29/09/2024 00:01:42
高压电池(后轮驱动)(结构化电池组)(三相)(拆卸和安装)
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)。
- 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 - 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
。
拆卸
- 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。
- 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(结构化电池组)(排放和重新加注).
注Select Run. Close once the routine is completed., then touch
- 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).
-
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
2-post lift.
注Assistance 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 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.
- Remove the front aero shield panel. See 面板 - 流线型护板 - 前(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.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.
-
Raise the vehicle to free it
from the HV battery.
注Assistance is recommended.
-
Remove the battery from
under the vehicle.
注Assistance is recommended.
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。
-
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.
-
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.
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 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.
注1x clip.
- 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).
- Perform a vacuum refill of the cooling system. See 冷却系统(真空重新加注).
- Connect LV power. See 12V/低压电源(断开和连接).
- 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
-
Exit Service Mode through
the touchscreen.
- 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 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"
- 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).