2022-06-17

Safety Cap - Busbar - Charge Port to HV Battery (China) (Remove and Replace)

Correction code 44015132 0.25 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 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 proper PPE is worn when performing the below procedure.

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Warning
This procedure is a DRAFT. Although it has been validated, Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near High Voltage systems and components.
  1. Open LH front door
  2. Lower LH front window
  3. Open LH rear door
  4. Fold 60 seat into down position
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    Note
    Seat can be folded from the backrest button or trunk switch, If seat cushion is not present, protect the seat as required
  5. Open liftgate
  6. Remove parcel shelf
  7. Remove trunk load floor
  8. Remove side load floor trim
  9. Remove the trunk sill panel
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    Note
    6x clips, 4x guides. Corners or bottom edge are good grabbing points for removal, Can use plastic trim tool or just your hands
  10. Using center display open charge port door
  11. Open hood
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    Note
    Via Center Display > Controls > Frunk Open
  12. Remove rear underhood apron
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    Note
    8x clips
  13. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Power Off
  14. Disconnect LV battery connector and First Responder Loop
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
  15. Verify operation of multimeter
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
  16. Remove all items from pockets and ensure not wearing metal items
  17. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  18. Put on HV insulating gloves and leather over gloves
  19. Verify there is no high voltage present at the charge port
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify you are using a proper ground, Measure B+ to B-, B- to ground, and B+ to Ground, If voltage is greater than 10V then contactors are not open or are welded closed, Stop work and reach out to Service Engineering,
  20. Remove the leather glove protectors and HV insulating gloves
  21. Remove rear wall trim
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    Note
    4x push clips, 2x datums
  22. Remove LH trunk bracket assembly
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    Note
    4x clips, 1 datum, Pull bracket straight up
  23. Remove rear trunk floor
  24. Remove LH side bolster trim
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    Note
    1x clip, 1x tab, Start by releasing upper portion
  25. Separate LH C-pillar trim from LH upper C-pillar trim
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    Note
    4x clips, 4x datums
  26. Release LH upper C-pillar trim and move aside
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    Note
    7x clips
  27. Release clips securing LH trunk side trim and remove
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    Note
    3x push clips, 3x clips, 2x connectors
  28. Release charge port connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Carefully remove white locking tab, Depress tab to release connection from the charge port, Continue to pull off connector, The connection is intended to disengage the safety cap when released
  29. Remove charge port safety cap
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    Note
    2x tabs
  30. Install charge port safety cap
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    Note
    2x tabs, Safety cap will click into position
  31. Secure charge port connection
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    Note
    1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place
  32. Install LH trunk side trim and secure clips
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    Note
    3x push clips, 3x clips, 2x connections
  33. Install LH upper C-pillar trim
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    Note
    7x clips, Replace any damaged clips
  34. Secure LH C-pillar trim onto LH upper C-pillar trim
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    Note
    4x clips, 4x datums, Replace any damaged clips, Verify seated properly
  35. Install LH side bolster trim
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    Note
    1x clip, 1x tab, Replace clip if damaged, Hook bottom portion and then secure the top
  36. Install rear trunk floor
  37. Install LH trunk bracket assembly
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    Note
    4x clips, 1 datum
  38. Install rear wall trim
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    Note
    4x push clips, 2x datums
  39. Install trunk sill panel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 4x guides
  40. Install side load floor
  41. Install trunk load floor
  42. Install parcel shelf
  43. Close liftgate
  44. Fold 60 seat into vertical position
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    Note
    Remove seat cushion protection
  45. Close LH rear door
  46. Connect First Responder Loop and LV battery connector
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    Note
    2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  47. Install rear underhood apron
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    Note
    8x clips
  48. Close hood
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    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  49. Raise LH front window
  50. Close LH front door