29/09/2024 00:01:46
高压电池(后轮驱动)(结构化电池组)(三相)(拆卸和更换)
校正代码 16010132 5.58 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)。
- 2024-09-11: Added step to support the LV system.
- 2024-06-13: Updated lift pad adapter PNs.
- 2023-11-21: Added new lift pad instructions.
- 2023-11-07: Updated UI steps and added references to wade seal procedures.
- 2023-06-01: Added Special Tools list.
- 2023-06-01: Corrected link to correct procedure for 中控台 (2.0)(结构化电池组)(拆卸和安装).
- 2023-05-22: Added conspicuous discharge warning table.
- 1936724-00-A - 通用举升机垫适配器
- 1020566-00-F 电池操作台手动升降机总成
- 1065131-00-A Battery Coolant Drain Kit
- 1108272-00-B 变流器逻辑连接器盖,3DU
- 1050448-00-B Coolant Vacuum Refill Tool
- 1754057-00-A Current Probe, Clamp, DC, 600V
- 1076927-00-A Hioki Tester
- 1129166-00-A H 型车架起重机,欧洲、中东和非洲
- 1133787-00-A Key, Seat Belt Release, Model 3
- 1134523-00-B Kit, Alignment Rods, Battery, M3
- 1133843-00-A 冷却液排放和加注适配器套件,M3
- 1479505-00-A Kit, M3 Vacuum Fill Coolant Adapter
- 1135762-00-A 冷却软管维修堵头套件,Model 3
- 1637160-00-A MYSP and Palladium Pack Lift Attachment
- 1076928-00-A Test Probes - Hioki 9461
- 1080589-00-A Wheel Chocks
警告
只有接受过高压安全意识培训并完成全部所需认证课程(如适用)的维修技工才允许执行此程序。处理高压线缆、母排或接头时,务必全程穿戴最低防护等级为 0 (1000V) 的适当个人防护装备 (PPE)及高压绝缘手套。有关其他安全信息,请参阅技术注意事项 TN-15-92-003,高压安全意识注意事项
。
Discharge
警告:为遵从当地法律规定,高压锂电池必须在放电后打包运输。此外,高压电池也必须在放电后进行存放。要进行运输的高压电池,其充电状态 (SoC) 必须小于 30% 或 50%(以地区规定为准)。如果运输方式未知或不确定,或者电池需要存放,则建议将高压电池放电至 30% 以下。
警告:切勿运输或存放已失去高压绝缘的高压电池。请先验证高压电池绝缘状况,再打包运输或进行存放。请参阅 Toolbox 文章#41977中所述的高压电池通信工具,以确定高压电池参数是否处于运输或存放的安全限值范围内。 |
注
如果可能,请在拆卸高压电池前执行放电程序。与拆下电池后使用电池放电工具相比,此方法用时更短,所需用户交互也较少。只有通过认证的技术人员才能使用电池放电工具。.
注
放电程序的步骤主要在维修时间进行,可由维修顾问/前台团队以及维修技术人员执行。.
- For Front of House and Service Advisors
-
Identify the vehicle SOC.
- If the SOC is less than the specified values, proceed with removal. See 拆卸.
- If the SOC is greater than the specified values, lower all of the vehicle windows and turn on the climate control system to maximum defrost. This setting will discharge the battery by approximately 10% SOC every hour.
- Move the vehicle to a location where it can safely continue to discharge the battery unattended.
- Identify the vehicle SOC every half-hour.
- When the SOC is below 50% for surface transport, or below 30% for air transport, turn off the climate control system, raise the windows, and then move the vehicle to the service bay.
- For Service Technicians
-
Identify the vehicle SOC Max
value.
- If the SOC Max value is less than the specified values, proceed with removal. See 拆卸.
- If the SOC Max value is greater than the specified values, continue to the next step.
- Move the vehicle to a location where it can safely discharge the battery unattended.
- Enable Service Mode Plus. See 维护模式增强版.
- On the vehicle touchscreen, touch .
-
Touch Start HV Discharge, and
then in the window that opens, touch Run.
注The discharge routine starts and will automatically stop when the SOC Max value for surface transport has been attained.
- After discharge is complete, move the vehicle to the service bay.
拆卸
- Verify that the vehicle software version is at 2023.20 or later, and if not, update to the latest version. See 软件更新.
- Remove the LH rocker panel carrier. See 支架 - 门槛板 - LH(拆卸和更换).
-
Remove the butyl patches (x2) that
cover the LH rocker access holes.
-
安装举升垫适配器。
- 仅适用于欧洲、中东和非洲:安装举升机垫适配器,Model Y (1614078-00-A)
- 其他地区:安装通用举升垫适配器 (1936724-00-A)。
警告请勿使用任何其他举升垫适配器。注欧洲、中东和非洲以外的地区:使用通用举升垫适配器 (1936724-00-A) 代替举升机垫适配器,Model Y (1614078-00-A)。请弃用任何其他版本的举升垫适配器。注通用举升垫适配器在欧洲、中东和非洲尚不可用。请确保在 Model Y 上使用 Model Y 橡胶举升垫,在 Model 3 上使用 Model 3 举升垫。通用举升垫适配器说明:
- 将与举升机类型相匹配的正确螺纹适配器安装到举升机适配器上。
- 确保将螺纹止动垫圈正确安装并紧固至举升机适配器底部。如果未安装螺纹止动垫圈,请勿继续使用举升机适配器。
- 将举升机适配器安装到举升臂上,使黑色的举升垫朝向车辆。警告确保适配器安装方向正确。
- 调整举升臂位置,使举升机适配器与车辆上的固定销孔对齐。
- 抬起举升臂,将举升垫完全放置到车辆上。
- 确保所有 4 个适配器均已完全就位在车辆上。
- Repeat steps 2 through 4 for the RH side of the vehicle.
- Open all doors and lower the windows.
- Release the LH and RH parking brake calipers. See 驻车制动 - 钳 - 后 - LH(释放).
-
Run the Thermal Fill Drain (Coolant
Only) routine using the touchscreen. See 冷却系统(非结构化电池组) (排放和重新加注).
注Select Run. Close once the routine is completed., then touch
- Disconnect the laptop from the vehicle.
- Remove the seats and the interior carpet from the vehicle. See 地毯 - 全套内饰(拆卸和更换).
- Remove the center console. See 中控台 (2.0)(结构化电池组)(拆卸和安装).
-
Remove LH riser side carpet support
bracket.
注2x tabs
-
Remove RH riser side carpet support
bracket
注2x tabs
-
Remove and discard the bolts (x4) that
attach the LH and RH center console lower rails.
-
Remove LH and RH floor ducts
注2x clips
-
Release the center console harness
from the HV battery.
注1x 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 lift.
注Recommend assistance. 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
举升车辆 - 双柱举升机.
注Verify 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.
注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 the front aero shield panel. See 面板 - 流线型护板 - 前(非结构化电池组) (拆卸和更换).
-
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 面板 - 流线型护板 - 中间(拆卸和更换).
- 执行车辆高压禁用程序。请参阅车辆高压禁用程序 (结构化电池组)。
- 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.
-
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 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.
-
Install the PCS flush adapter onto the
PT supply hose.
注Remove plugs as needed. Perform a push-pull-push test to make sure the adapter is fully seated.
-
Attach the coolant cart flush hose to
the regulator and PCS flush adapter.
注Make sure that the regulator valve is closed. The pressure regulator is not adjustable.
-
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.
-
Attach a compressed air line to the
coolant pressure tester.
注Make sure the valve on the pressure regulator is closed.
-
Slowly open the valve on the pressure
regulator and allow the coolant to completely drain.
注Keep an eye on all hose connections to verify there are no leaks from the tools.
-
Close the valve on the pressure
regulator when coolant has stopped draining from the RDU inverter inlet hose.
-
Disconnect the compressed air line
from the coolant pressure tester.
-
Position the coolant drain container
underneath the LH front of the HV battery.
-
Remove the PCS flush adapter from the
PT supply hose.
注Plug hose connections.
-
Remove the PT flush fitting adapter
from the cart pressure hose.
-
Position the coolant drain container
underneath the center front of the HV battery pack.
注Position underneath the front left manifold battery supply tube.
-
Disconnect the front left manifold
battery supply tube.
注Plug hose connections.
-
Attach the battery drain fitting
adapter onto the female front left manifold battery supply tube.
注Make sure that the valve is closed and that the adapter is locked to the manifold tube.
-
Attach the coolant cart flush hose to
the battery drain fitting adapter.
-
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.
-
Attach a compressed air line to the
coolant pressure tester.
注Make sure the valve on the pressure regulator is closed.
-
Open the valve on the battery drain
fitting adapter.
-
Slowly open the valve on the pressure
regulator and allow the coolant to completely drain.
注Keep an eye on all hose connections to verify there are no leaks from the tools.
-
Close the valve on the pressure
regulator once coolant has stopped draining from the HV battery RH front inlet
port.
-
Disconnect the compressed air line
from the coolant pressure tester.
-
Position the coolant drain container
underneath the center front of the HV battery pack.
注Position underneath the front left manifold battery supply tube.
-
Remove the battery drain fitting
adapter from the female front left manifold battery supply tube.
注Plug hose connections.
-
Remove the battery drain fitting
adapter from the cart drain hose.
-
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Recommend assistance. 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 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 V
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.
注Recommend assistance.
-
Remove the battery from under the
vehicle.
注Recommend assistance.
-
Release the PT supply tube from the
rear of the HV battery pack.
注Plug hose connections.
-
Remove the PT supply tube from the LH
side of the HV battery pack.
注Each clamp has 1x datum that need to be released from the bracket holes.
-
Remove the FDU dummy plug from the HV
battery pack.
注Disengage the locking tab, then release the connector body.
-
Remove the front left manifold battery
supply tube from the HV battery pack.
注Use a shop towel to clean any residue coolant as necessary. Plug hose connections.
-
Remove the PT return tube from the RH
side of the HV battery pack.
注Each clamp has 3x datums that need to be released from 3x bracket holes
-
Attach the HV battery H-frame to the
gantry and raise it into position.
-
Position the HV battery under the
gantry.
注Recommend assistance
-
Attach the P2 sling adapter onto the
HV battery pack.
注4x locking joints. The hoist is color coded and will come with instructions. Verify locking joints are fully secured, DO NOT secure the middle joints. Perform a push and pull test. If not properly secured, then top pin will be recessed. Take care to secure properly and safely.
-
Raise the HV battery pack off the
battery table.
-
Position the gantry over a
pallet.
注Recommend assistance
-
Lower the HV battery pack onto the
pallet.
-
Release the P2 battery sling adapter
from the HV battery pack.
注Push down on top pin to release.
-
Raise the gantry and H-frame from the
old HV battery pack.
-
Remove the logic cap from the old HV
battery pack.
安装
注
如果前车底 (FUB) 或后车底 (RUB) 铸件出现螺纹损坏,请参阅TN-15-92-001 - Installing Heli-Coil Inserts了解使用螺纹护套进行修复的说明。
警告
对于前车底或后车底上出现的螺纹损坏,仅可使用零件号为 TPN 1056157-09-A 的螺纹护套进行修复。
注
如果执行了螺纹修复,请将校正代码 70060005 - 螺纹修复作为一项单独工项添加至“服务工单”中。
-
Open the crate top of the crate that
contains the new HV battery pack.
注Recommend assistance.
-
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 涉水密封条 - 高压电池 (结构化电池组)(返工).
- If the damage is more than 25 mm, replace the wade seal. See 涉水密封条 - 高压电池 (结构化电池组)(拆卸和更换).
- If there is no damage, clean the seal with water and dry the surface completely.
-
Install the logic cap onto the new HV
battery pack.
-
Remove the fasteners that attach the
new HV battery pack to the crate/pallet.
-
Position the gantry and H-frame over
the crate, and then attach the P2 sling adapter to the new HV battery pack.
注4x locking joints. The hoist is color coded and comes with instructions. Make sure that the locking joints are fully secured. DO NOT secure the middle joints. Perform a push-pull test. If not properly secured, the top pin will be recessed. Take care to secure properly and safely.
-
Raise the new HV battery pack off the
crate.
注Recommend assistance.
-
Move the gantry away from the crate
and bring the HV battery table in position.
注Recommend assistance
-
Lower the HV battery pack onto the
battery table.
注Recommend assistance. Make sure to align the battery pack to the table with clear access to all bolt-to-body holes.
-
Release the P2 sling adapter from the
HV battery pack.
注4x locking joints. Push down on top pin to release.
-
Remove the HV battery pack from under
the gantry.
注Recommend assistance.
-
Position the gantry over the old HV
battery pack.
注Recommend assistance.
-
Lower the gantry and H-frame and
secure the P2 sling adapter to the old HV battery pack.
注4x locking joints. The hoist is color coded and comes with instructions. Make sure that the locking joints are fully secured. DO NOT secure the middle joints. Perform a push-pull test If not properly secured, the top pin will be recessed. Take care to secure properly and safely.
-
Raise the old HV battery pack above
height of crate.
-
Position the crate underneath the old
HV battery pack.
-
Lower the old HV battery pack onto the
crate.
注Recommend assistance.
-
Release the P2 sling adapter from the
old HV battery pack.
注4x locking joints. Push down on top pin to release.
-
Raise the gantry and H-frame from the
old HV battery pack.
-
Lower the gantry and remove the HV
battery H-frame from the gantry.
-
Install fasteners to attach the old HV
battery pack to the crate hand tight.
-
Close the crate top housing the old HV
battery pack.
注Recommend assistance
-
Install the PT return tube onto the RH
side of the HV battery pack.
注6x clamps, 6x brackets. Each clamp has 3x datums that need to be secured onto 3x bracket holes.
-
Install the front left manifold
battery supply tube onto the HV battery pack.
注1x spring clip, 3x clips. Remove plugs as needed.
-
Install the FDU dummy plug onto the HV
battery pack.
注Fully seat the connector body, then engage the locking latch.
-
Install the PT supply tube to the LH
side of the HV battery pack.
注6x clamps, 6x brackets. Each clamp has 1x datum that need to be secured to the bracket holes.
-
Attach the PT supply tube onto the
rear of the HV battery pack.
注1x spring clip, 2x clips. Remove plugs as needed.
-
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.
-
Inspect and clean the body side of the
HV battery wade seal interface.
注Clean with water and dry surface completely.
-
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Recommend assistance
-
Carefully lower the vehicle onto the
HV battery pack and align the battery holes with the rods.
注Recommend assistance. 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 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Recommend assistance.
-
Seat all bolts (x 34) 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 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.
注1x clip
- Install the mid aero shield panel. See 面板 - 流线型护板 - 中间(拆卸和更换).
-
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.
注1x spring clip. Remove plugs as needed.
-
Attach the PT coolant hose onto the LH
side of the front HV battery bash plate.
注1x 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.
注1x spring clip. Remove plugs as needed.
-
Attach the PT return hose to the RH
front side of the HV battery pack.
注1x clip
-
Connect the HV battery RH front inlet
hose.
注1x spring clip. Remove plugs as needed.
-
Attach the HV battery RH front inlet
hose to the skid plate.
注1x clip
-
Position the coolant drain container
underneath the center front of the HV battery pack.
注Position container underneath front left manifold battery supply tube.
-
Connect the front left manifold
battery supply tube.
注1x 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 面板 - 流线型护板 - 前(非结构化电池组) (拆卸和更换).
-
Fully lower the vehicle, and then push
the vehicle away from the lift.
注Recommend assistance. 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.
注1x clip.
-
Install the LH and RH floor
ducts.
-
Install new bolts (x4) that attach the
LH and RH center console lower rails (torque 4.5 Nm).
注Slide rails rearward to engage it onto center console riser assembly.
-
Install the LH riser side carpet
support bracket.
-
Install the RH riser side carpet
support bracket.
- Install the center console. See 中控台 (2.0)(结构化电池组)(拆卸和安装).
- Install the seats and the interior carpet to the vehicle. See 地毯 - 全套内饰(拆卸和更换).
- Connect LV power. See 12V/低压电源(断开和连接).
- Connect an LV maintainer to the vehicle, but do not disconnect the LV battery. See 低压维护设备(连接和断开).
- Perform a vacuum refill of the cooling system. See 冷却系统(真空重新加注).
- 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 网关(解锁).
-
Perform a coolant purge from the
touchscreen.
注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 Run and allow the routine to complete.
, touch
- Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3(连接和断开).
- Enable Service Mode Plus. See 维护模式增强版.
- On the vehicle touchscreen, touch .
- Under High-Voltage-Battery, touch High Voltage Battery Replacement.
- Under After High Voltage Battery Replacement, touch CAN ECU Redeploy, and then in the window that opens, touch Run.
- Under After High Voltage Battery Replacement, touch High Voltage Battery Replacement Routine, and then in the window that opens, touch Run.
- Disable Service Mode Plus. See 维护模式增强版.
- Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3(连接和断开).
-
Exit Service Mode through the
touchscreen.
- Disconnect the 12V/LV battery maintainer.
- Install the HEPA filter assembly. See 总成 - 过滤器 - 高效分子空气 (HEPA)(拆卸和更换).
- Install the rear underhood apron. See 前备箱挡板 - 后部(拆卸和更换).
-
Remove the lift pad adapters from the
LH and RH rocker panel.
注2x lift pad adapters per side.
-
Install butyl patches onto the LH and
RH rocker panel access holes.
注2x 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" (5 cm x 6.5 cm).
- Install the LH and RH rocker panel carrier. See 支架 - 门槛板 - LH(结构化电池组)(拆卸和更换).
- Install the LH and RH rocker panel covers onto the rocker panel carrier. See 盖板 - 门槛板 - 下 - LH(拆卸和更换).