19/12/2023 03:21:50

Ski - Side Rail - HV Battery - LH (Remove and Replace)

Correction Code 16012302

  • 2023-12-19: Updated install procedure.
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Warning
Only technicians who have been trained in High Voltage (HV) 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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
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Note
This note is for vehicles equipped with HV batteries 2.0:

The original umbrella valves (1026758-00-* and 1091912-00-A) do not have a breather:

Newer umbrella valves (1517973-00-A and 1092155-00-B) have a breather in the 3rd position:

Perform the following based on the type of HV battery installed on the vehicle:
  • If the HV battery has a breather on the original bump cover (1055911-00-D) and/or several breathers installed along the side ski in the umbrella valve ganged assemblies, you can use the original or the newer umbrella valves.
  • If the HV battery does not have a breather on the newer bump cover (1055910-01-E), only install the newer umbrella valves.

Special tools required for this procedure:

Supplier Part Number Description Quantity
Tesla 1080513-00-A Grip Quick-Ratcheting Bar Clamp - 6 in. 2

Removal

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Note
This procedure shows pictures of the side rail ski on HV Battery 1.0/1.5. The procedure for HV Battery 2.0 is identical.
  1. Remove the HV Battery. See HV Battery (RWD/AWD) (Remove and Install) .
  2. Use clamps to secure the side ski on each side of the 2 front bolts.
    Tip: Place the clamps as close to the bolts as possible without blocking access.
  3. Remove and discard the 2 front bolts (torque 12 Nm).
  4. Release the clamp closest to the front of the HV battery and move it adjacent to the next remaining front bolt.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    It is necessary to keep constant pressure on the side ski adjacent to the bolt being removed to avoid damaging or stripping the bolt.
  5. Remove the next remaining front bolt (torque 12 Nm).
  6. Repeat steps 4 and 5 until all bolts (x10) are removed from the side ski.
  7. Pull the side ski away from the HV battery and pivot it downwards to remove it from the HV Battery.

Installation

Installation procedure is the reverse of removal, except for the following:

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Note
Clean the affected areas before installation.
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CAUTION
Replace all patchbolt(s).
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CAUTION
Use the clamps to keep constant pressure on the side ski adjacent to the bolt being installed to avoid damaging or stripping the bolt.
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Note
The new style side rail skis (black in color), designed for HV battery 2.0, can be mounted on HV batteries 1.5 (1096346-01-A). A modified version of this rail ski has been designed to fit on HV batteries 1.0 (1450645-01-A). HV batteries 1.0 have a cap welded to the HV battery enclosure, and HV batteries 1.5 have a metallic piece that can be removed.
  1. Make sure that no umbrella valves were damaged during removal of the side ski. Replace any damaged umbrella valves.
  2. Wipe the surface of the front side of the side rail ski with a clean cloth, and then install the silicone end foam seal on the front of each side rail ski.
  3. Install plastic front, mid, and rear side ski covers on both sides of the HV battery, securing them with push-pull clips.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The plastic side ski covers are necessary to protect the umbrella valves from road debris and water ingress. Do not return an HV battery to a customer without the side ski covers installed.
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    Note
    The push-pull clips that secure the side ski covers are one-time use. If removed, the push-pull clip should be discarded and replaced with a new push-pull clip.
  4. Clean the LH and RH front corners of the HV battery with a nylon brush and a shop towel, and then wipe the areas with an IPA wipe.
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    Note
    Allow 1 minute for the IPA to dry.
  5. On both sides of the HV battery, seal the gaps between the outer ski edge and the plastic cover and the gap between the inner side ski edge and the HV battery enclosure.