my Tesla Model S Original (2012-2020) has a strong chemical smell what's happening

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

3 min read

541 words

⚠️ Safety Warning

This issue requires immediate attention. If you are not experienced with automotive repairs, consult a professional mechanic. Working on critical systems can be dangerous.

Problem Statement

Learn how to diagnose and fix a strong chemical smell in Tesla Model S (2012-2020). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Cooling System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the high-voltage battery before performing any repairs or inspections to prevent electric shock.
•Allow the vehicle to cool down before working on the battery or cooling system.

Symptoms

•Strong chemical odor, possibly resembling burnt plastic or electronics
•Increased cabin odor when the vehicle is operating
•Possible decrease in power or performance during driving
•Warning messages on the dashboard related to battery or charging
•Overheating of the battery pack or electric components

Diagnostic Steps

1
Inspect the vehicle for any visible signs of damage or leakage, particularly around the battery pack and wiring.
2
Use the vehicle's onboard diagnostics to check for any warning messages or error codes related to the battery or charging system.
3
Check the battery coolant levels and inspect the cooling system for leaks or blockages.
4
Examine the battery pack for any signs of swelling, damage, or corrosion on terminals.
5
Assess the condition of any wiring or connectors associated with the battery and charging system.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Socket set
•Torque wrench
•Coolant filling tool
•Multimeter

Parts Required

•Tesla-approved coolant
•Replacement hoses or connectors (if damaged)
•Battery pack (if failure is confirmed)

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Symptoms

•Strong chemical odor, possibly resembling burnt plastic or electronics

•Increased cabin odor when the vehicle is operating

•Possible decrease in power or performance during driving

•Warning messages on the dashboard related to battery or charging

•Overheating of the battery pack or electric components

Diagnostic Steps

1
Inspect the vehicle for any visible signs of damage or leakage, particularly around the battery pack and wiring.
2
Use the vehicle's onboard diagnostics to check for any warning messages or error codes related to the battery or charging system.
3
Check the battery coolant levels and inspect the cooling system for leaks or blockages.
4
Examine the battery pack for any signs of swelling, damage, or corrosion on terminals.
5
Assess the condition of any wiring or connectors associated with the battery and charging system.

Solution

1. Preparation

Ensure the vehicle is parked on a flat surface and is powered down.
Disconnect the high-voltage battery system by following the manufacturer's instructions for the Model S.
Wear appropriate personal protective equipment (PPE) such as gloves and safety glasses.

2. Inspect and Repair Battery Cooling System

Sub-steps:
1. Locate the battery cooling reservoir and check the coolant level. If low, top off with Tesla-approved coolant.
2. Inspect the hoses and connectors for leaks; replace any damaged components.
3. Remove the battery pack cover if necessary to inspect the internal cooling system for blockages or damage.
4. Clean any debris from the cooling fins and ensure airflow is unobstructed.

3. Address Chemical Smell Source

Sub-steps:
1. If the battery pack shows signs of swelling or damage, contact Tesla service for battery replacement.
2. If there are damaged wires or connectors, replace them with OEM parts.
3. Inspect the electric motor and inverter for overheating signs, and replace any components as necessary.

4. Reassemble Components

Sub-steps:
1. Reinstall any covers or components removed during inspection.
2. Ensure all connections are secured and torque bolts to manufacturer specifications, typically around 10-15 Nm.
3. Refill any coolant as needed and ensure the system is properly sealed.