why does my Tesla Model S Original (2012-2020) have a burning smell when driving?

Tesla Model S Plaid/Refresh (2021-present)

Error Codes

2-4 hours

Time

medium

Difficulty

high

Severity

3 min read

552 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 to diagnose and fix the burning smell issue in Tesla Model S (2012-2020). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Brakes

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical systems to prevent shock.
•Allow the vehicle to cool before inspecting brake components to avoid burns.

Symptoms

•Burning smell noticeable inside the cabin
•Reduced braking performance
•Unusual sounds from the brake system (squealing or grinding)
•Warning lights illuminated on the dashboard
•Increased heat from brake components
•Potential issues with battery temperature or performance

Diagnostic Steps

1
Inspect the brake system for signs of wear or overheating, including brake pads and rotors.
2
Check for any visible electrical issues, such as exposed wiring or burnt connectors.
3
Use an OBD-II scanner to check for any error codes related to the vehicle's systems.
4
Inspect the battery compartment for signs of thermal runaway or overheating.
5
Examine the drivetrain components for any signs of friction or overheating.
6
Perform a visual inspection of the motor and associated wiring for any damage.

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
•Multimeter
•Brake cleaner
•Dielectric grease

Parts Required

•Brake pads
•Brake rotors (if necessary)
•Electrical connectors (if damaged)
•Battery cooling fluid

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Diagnostic Steps

1
Inspect the brake system for signs of wear or overheating, including brake pads and rotors.
2
Check for any visible electrical issues, such as exposed wiring or burnt connectors.
3
Use an OBD-II scanner to check for any error codes related to the vehicle's systems.
4
Inspect the battery compartment for signs of thermal runaway or overheating.
5
Examine the drivetrain components for any signs of friction or overheating.
6
Perform a visual inspection of the motor and associated wiring for any damage.

Solution

1. Preparation

Gather tools and parts needed for inspection and repair.
Ensure vehicle is parked on a flat surface and turned off.
Disconnect the battery to prevent electrical shock (if working on electrical systems).

2. Inspect and Replace Brake Components

Inspect Brake Pads and Rotors:
- Remove the wheel using a socket set.
- Inspect brake pads for wear; replace if less than 3mm thick.
- Check rotors for warping or scoring; machine or replace if damaged.
Replace Brake Pads:
- Remove the caliper using a torque wrench.
- Replace old brake pads with new ones, ensuring proper orientation.
- Reinstall the caliper and torque to manufacturer specifications.

3. Check Electrical Connections

Inspect Wiring:
- Visually inspect all wiring around the battery and motor for signs of fraying or melting.
- Replace any damaged wires with the appropriate gauge wire.
Clean Connectors:
- Disconnect and clean any corroded electrical connectors.
- Apply dielectric grease to prevent future corrosion.

4. Battery Inspection

Check Battery Cooling:
- Inspect the battery cooling system for blockages or leaks.
- Clean any debris from the battery cooling vents.
Replace Battery Cooling Fluid:
- Drain and replace battery cooling fluid if contaminated or low.

5. Test Drive

Conduct a test drive to ensure the burning smell is no longer present and the vehicle operates normally.