01/04/2024 14:04:55

Ski - Center Rail - HV Battery (Dual Motor) (Remove and Replace)

Correction code 16102612 1.38 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.

  • 2023-10-24: Updated with center rail ski orientation steps.
  • 1140311-00-A Lever Lock, HV Connector, Model 3
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

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

  1. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  2. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  3. Remove the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  4. Remove the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  5. Position a coolant drain container below the HV battery manifold hose.
  6. Release the clip, disconnect the HV battery RH supply manifold from the HV battery LH supply manifold, and then immediately plug the male and female fittings.
  7. Remove the bolt that attaches the front drive unit HV harness to the front drive unit.
    Tip: Use of the following tool(s) is recommended:
    • EP10 socket
  8. Slide the release to unlock the front drive unit HV connector handle of the front drive unit to HV battery harness from the secured position.
  9. Fully raise the handle on the front drive unit HV connector.
  10. Remove the front drive unit HV connector from the front drive unit HV header.
  11. Release the bracket that attaches the HV connectors to the bulk head.
  12. Disconnect the PTC heater HV electrical harness, and then remove the PTC heater HV electrical harness from the connector bracket.
  13. Disconnect the A/C compressor HV electrical harness, and then remove the A/C compressor HV electrical harness from the connector bracket.
  14. Release the clips that attach the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then separate the bracket from the battery.
  15. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  16. Remove the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  17. Position the coolant drain under the RH rear of the HV battery.
  18. Release the clip, disconnect the RH inner HV battery return hose fitting from the RH end of the HV battery platter enclosure, and then quickly plug both the male and female fittings.
  19. Remove the coolant drain from under the vehicle.
  20. Slide the release to unlock the HV battery PTC heater and A/C compressor connector handle of the PTC heater and A/C compressor to HV battery harness from the secured position.
  21. Fully raise the handle on the HV battery PTC heater and A/C compressor connector.
  22. Remove the HV battery PTC heater and A/C compressor connector from the PTC heater and A/C compressor header.
  23. Release the clips that attach the RH inner HV battery return hose to the HV battery.
  24. Slide the release to unlock the HV battery front drive unit connector handle of the front drive unit to HV battery harness from the secured position.
  25. Fully raise the handle on the HV battery front drive unit connector.
  26. Remove the HV battery front drive unit connector from the HV battery header.
  27. If the center rail ski is being removed to replace the HV harnesses, use a paint pen to mark an "F" at the front end of the ski.
    Informational PurposesAn informational icon, calling your attention
    Note
    Some center rail skiis have an arrow stamped into the extrusion to indicate the front end.
  28. With an assistant, remove the bolts (x6) that attach the center rail ski to the HV battery.
    Tip: Use of the following tool(s) is recommended:
    • EP14 socket
  29. Remove the center rail ski from the vehicle.
  30. If the center rail ski is being replaced, set the replacement ski next to the ski just removed, and align the bolt through holes (x6) side by side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The ski appears to be symmetrical, but it is not.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the front pointing arrows stamped into skiis are side by side as well.
  31. Remove the cap cover at the front of the HV battery center rail ski.
  32. Remove the cap cover at the rear of the HV battery center rail ski.
  33. Remove the HV battery to front drive unit harness from the center of the HV battery center rail ski.
  34. Remove the PTC heater and A/C compressor electrical harnesses from the sides of the HV battery center rail ski.

Install

  1. Install the PTC heater and A/C compressor electrical harness into the sides of the HV battery center rail ski.
    Informational PurposesAn informational icon, calling your attention
    Note
    The end of the harness with 2 connectors goes to the front end of the center rail ski.
    Informational PurposesAn informational icon, calling your attention
    Note
    Some center rail skiis have an arrow stamped into the extrusion to indicate the front end.
  2. Install the HV battery to front drive unit harness into the center of the HV battery center rail ski.
    Informational PurposesAn informational icon, calling your attention
    Note
    The end of the harness with the plastic bracket goes to the front end of the center rail ski.
  3. Install the cap cover at the rear of the HV battery center rail ski.
  4. Install the cap cover at the front of the HV battery center rail ski.
  5. With an assistant, install the center rail ski to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    The end of the center rail ski with 3 connectors goes to the front of the vehicle.
  6. Install the bolts that attach the center rail ski to the HV battery.
    35 Nm (25.8 lbs-ft)
    32 Nm (23.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • EP14 socket
  7. If not already done so, use a paint pen to mark an "F" at the front end of the center rail ski.
  8. Fully raise the handle on the HV battery front drive unit connector of the front drive unit to HV battery harness.
  9. Install the HV connector special tool onto the HV battery front drive unit connector.
  10. Use both hands to firmly connect the HV battery front drive unit connector of the front drive unit to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  11. Remove the HV connector special tool from the HV battery front drive unit connector.
  12. While pressing the HV battery front drive unit connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  13. Slide the release to lock the HV battery front drive unit connector handle in the secured position.
  14. Verify that the HV battery front drive unit connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and front drive unit problems later on.
  15. Fully raise the handle on the HV battery PTC heater and A/C compressor connector of the PTC heater and A/C compressor to HV battery harness.
  16. Use both hands to firmly connect the HV battery PTC heater and A/C compressor connector of the PTC heater and A/C compressor to HV battery harness to the HV battery header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  17. While pressing the HV battery PTC heater and A/C compressor connector onto the HV battery header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  18. Slide the release to lock the HV battery PTC heater and A/C compressor connector handle in the secured position.
  19. Verify that the HV battery PTC heater and A/C compressor connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and PTC heater or A/C compressor problems later on.
  20. Position the coolant drain under the RH rear of the HV battery.
  21. Remove the plugs from the male and female fittings, quickly connect the RH inner HV battery return hose to the HV battery platter enclosure, and then fasten the clip.
  22. Remove the coolant drain from under the RH rear of the HV battery.
  23. Fasten the clips that attach the RH inner HV battery return hose to the HV battery.
  24. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  25. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  26. Install the PTC heater and A/C compressor electrical harness bracket to the front of the HV battery, and then fasten the clips that attach the bracket to the HV battery.
  27. Install the A/C HV electrical harness into the connector bracket, and then connect the A/C HV electrical harness.
  28. Install the PTC heater HV electrical harness into the connector bracket, and then connect the PTC heater HV electrical harness.
  29. Install the bracket that attaches the HV connectors to the bulk head.
  30. Position the coolant drain under the LH front of the HV battery.
  31. Remove the plugs from the HV battery RH supply manifold and the HV battery LH supply manifold, immediately connect the male and female fittings, and then fasten the clip.
  32. Install the front HV battery skid plate. See Skid Plate - HV Battery - Front (Remove and Replace).
  33. Fully raise the handle on the front drive unit HV connector of the front drive unit to HV battery harness.
  34. Install the HV connector special tool onto the front drive unit HV connector.
  35. Use both hands to firmly connect the front drive unit HV connector of the front drive unit to HV battery harness to the front drive unit HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  36. Remove the HV connector special tool from the front drive unit HV connector.
  37. While pressing the front drive unit HV connector onto the front drive unit HV header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  38. Slide the release to lock the front drive unit HV connector handle in the secured position.
  39. Verify that the front drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and front drive unit problems later on.
  40. Install the bolt that attaches the front drive unit HV harness to the front drive unit.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • EP10 socket
  41. Install the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  42. Remove the coolant bottle cap, and then fill the coolant to the "Max" level.
  43. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  44. Connect a laptop with Toolbox to the vehicle.
  45. In Toolbox, click the Actions/Autodiag tab, and then type "Purge" in the search field.
  46. Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeDrive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air PurgeDrive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air PurgeDrive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air PurgeDrive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air PurgeDrive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air PurgeDrive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air PurgeThermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge StartThermal ➜ Coolant System ➜ Coolant Purge Start, and then click Run.
  47. Click the "X" at the top right of the window once the routine is complete.
  48. Install the coolant bottle cap.
  49. Disconnect the laptop from the vehicle.
  50. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  51. Raise all the windows and close all the doors.