2025-03-27

Flood Port (Remove and Replace)

Correction code 16102712 1.38 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 proper PPE is worn when performing the below procedure.

  • 2025-03-10: Updated procedure for flood port plunger.
  • 2025-02-12: Updated entire procedure to replace all flood ports (x5).
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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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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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.
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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 glove and safety information.

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CAUTION
The flood port housing is not serviceable. This procedure only replaces the flood port plunger.
Figure 1. Flood port assembly
Figure 2. Flood port housing
Figure 3. Flood port plunger
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CAUTION
The flood ports on the LH side of the vehicle have hats installed on the flood port housing inside the HV battery enclosure. Removing the flood port housing on the LH side of the vehicle will cause the housing to unseat from the hat, which may cause the hat to become urecoverable in the HV battery.

Remove

  1. Open all the doors and lower all the windows.
  2. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  3. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect LV power. See LV Power (Disconnect and Connect).
  6. Perform vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  7. Use 6 inch needle nose pliers to remove the plunger from the LH front flood port. Repeat this step for the remaining flood ports (x5).
    Informational PurposesAn informational icon, calling your attention
    Note
    If necessary, use a pick to clean the grooves before removal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT remove the flood port housing on the LH side of the vehicle. Removing the flood port housing on the LH side of the vehicle will cause the flood port to unseat from the flood port hat.
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    CAUTION
    Using smaller needle nose pliers may be less effective.
    1. Use the pliers to grip the grooves on the flood port plunger.
      Informational PurposesAn informational icon, calling your attention
      TIp
      There are 3 grooves that are deeper than the others. Applying the pliers to one of the 3 grooves will provide better grip.
    2. Rotate the plunger counter-clockwise in 90 degree increments while gently pulling the plunger away from the vehicle.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not pull the plunger from the flood port housing without rotating. Using too much outward force without rotating the plunger may cause damage to the spring and/or housing.
    Figure 4. LH side flood ports (2x)
    Figure 5. RH side flood ports (2x)
    Figure 6. Rear flood port (1x)
    Figure 7. Flood port plunger
    Figure 8. Flood port plunger removed

Install

  1. Use an IPA wipe to thoroughly clean the LH front flood port seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute of dry time.
  2. Make sure the spring on the inside of the flood port housing is correctly seated. Reseat the spring if necessary.
    Figure 9. Unseated spring
    Figure 10. Seated spring
  3. Inspect the new flood port plunger for a printed QR code to ensure the correct part is being used.
  4. Carefully remove any wafer cap from the new flood port plunger assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to drop any wafers. If wafers are dropped, discard the plunger assembly and replace it with a new one.
    Figure 11. Wafer cap
    Figure 12. Flood port wafers
  5. Install the LH front flood port plunger into the flood port housing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Press firmly until there are audible clicks.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure there is no gap between the plunger and housing once installed.
    Informational PurposesAn informational icon, calling your attention
    Note
    If necessary, rotate the plunger clockwise during install.
  6. Repeat step 1 through step 5 for the the remaining flood port plungers.
    Figure 13. LH side flood ports (x2)
    Figure 14. RH side flood ports (x2)
    Figure 15. Rear flood port (1x)
  7. Perform HV battery air leak test. See HV Battery Air Leak Test (In Vehicle).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT skip steps to perform the air leak test. If the air leak test fails, create a session and escalate.
  8. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  9. Fully lower the vehicle.
  10. Reconnect LV power. See LV Power (Disconnect and Connect).
  11. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  12. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  13. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  14. Raise the LH front window and close all the doors.