the 2nd row 60 seat
connector from the LH seat frame.
-
Disconnect the 3-phase
connector from the HV battery.
NoteRelease locking tab upwards then lift up the connector.
-
Remove the bolt that
attaches the busbar cover access door.
-
Remove the bolts that attach
the charge port busbar kit to the HV header.
-
Release the LH body harness
from the rear body and move it aside.
-
Lift the busbar kit
connector to remove it from the HV header.
NoteUse an inflatable airbag to suspend the busbar away from the HV header during removal and installation. Hold busbar firmly as there is tension on it.FF
-
Disconnect the HVC logic
connector and install the logic cap.
NoteRelease the locking tab, then pivot the handle downward to release connector.
-
Disconnect the LV power
connector from the HV battery.
-
Close all doors.
NoteLatch the rear doors to prevent accidental closure.
- Raise the vehicle to a comfortable working height.
-
Position a coolant drain
container underneath the LH front of the HV battery.
-
Disconnect the PT supply
hose at the LH front side of the vehicle.
NotePlug the hose connections.
-
Position the coolant drain
container underneath the LH RDU area.
NotePosition neck to catch all coolant loss.
-
Release the RDU inverter
inlet hose from the RDU.
-
Disconnect the RDU inverter
inlet hose from the fluid coupling.
NotePlug the drive unit coupling.
-
Position the coolant drain
container underneath the front left manifold battery supply hose.
-
Disconnect the front left
manifold battery supply hose.
NotePlug hose connections.
-
Position the coolant drain
container underneath the RH front of the HV battery.
-
Disconnect the HV battery RH
front inlet hose.
NotePlug hose connections.
-
Release the clip that
attaches the HV battery RH front inlet hose to the skid plate.
-
Position the coolant drain
container underneath the RH front of the HV battery.
-
Disconnect the PT return
hose at the RH front side of the vehicle.
NotePlug hose connections.
-
Release the clip that
attaches the PT return hose to the RH front side of the HV battery
pack.
-
Release the PT coolant hose
from the LH side of the front HV battery bash plate.
-
Position the coolant drain
container underneath the LH rear side of the HV battery.
-
Remove the RDU inverter
inlet hose.
NoteRotate the hose between the subframe and battery out of the vehicle.
-
Disconnect the compressor HV
harness from the HV battery.
NoteHold down the red locking tab, and the disengage the release lever. Do not force the release lever up.
-
Release the clips (x4) that
attach the compressor HV harness to the HV battery.
-
Release the RDU oil cooler
outlet pipe.
NotePlug hose connections.
-
Remove the RDU oil cooler
outlet pipe.
NoteRotate the pipe down over the RDU and rearward around the subframe.
- Remove the coolant drain container from underneath the vehicle.
-
Release the RDU HV cable
bracket from the RDU.
-
Disconnect the RDU HV cable
from the RDU.
NoteRelease the locking tab, and then rotate the release lever up to disengage the connector. Do not force the release lever up.
-
Remove the RDU HV
cable.
NoteRotate the cable underneath the logic cable harness between the subframe and the HV battery.
-
Remove the smaller bolts of
the LH and RH shear plates.
-
Loosen the large bolt that
attaches the LH shear plate and subframe to the body and rotate the shear
plate clear of the HV battery.
NoteHand tighten the bolt once the shear plate is in position.
-
Loosen the large bolt that
attaches the RH shear plate and subframe to the body and rotate the shear
plate clear of the HV battery.
NoteHand tighten the bolt once the shear plate is in position.
-
Put the battery table into
position and lower vehicle to support the battery.
NoteAssistance is recommended. Line up the table so the bolts at the front bash plate are accessible and the rear HV cables are accessible. Adjust the final battery table position using adjustable caster jacks on the table.
-
Loosen the front bolts that
attach the HV battery through the skid plate cover with ratchet, and then
remove them with a battery powered drill.
-
Loosen the bolts that attach
the skid plate to the vehicle with a ratchet, and then remove them with a
battery powered drill.
-
Loosen the bolts that attach
the rear HV battery to the vehicle with a ratchet, and then remove them with
a battery powered drill.
-
Loosen the LH bolts that
attach the HV battery to the vehicle with a ratchet, and then remove them
with a battery powered drill.
-
Loosen the RH bolts that
attach the HV battery to the vehicle with a ratchet, and then remove them
with a battery powered drill.
-
Raise the vehicle to free it
from the HV battery.
NoteAssistance is recommended.
-
Remove the battery from
under the vehicle.
NoteAssistance is recommended.
Install
-
Inspect and clean the wade
seal on the HV battery prior to installation.
If the wade seal is damaged, rework or replace the seal.
- If the damage is less than 25 mm, rework the wade seal. See Wade Seal - HV Battery (Structural Pack) (Rework).
- If the damage is more than 25 mm, replace the wade seal. See Wade Seal - HV Battery (Structural Pack) (Remove and Replace).
- If there is no damage, clean the seal with water and dry the surface completely.
-
Clean the HV connector
contact surface of any residual Penetrox.
NoteAllow 1 minute dry time after removing Penetrox. New busbar comes with Penetrox applied to the HV connector.
-
Clean the busbar HV
connector contact surface of any residual Penetrox.
NoteAllow 1 minute dry time after removing Penetrox. It is necessary to clean the HV connector during re-use of the busbar.
-
Apply Penetrox onto the HV
connector joints.
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads. Spread evenly to ensure that the contact surface is fully covered.
-
Install the HV battery
alignment rods (x2) onto the body.
NoteOnly use the smaller rods. Thread onto RH front most and LH rear most side holes.
-
Position the HV battery pack
under the vehicle.
NoteAssistance is recommended.
-
Carefully lower the vehicle
onto the HV battery pack and align the battery holes with the rods.
NoteAssistance is recommended. Make sure that coolant hoses and harnesses do not get pinched.
-
Remove the HV battery
alignment rods from the body once the HV battery is aligned.
-
Thread in by hand all bolts
that attach the HV battery to the vehicle. Do not install bolts to the shear
plates yet.
Note34x bolts. Includes top bolts. Start with bolts nr. 35-36-37-38 Ensure smooth thread engagement and bolts are not cross threaded into the casting.
-
Completely lower the vehicle
onto the battery pack.
NoteAssistance is recommended.
-
Seat all bolts (x34) that
attach the HV battery to the vehicle with a battery powered drill.
NoteEnsure smooth thread engagement and bolts are not cross threaded into the casting. Flush down the bolts. Do not over tighten bolts, fully torque them at later steps.
-
Fully torque the LH bolts
(x7) that attach the HV battery to the vehicle (torque 56 Nm).
NoteBolt position 1-7.
-
Fully torque the RH bolts
(x7) that attach the HV battery to the vehicle (torque 56 Nm).
NoteBolt position 16-22.
-
Fully torque the rear bolts
(x4) that attach the HV battery to the vehicle (torque 62 Nm).
NoteBolt position 10-13.
-
Fully torque the front bolts
(x6) that attach the HV battery through the bash plate openings (torque 90
Nm).
NoteLater production vehicles have E14 bolts torqued at 75 Nm. Bolt location 23 to 28.
-
Fully torque the front bolts
(x6) that attach the bash plate to the vehicle (torque 62 Nm).
NoteBolt location 29-34.
-
Loosen the RH rear subframe
bolt and align the RH rear shear plate with the HV battery.
NoteHand tighten bolt once the shear plate is in position.
-
Install the bolts that
attach the RH shear plate to the HV battery hand tight.
-
Torque the large bolt that
attaches the subframe and RH rear shear plate to the body (torque 130
Nm).
-
Torque the 2 smaller bolts
that attach the RH rear shear plate to the body (torque 62 Nm).
- Repeat steps 42 through 45 on the LH side of the vehicle.
-
Open the LH rear door.
NoteUse caution while working around this area not to damage any components.
-
Fully torque the LH rear
inner bolts (x2) that attach the HV battery pack to the vehicle (torque 49
Nm).
NoteBolt position 35-36.
-
Visually inspect the wade
seal to make sure that no gaps are present.
-
Close LH rear door.
NoteDo not latch the door.
-
Open the RH rear door.
NoteUse caution while working around this area not to damage any components
-
Fully torque the RH rear
inner bolts that attach the HV battery pack to vehicle (torque 49 Nm).
NoteBolt position 37-38.
-
Close RH rear door
NoteDo not latch the door.
- Raise vehicle and lower onto locks, then remove the battery table from under the vehicle.
-
Position the RDU HV cable up
to the RDU.
NoteRotate cable underneath logic cable harness between subframe and HV battery.
-
Connect the RDU HV cable
onto the RDU.
NoteVerify lever is in the upright and open position, then carefully seat connector and allow the lever to engage. Fully secure lever and verify red tab is locked. Do not damage any pins.
-
Secure the RDU HV harness
onto the HV battery.
NoteVerify lever is in the upright and open position, then carefully seat the connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked. Do not damage any pins.
-
Install the bolt that
attaches the RDU HV cable bracket to the RDU (torque 6 Nm).
-
Install the RDU oil cooler
outlet pipe.
NoteRotate up over the RDU and rearward around the subframe to oil cooler.
-
Attach the RDU oil cooler
outlet pipe.
Note2x spring clips, 5x clips. Remove plugs as needed
-
Attach the compressor HV
harness to the HV battery.
Note4x clips
-
Connect the compressor HV
harness onto the HV battery.
NoteVerify that the lever is in the upright and open position, then carefully seat the connector and allow the lever to engage. Fully secure lever and verify that the red tab is locked.
-
Install the RDU inverter
inlet hose.
Note2x spring clip, 1x clip. Rotate between subframe and battery into the RDU and PCS outlet. Remove plugs as needed.
-
Attach the RDU inverter
inlet hose to the RDU HV cable.
Note1x clip
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
-
Position a coolant drain
container underneath the LH front of the HV battery.
-
Connect the PT supply hose
at the LH front side of the vehicle.
Note1x spring clip. Remove plugs as needed.
-
Attach the PT coolant hose
onto the LH side of the front HV battery bash plate.
Note1x clip
-
Position the coolant drain
container underneath the RH front of the HV battery.
-
Connect the PT return hose
at the RH front side of vehicle.
Note1x spring clip. Remove plugs as needed.
-
Attach the PT return hose to
the RH front side of the HV battery pack.
Note1x clip
-
Connect the HV battery RH
front inlet hose.
Note1x spring clip. Remove plugs as needed.
-
Attach the HV battery RH
front inlet hose to the skid plate.
Note1x clip
-
Position the coolant drain
container underneath the front left manifold battery supply tube.
-
Connect the front left
manifold battery supply tube.
Note1x spring clip, 1x clip. Remove plugs as needed.
- Remove the coolant drain container from underneath the vehicle.
-
Release the LH front wheel
liner from the bungee strap.
-
Release the RH front wheel
liner from the bungee strap.
- Install the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
-
Fully lower the vehicle, and
then push the vehicle away from the lift.
NoteAssistance is recommended. Place wheel chocks to prevent the vehicle from moving. Note that this vehicle can only be safely pushed for a very short distance and at very slow speed.
-
Open all doors
NoteLatch rear doors to prevent accidental closure
-
Connect the LV power
connector to the HV battery.
NotePush the red locking tab down to secure the connection.
-
Remove the HVC logic cap,
and then connect HVC logic connector.
NotePivot the handle upward to engage the connector and secure the locking tab.
-
Position the busbar kit
connector and lower it onto the HV header.
-
Install the bolts (x2) that
attach the charge port busbar kit to the HV Header (torque 9 Nm).
-
Put on HV insulating gloves
and leather over gloves.
NoteCheck gloves for damage and expiry details. Refer to Service Document TN-15-92-003 for further details.
-
Perform a Hioki resistance
test at each HV joint from HV busbar lead to bolt head.
NoteThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed; proceed to the next step.
- Remove leather over gloves and HV insulating gloves.
-
Install the bolt that
attaches the busbar cover access door (torque 9 Nm).
-
Install the LH body harness
onto the rear body.
-
Connect the 3-phase
connector onto the HV battery.
NotePivot the handle downwards to engage the connector and secure the locking tab.
-
Attach the 2nd row 60 seat
connector to the LH seat frame.
Note1x clip.
-
Remove the tape from the
seat frame.
-
Install the bolts (x4) that
attach the LH and RH lower IP carrier brackets (torque 25 Nm)..
-
Install the center console
harness to the HV battery.
Note1x clip.
- Install the center console. See Center Console (2.0) (Structural Pack) (Remove and Install).
- Install the seats and the interior carpet to the vehicle. See Carpet - Interior Complete (Remove and Replace).
- Perform a vacuum refill of the cooling system. See Cooling System (Vacuum Refill).
- Connect LV power. See 12V/LV Power (Disconnect and Connect).
- Press and hold the Park button to exit EPB service mode.
-
Access the thermal system
routines using the UI: Select
.
- Unlock the vehicle gateway. See Gateway (Unlock).
-
Perform a coolant purge from
the touchscreen.
NoteTouch time only. Wait until coolant pumps stop running (audible noise), "Routine Passed" appears, but pumps will run for 10 minutes. If you start another routine during this time, it will fail. Make sure vehicle is not in "Drive". Routine is still running despite the completed message. Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM. The rest will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL. Putting the vehicle into "Drive" will stop this routine. If speeds hover at 7000 RPM, this indicates the pumps are air locked; perform a vacuum fill. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
-
Inspect the coolant level at
the reservoir and top off as necessary.
NoteEnsure coolant is filled using G-48 coolant.
-
Install the coolant bottle
cap.
-
Perform the Thermal
Performance Test using the touchscreen: touch Run and allow
the routine to complete.
, touch
-
Exit Service Mode through
the touchscreen.
- Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
-
Remove the lift pad adapters
from LH and RH rocker panel.
Note2x lift pad adapters per side.
-
Install butyl patches onto
the LH and RH rocker panel access holes.
Note2x butyl patches per side. Apply pressure along patch to verify it is fully secured to body. Use new butyl patches if needed, Roughly 2" x 2 1/2"
- Install the LH and RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
- Install the LH and RH rocker panel covers onto the rocker panel carrier. See Cover - Rocker Panel - Lower - LH (Remove and Replace).