Correction code NEW NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

1. Open tailgate
   Note

   Press button to release

   

2. Open LH front door
   Note

   Push LH B-pillar door trigger to release

   

   

3. Lower LH front window

   

4. Open powered front trunk
   Note

   Via exterior switch or UI

   

   

5. Using MCU open charge port door

   

6. Power down vehicle via UI
   Note

   Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off

   

7. Remove rear underhood apron
   Note

   9x clips

   

   

8. Disconnect FRL connector then disconnect MV battery connector
   Note

   2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules

   

   

   

9. Verify operation of multimeter
   Note

   Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals

   

   

10. Remove all items from pockets and ensure not wearing metal items

    

11. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003

    

12. Put on HV insulating gloves and leather over gloves

    

13. Verify there is no high voltage present at the charge port
    Note

    Measure B+ to B-, and B+ to Ground and B - to Ground, Place Alligator clip onto body panel

    

    

    

    

14. Remove leather over gloves and HV insulating gloves
15. Remove both LH rear fore and aft fender flares
    Note

    12 clips, 9x tabs

    

16. Remove clips securing LH rear wheel liner to aft fender flare carrier
    Note

    2x clips

    

17. Remove LH rear aft fender flare carrier
    Note

    2x bolts, 10mm, 7 Nm, 2x datum

    

    

18. Remove clips securing LH rear wheel liner to fore fender flare carrier
    Note

    5x clips

    

    

19. Remove LH rear fore fender flare carrier
    Note

    6x bolts, 10mm, 7 Nm, 1x connector, Disconnect BLE module then remove carrier, Release locking tab

    

    

    

20. Remove fastener covers from bed floor assembly
    Note

    14x covers

    

    

    

    

    

21. Remove bed floor assembly
    Note

    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance

    

    

    

    

22. Remove LH sail applique
    Note

    15x clips, 1x connector, 1x harness clip, Lift rear edge first to remove connector and harness clip

    

    

    

    

23. Remove LH upper bed side wall assembly
    Note

    13x clips, Start from rear, Pull from the bottom downwards

    

    

24. Remove LH bed closeout panel
    Note

    6x clips, 1x tab, Release LH tailgate cable by disengaging lock spring from bolt and sliding cable eyelet off to allow removal of bed closeout panel from vehicle

    

    

    

    

25. Remove LH lower bed side wall
    Note

    2x bolt, 15mm, 25 Nm, 4x bolts, 10mm, 11 Nm, 4x nuts, 10mm, 10 Nm, 1x connector, 4x L track fastener covers

    

    

    

    

    

    

    

26. Remove bolt securing busbar HV connector lid
    Note

    1x bolt, EP10, 9 Nm

    

27. Remove bolts securing HV connector to DC FC header
    Note

    2x bolts, 10mm, 9 Nm

    

28. Release HV connector from DC FC header
    Note

    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly

    

29. Remove connector from chargeport assembly
    Note

    1x connectors, Remove white locking tab, Depress tab to release connection from the charge port, Continue to pull off connector, The charge port connection is intended to disengage safety cap when released, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector

    

30. Remove chargeport door and LV connector
    Note

    2x connector, 1x clip

    

31. Remove bolt securing ground cable to busbar assembly
    Note

    1x bolt, 10mm, 6.5 Nm

    

32. Release chargeport from outer sail
    Note

    1x bolt, 10mm, 6.5 Nm

    

33. Remove bolts securing chargeport assembly onto body
    Note

    2x bolts, 10mm, 6 Nm, Use only hand tools, Risk of galling if power tools used on stainless fasteners

    

34. Remove chargeport and busbar from vehicle

    

    

35. Clean HV connector contact surface of residual Penetrox
    Note

    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector

    

36. Apply Penetrox onto HV connector joints
    Note

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

    

37. Position chargeport busbar assembly onto vehicle

    

    

38. Install bolts securing charge port busbar kit to HV Header
    Note

    2x bolts, 10mm, 9 Nm

    

39. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Note

    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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), stop work and escalate the Toolbox session.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), hioki test passed, proceed to next step

    

    

40. Install bolts securing chargeport assembly onto body
    Note

    2x bolts, 10mm, 6 Nm, Use only hand tools, Risk of galling if power tools are used on stainless fasteners

    

41. Install chargeport to outer sail
    Note

    1x bolt, 10mm, 6.5 Nm

    

42. Install busbar ground bolt
    Note

    1x bolt, 10mm, 6.5 Nm

    

43. Install chargeport door and LV connector
    Note

    2x connectors, 1x clip

    

44. Engage charge port connector
    Note

    1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place

    

45. Install LH lower bed side wall
    Note

    2x bolt, 15mm, 25 Nm, 4x bolts, 10mm, 11 Nm, 4x nuts, 10mm, 10 Nm, 1x connector, 4x L track fastener covers

    

    

    

    

    

    

    

    

46. Install LH bed closeout panel
    Note

    6x clips, 1x tab, Secure LH tailgate cable once closeout installed

    

    

    

47. Install LH upper bed side wall assembly
    Note

    13x clips, Replace any missing or damaged clips, Lift tonneau seal as required

    

    

48. Install LH sail applique
    Note

    15x clips, 1x connector, 1x harness clip, Replace any broken clips

    

    

49. Install bed floor assembly
    Note

    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance

    

    

    

    

    

50. Install fastener covers onto bed floor assembly
    Note

    14x covers

    

    

    

    

51. Install LH rear fore fender flare carrier
    Note

    6x bolts, 10mm, 7 Nm, 1x connector, Connect BLE then install carrier, Engage locking tab

    

    

    

52. Install clips securing LH rear wheel liner to fore fender flare carrier
    Note

    5x clips

    

    

53. Install clips securing LH rear wheel liner to aft fender flare carrier
    Note

    2x clips

    

54. Install both LH rear fore and aft fender flares
    Note

    12 clips, 9x tabs

    

55. Connect FRL connector then connect MV battery connector
    Note

    2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down

    

    

    

56. Install rear underhood apron
    Note

    9x clips, Adjust windshield seal as required

    

    

57. Close powered front trunk
    Note

    Via exterior switch or UI

    

58. Raise LH front window

    

59. Close LH front door

    

60. Close tailgate