22/05/2024 15:16:30

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

Correction code 44501102 0.84 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-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 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.

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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 all doors and windows.
  2. Move the driver seat and front passenger seat fully forward.
  3. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  4. Open the trunk.
  5. Open the hood.
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Open the charge port door.
  8. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  9. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  10. Remove the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  11. Put the LH 2nd row seat back in the vertical position.
  12. Remove the bolts that attach the charge port harness bracket at the ancillary bay.
  13. Release the clips (x2) that attach the electrical harness to the charge port harness bracket at the ancillary bay, and then remove the bracket from the vehicle.
  14. Slide the release to unlock the DC input connector handle of the charge port to HV battery harness from the secured position.
  15. Fully raise the handle on the DC input connector.
  16. Remove the DC input connector from the ancillary bay DC input header.
  17. Slide the release to unlock the 3-phase connector handle of the charge port to HV battery harness from the secured position.
  18. Fully raise the handle on the 3-phase connector.
  19. Remove the 3-phase connector from the ancillary bay 3-phase header.
  20. Remove the LH 2nd row buckle. See Buckle - 2nd Row - LH (Remove and Replace).
  21. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  22. Remove the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  23. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  24. Remove the trunk garnish. See Garnish - Trunk (Remove and Replace).
  25. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  26. Release the clips (x4) that attach the Low Voltage (LV) harness along the charge port harness.
  27. Release the clips (x3) that attach the charge port harness located on top of the rear LH wheelwell and C-pillar.
  28. Disconnect the LH taillight electrical connector.
  29. Disconnect the LV electrical connectors from the charge port ECU.
  30. Release the edge clip that attaches the LV electrical harness to the charge port closeout panel.
  31. Slightly pull on the closeout panel. At the same time, insert a plastic trim tool inwards to start releasing the lower clips, and then pull the closeout panel towards the front of the vehicle while releasing the remaining clips.
  32. Remove the bolt that attaches the charge port ground to the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    The ground cable is green with a yellow stripe and is located at the top of the inner wheel housing.
  33. Pull the manual release cable up and away from the cable hold down clip, or pull up the cable vertically away from the charge port assembly.
  34. Remove the bolts that attach the charge port assembly to the body.
  35. Release the charge port harness from the body by lifting up the harness reference point up and over the body.
  36. Pull the rear side of the charge port harness away from the body for access.
  37. Pull the entire rear side of the charge port harness away from the body.
  38. Carefully route the front of the charge port harness underneath the LV electrical harness. Move the front of the charge port harness under and away from the LV electrical harness, and then bring the harness upwards.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not damage the LV electrical harness.
  39. With an assistant, remove the charge port harness from the body.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the LV electrical harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Have a second person hold the rear of the charge port harness (charge port inlet side) as the front side of the harness is fed through and underneath the LV electrical harness.
  40. Remove the charge port harness from the vehicle.

Install

  1. Put the new charge port harness into the vehicle and feed the harness through the LV electrical harness.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Install the charge port harness carefully to prevent damage to the harness.
  2. With an assistant, route the charge port harness into position. Have a second person hold the rear of the charge port harness (charge port inlet side) as the harness is fed under the LV electrical harness.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Install the charge port harness carefully to prevent damage to the harness.
  3. Install the clips (x3) that attach the charge port harness to the vehicle at the C-pillar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of clips on newer vehicles might vary.
  4. Fully raise the handle on the DC input connector of the charge port to HV battery harness.
  5. 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.
  6. 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.
  7. Slide the release to lock the DC input connector handle in the secured position.
  8. 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.
  9. Fully raise the handle on the 3-phase connector of the charge port to HV battery harness.
  10. Use both hands to firmly connect the 3-phase connector of the charge port to HV battery harness to the ancillary bay 3-phase 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.
  11. While pressing the 3-phase connector onto the 3-phase 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.
  12. Slide the release to lock the 3-phase connector handle in the secured position.
  13. 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.
  14. Install the bolts (x2) that attach the charge port harness bracket to the vehicle at the ancillary bay.
    10 Nm (7.4 lbs-ft)
  15. Install the clips (x2) that attach the electrical harness to the charge port harness bracket at the ancillary bay.
  16. Install the clips (x4) that attach the LV electrical harness along the C-pillar area.
  17. Install the charge port harness on the vehicle near the charge port assembly, and then install the clips (x2) that attach the LV electrical harness onto the charge port harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift the charge port harness reference point up and over the body. The reference point should be reset into the body.
  18. Install the bolt that attaches the charge port harness ground to the body.
    6 Nm (4.4 lbs-ft)
  19. Install the charge port door grommet on the body
  20. Install the bolts (x3) that attach the charge port 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.
  21. Insert the manual release cable back into the locking tab; push down on the release back to secure it into the locking tab.
  22. Install the clips that attach the charge port closeout panel.
  23. Install the edge clip that attaches the LV electrical harness to the charge port closeout panel.
  24. Connect the LV charge port ECU electrical connectors.
  25. Connect the electrical harness to the taillight connector.
  26. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  27. Install the trunk garnish. See Garnish - Trunk (Remove and Replace).
  28. Install the trunk sill trim panel. See Trim - Sill - Trunk (Remove and Replace).
  29. Install the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  30. Close the trunk.
  31. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  32. Install the LH 2nd row buckle. See Buckle - 2nd Row - LH (Remove and Replace).
  33. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  34. Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  35. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  36. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  37. Move the driver seat and front passenger seat back to their original position.
  38. Reinstall the vehicle firmware. See Software Reinstall - Touchscreen.
  39. Verify for proper operation of the charge port. Use the customer's mobile connector, if available.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  40. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  41. Close the hood and all doors.