Tesla Model S: HV Rapid Mate Vehicle Side (Remove and Replace)
Removal
- Remove the HV battery assembly(refer to procedure).
- Lower the vehicle, but keep it in position to raise it in a
later step.
- Remove the 2nd row seat cushion frame (refer to procedure) .
- Remove the high voltage junction box (HVJB) cover:
- 1st Generation, refer to procedure
- 2nd Generation, refer to procedure
- Mark the HV cables from the drive inverter appropriately as
positive and negative.
- 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).
- 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.
- Raise and support the vehicle (refer to procedure).
Note: The following steps are performed from beneath the
vehicle.
- Release the bolt that secures the ground strap to the vehicle
(torque 6 Nm).
- Remove the 2 bolts that secure the Rapid Mate connector to the
body (torque 9 Nm).
- Remove the 2 bolts that secure the plastic cover to the body
(torque 6 Nm).
- Pull the HV cables out of the vehicle and remove the Rapid Mate
assembly.
Installation
Installation procedure is the reverse of removal.
READ NEXT:
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
SEE MORE:
Warning: To avoid personal injury, wear cut-resistant
gloves when performing this operation.
Note: Use Dow Betaseal Express or an equivalent fast-curing
glass adhesive to perform this procedure.
Special tool recommended for this procedure:
Supplier
Warning: "Jack mode" must
be activated on vehicles with air suspension before lifting the
vehicle. Failure to do this might lead to suspension damage and
could cause serious personal injury.
Note: Vehicles with air
suspension might need the suspension to be set to "High" or "Very