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.
注
Release 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.
注
Use 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.
注
Release the locking
tab, then pivot the handle downward to release connector.
Disconnect the LV power
connector from the HV battery.
Close all doors.
注
Latch 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.
注
Plug the hose
connections.
Position the coolant drain
container underneath the LH RDU area.
注
Position 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.
注
Plug 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.
注
Plug hose
connections.
Position the coolant drain
container underneath the RH front of the HV battery.
Disconnect the HV battery RH
front inlet hose.
注
Plug 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.
注
Plug 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.
注
Rotate the hose between
the subframe and battery out of the vehicle.
Disconnect the compressor HV
harness from the HV battery.
注
Hold 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.
注
Plug hose
connections.
Remove the RDU oil cooler
outlet pipe.
注
Rotate 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.
注
Release 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.
注
Rotate 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.
注
Hand 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.
注
Hand tighten the bolt
once the shear plate is in position.
Put the battery table into
position and lower vehicle to support the battery.
注
Assistance 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.
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.
注
Allow 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.
注
Allow 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.
注
Apply 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.
注
Only use the smaller
rods. Thread onto RH front most and LH rear most side holes.
Position the HV battery pack
under the vehicle.
注
Assistance is
recommended.
Carefully lower the vehicle
onto the HV battery pack and align the battery holes with the rods.
注
Assistance 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.
注
34x 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.
注
Assistance is
recommended.
Seat all bolts (x34) that
attach the HV battery to the vehicle with a battery powered drill.
注
Ensure 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).
注
Bolt position
1-7.
Fully torque the RH bolts
(x7) that attach the HV battery to the vehicle (torque 56 Nm).
注
Bolt position
16-22.
Fully torque the rear bolts
(x4) that attach the HV battery to the vehicle (torque 62 Nm).
注
Bolt position
10-13.
Fully torque the front bolts
(x6) that attach the HV battery through the bash plate openings (torque 90
Nm).
注
Later 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).
注
Bolt location
29-34.
Loosen the RH rear subframe
bolt and align the RH rear shear plate with the HV battery.
注
Hand 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.
注
Use 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).
注
Bolt position
35-36.
Visually inspect the wade
seal to make sure that no gaps are present.
Close LH rear door.
注
Do not latch the
door.
Open the RH rear door.
注
Use 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).
注
Bolt position
37-38.
Close RH rear door
注
Do 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.
注
Rotate cable underneath
logic cable harness between subframe and HV battery.
Connect the RDU HV cable
onto the RDU.
注
Verify 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.
注
Verify 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.
注
Rotate up over the RDU
and rearward around the subframe to oil cooler.
Attach the RDU oil cooler
outlet pipe.
注
2x spring clips, 5x
clips. Remove plugs as needed
Attach the compressor HV
harness to the HV battery.
注
4x clips
Connect the compressor HV
harness onto the HV battery.
注
Verify 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.
注
2x 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.
Fully lower the vehicle, and
then push the vehicle away from the lift.
注
Assistance 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
注
Latch rear doors to
prevent accidental closure
Connect the LV power
connector to the HV battery.
注
Push the red locking
tab down to secure the connection.
Remove the HVC logic cap,
and then connect HVC logic connector.
注
Pivot 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.
注
Check 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.
注
The 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.
注
Pivot the handle
downwards to engage the connector and secure the locking tab.
Attach the 2nd row 60 seat
connector to the LH seat frame.
注
1x 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.
Touch 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.
注
Ensure coolant is
filled using G-48 coolant.
Install the coolant bottle
cap.
Perform the Thermal
Performance Test using the touchscreen: touch Thermal > Actions > Test Thermal
Performance > Start, touch Run and allow
the routine to complete.
校正代码
16010131 4.14 注意：除非本程序中另有明确规定，否则上述校正代码和 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。要提供有关 FRT 值的反馈，请发送电子邮件至LaborTimeFeedback@tesla.com。注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。
