Tesla Model S: HV Rapid Mate Vehicle Side (Remove and Replace)

Removal

1. Remove the HV battery assembly(refer to procedure).
2. Lower the vehicle, but keep it in position to raise it in a later step.
3. Remove the 2nd row seat cushion frame (refer to procedure) .
4. Remove the high voltage junction box (HVJB) cover:
   • 1st Generation, refer to procedure
   • 2nd Generation, refer to procedure
5. Mark the HV cables from the drive inverter appropriately as positive and negative.

   

6. Remove the 2 bolts at the rear of the HVJB that secure the HV cables from the drive inverter and HV battery (torque 9 Nm).

   

7. Pull the HV cables that lead to the HV battery out from the HVJB. Leave the HV cables that lead to the drive inverter in place.
8. Raise and support the vehicle (refer to procedure).

9. Release the bolt that secures the ground strap to the vehicle (torque 6 Nm).

   

10. Remove the 2 bolts that secure the Rapid Mate connector to the body (torque 9 Nm).

    

11. Remove the 2 bolts that secure the plastic cover to the body (torque 6 Nm).

    

12. Pull the HV cables out of the vehicle and remove the Rapid Mate assembly.

Installation procedure is the reverse of removal.

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