2025-02-12

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.

  • 2025-02-12: 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.

Remove

  1. Open all four doors
  2. Lower LH front window
  3. Remove LH body side secondary seal from rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Seal still attached to vehicle at rear door area
  4. Release tabs and clips securing LH scuff plate
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    Note
    7x tabs, 7x clips, Release upper tabs and then proceed to release bottom clips
  5. Remove LH scuff plate from vehicle
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    Note
    Slide out towards rear of vehicle between rear door and body
  6. Remove clip securing rocker panel to LH front wheelhouse liner
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    Note
    1x push clip
  7. Remove clips securing rocker panel to LH rear wheelhouse liner
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    Note
    2x push clips
  8. Remove bolts securing LH fairing and remove from vehicle
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    Note
    2x bolts, 8mm, 3 Nm, 5x tabs
  9. Release bolt covers on bottom edge of LH rocker panel
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    Note
    3x covers
  10. Remove bolts securing LH rocker panel to body
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    Note
    7x upper bolts, 10mm, 3 Nm, 4x lower bolts, 10mm, 3 Nm
  11. Remove LH rocker panel from vehicle
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    Note
    Release at front and rear fenders
  12. Remove RH body side secondary seal from rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Seal still attached to vehicle at rear door area
  13. Release tabs and clips securing RH scuff plate
    Informational PurposesAn informational icon, calling your attention
    Note
    7x tabs, 7x clips, Release upper tabs and then proceed to release bottom clips
  14. Remove RH scuff plate from vehicle
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    Note
    Slide out towards rear of vehicle between rear door and body
  15. Remove clip securing rocker panel to RH front wheelhouse liner
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    Note
    1x push clip
  16. Remove clips securing rocker panel to RH rear wheelhouse liner
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    Note
    2x push clips
  17. Remove bolts securing RH fairing and remove from vehicle
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    Note
    2x bolts, 8mm, 3 Nm, 5x tabs
  18. Release bolt covers on bottom edge of RH rocker panel
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    Note
    3x covers
  19. Remove bolts securing RH rocker panel to body
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    Note
    7x upper bolts, 10mm, 3 Nm, 4x lower bolts, 10mm, 3 Nm
  20. Remove RH rocker panel from vehicle
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    Note
    Release at front and rear fenders
  21. Raise and support vehicle
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    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
  22. Open hood
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    Note
    Select Controls > Frunk Open
  23. Remove rear underhood apron
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    Note
    8x clips
  24. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Power Off
  25. 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
  26. 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
  27. Raise vehicle fully and lower lift onto locks
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    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  28. Release mid aero shield
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    Note
    4x push clips
  29. Remove mid aero shield
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    Note
    16x bolts, 10mm, 6 Nm
  30. Remove all items from pockets and ensure not wearing metal items
  31. 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
  32. Put on HV insulating gloves and leather over gloves
  33. Remove PRDU dummy plug from HV battery pack
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    Note
    1x connector, Disengage locking tab, then release connector body
  34. Verify no high voltage at RH rear RDU HV header
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  35. Secure PRDU dummy plug to HV battery pack
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    Note
    1x connector, Fully seat connector body, then engage locking latch
  36. Remove leather glove protectors and HV insulating gloves
  37. Remove flood port 2.0 from HV battery assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    5x flood ports, 8x tabs on each flood port, Remove the center core from flood port, Use a pocket screw driver to counter hold flood port, Then carefully use a pick tool to release 8x tabs securing flood port to HV battery, Discard after removal, Do not damage the inner green flood port hat on the inside of HV battery located on the left side of the vehicle

Install

  1. Install flood port 2.0 into HV battery assembly
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    Note
    5x flood ports, 8x tabs on each flood port, Apply pressure along flood port to engage the tabs, Rotate flood port clockwise, An audible click ensures that the flood port is fully seated, Perform push-pull-push test to verify installation
  2. Remove gore breathers from rear breather assembly
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    Note
    4x breathers, Breathers are to be re-used, Be cautious during removal and do not incur damage, If damaged proceed to replacement, Located at rear of pack
  3. Secure tapered plugs into the three indicated breather holes
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    Note
    3x tapered plugs, Do not push plugs too far inside
  4. Secure the leak test adapter onto the fourth breather hole. The other end of the hose will be attached to the CTS machine
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    Note
    1x leak test adapter
  5. Close both valves on the regulator test tool
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    Note
    Verify valves are closed
  6. Secure enclosure leak tester fitting to the leak test adapter
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    Note
    If required, safely secure the leak tester air line in a manner where it will not tug the adapter off
  7. Connect regulator to air supply
  8. Turn right side regulator valve to the open position
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    Note
    Open valve closest to the air line, By turning the valve knob to a horizontal position, The valve is fully open
  9. Set regulator to 0.275 psi
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    Note
    Allow regulator to stablize
  10. Open the left side regulator valve to allow air into the HV battery
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    Note
    Close right side regulator valve when the pressure reaches 0.3 psi and stabilizes, It will take roughly 60 seconds to reach 0.3 psi
  11. Wait 60 seconds to allow pressure to stabilize
  12. Record start pressure value
  13. Wait 30 seconds for test
  14. Record end pressure value
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    Note
    If pressure did not drop more than 0.026 psi, continue to next step, If pressure dropped more than 0.026 psi, then inspect HV battery enclosure for leaks
  15. Disconnect air supply from leak tester
  16. Release enclosure leak tester fitting from the leak test adapter
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    Note
    Release the leak tester air line if previously secured
  17. Release leak test adapter from breather hole
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    Note
    1x leak test adapter
  18. Release tapered plugs from the breather holes
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    Note
    3x tapered plugs
  19. Secure gore breathers onto rear breather assembly
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    Note
    4x gore breathers, If breathers were damaged replace as required
  20. Install mid aero shield
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    Note
    16x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle
  21. Position mid aero shield
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    Note
    4x push clips
  22. Lower vehicle fully
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  23. 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
  24. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  25. Close hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  26. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower lift arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  27. Install LH rocker panel onto vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure at front and rear fenders, Be sure to insert rocker above jack pads
  28. Install bolts securing LH rocker panel to body
    Informational PurposesAn informational icon, calling your attention
    Note
    7x upper bolts, 10mm, 3 Nm, 4x lower bolts, 10mm, 3 Nm
  29. Secure covers on bottom edge of LH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x covers
  30. Install LH rear wheel fairing and secure bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 8mm, 3 Nm, 5x tabs
  31. Install clips securing rocker panel to LH rear wheelhouse liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  32. Install clip securing rocker panel to LH front wheelhouse liner
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  33. Position LH scuff plate for installation
  34. Secure tabs and clips securing LH scuff plate
    Informational PurposesAn informational icon, calling your attention
    Note
    7x tabs, 7x clips, Secure lower clips and then proceed to secure upper tabs
  35. Install body side secondary seal onto LH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Apply new double sided adhesive to rear bottom section of secondary seal
  36. Install RH rocker panel onto vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure at front and rear fenders, Be sure to insert rocker above jack pads
  37. Install bolts securing RH rocker panel to body
    Informational PurposesAn informational icon, calling your attention
    Note
    7x upper bolts, 10mm, 3 Nm, 4x lower bolts, 10mm, 3 Nm
  38. Secure covers on bottom edge of RH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x covers
  39. Install RH rear wheel fairing and secure bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 8mm, 3 Nm, 5x tabs
  40. Install clips securing rocker panel to RH rear wheelhouse liner
    Informational PurposesAn informational icon, calling your attention
    Note
    2x push clips
  41. Install clip securing rocker panel to RH front wheelhouse liner
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  42. Position RH scuff plate for installation
  43. Install tabs and clips securing RH scuff plate
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    Note
    7x tabs, 7x clips, Secure lower clips and then proceed to install upper tabs
  44. Install body side secondary seal onto RH rocker panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip, Apply new double sided adhesive to rear bottom section of secondary seal
  45. Close all four doors
  46. Raise LH front window