15/12/2023 01:35:43

HV Harness Assembly- Charge Port to HV Battery (Single-Phase) (Remove and Replace)

Correction code 44500502 0.78 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 LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2023-10-27: Update charge port to body bolt torque to 9 Nm.
  • 2023-10-10: Add a caution to not manually close the charge port door.
  • 1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Make sure that the HV gloves are not expired. HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12-month period.

Remove

  1. Open the trunk.
  2. Open the charge port door.
  3. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  6. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  7. Lift the HV cap straight up from over the DC input connector on the LH side of the ancillary bay, and then remove the HV cap from the vehicle.
  8. Remove the 2nd row LH seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  9. Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the ancillary bay.
  10. Remove the bolts that attach the charge port to HV battery harness bracket at the ancillary bay, and then remove the bracket from the vehicle.
  11. Slide the release to unlock the DC input connector handle of the charge port to HV battery harness from the secured position.
  12. Fully raise the handle on the DC input connector.
  13. Remove the DC input connector from the ancillary bay DC input header.
  14. Release the clip that attaches the charge port to HV battery harness to the LH lower C-pillar.
  15. Remove the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  16. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  17. Remove the rear trunk carpet. See Carpet - Rear Trunk (Remove and Replace).
  18. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  19. Release the edge clip that attaches the low voltage electrical harness to the charge port closeout panel.
  20. Disconnect the low voltage electrical harness from the charge port ECU connector.
  21. Release the clips that attach the charge port closeout panel to the charge port, and remove the panel from the charge port.
  22. Remove the bolt that grounds the charge port assembly to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is not necessary for the newer type of charge port to HV battery harnesses.
  23. Remove the bolts that attach the charge port assembly to the body.
  24. Release the clips that attach the low voltage electrical harness to the body and to the rear LH wheel well.
  25. Release the clips that attach the charge port to HV battery harness at the charge port.
  26. Remove the bolt that attaches the charge port to HV battery harness bracket on top of the rear LH wheel well.
    Informational PurposesAn informational icon, calling your attention
    Note
    The newer type of charge port to HV battery harness brackets have an integrated grounding lug.
  27. Release the clips (x5) that attach the low voltage electrical harness along the charge port to HV battery harness.
  28. Remove the bolt that attaches the charge port to HV battery harness bracket at the LH lower C-pillar.
  29. Release the clips (x3) that attach the charge port to HV battery harness on top of the rear LH wheel well and C-pillar, and then remove the harness from the vehicle.

Install

  1. If a newer type of charge port to HV battery harness is replacing an older type of harness in an older vehicle, prepare the rear LH wheel well by sanding off the E-coat from around the ground point.
  2. Install the charge port to HV battery harness into the vehicle, and then fasten the clips (x3) that attach the harness on top of the rear LH wheel well and C-pillar.
  3. Install the bolt that attaches the charge port to HV battery harness bracket at the LH lower C-pillar.
    6 Nm (4.4 lbs-ft)
  4. Fasten the clips (x5) that attach the low voltage electrical harness along the charge port to HV battery harness.
  5. Install the charge port to HV battery harness bracket on top of the rear LH wheel well, and then install the bolt that attaches the bracket to the wheel well.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The newer type of charge port to HV battery harness brackets have an integrated grounding lug.
  6. Fasten the clips that attach the charge port to HV battery harness at the charge port.
  7. Fasten the clips that attach the low voltage electrical harness to the body and to the rear LH wheel well.
  8. Install the charge port assembly to the body, and then install the bolts that attach the assembly to the body.
    9 Nm (6.6 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the harness is routed out, and the adhesive pad with zip tie is properly mounted if it is installed.
  9. Install the bolt that grounds the charge port assembly to the body.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    This step is not necessary for the newer type of charge port to HV battery harnesses.
  10. Install the charge port closeout panel to the charge port, and then fasten the clips that attach the panel to the charge port.
  11. Connect the low voltage electrical harness to the charge port ECU connector.
  12. Fasten the edge clip that attaches the low voltage electrical harness to the charge port closeout panel.
  13. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  14. Install the rear trunk carpet. See Carpet - Rear Trunk (Remove and Replace).
  15. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  16. Install the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  17. Fully raise the handle on the DC input connector of the charge port to HV battery harness.
  18. Use both hands to firmly connect the DC input connector of the charge port to HV battery harness to the ancillary bay DC input header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly.
  19. While pressing the DC input connector onto the DC input header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  20. Slide the release to lock the DC input connector handle in the secured position.
  21. Verfiy that the connector is fully seated, and compare both sides of the connector, that it is properly latched in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and charging problems later on.
  22. Fasten the clip that attaches the charge port electrical harness to the vehicle.
  23. Install the charge port to HV battery harness bracket to the body, and install the bolts that attach the bracket to the body.
    10 Nm (7.4 lbs-ft)
  24. Fasten the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the ancillary bay.
  25. Install the 2nd row LH seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  26. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  27. Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  28. Install the foam cover to the LH side of the ancillary bay.
  29. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  30. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  31. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  32. Reinstall the vehicle firmware. See Software Reinstall - Touchscreen.
  33. Verify proper operation of the charge port and that the vehicle charges.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.