Correction code 44012106

1. Move both front seats fully forward.

   

2. Open hood.
3. Open Liftgate.
4. Remove parcel shelf.

   

5. Remove trunk load floor.

   

6. Remove trunk sill panel.
   Note

   4x clips, 4x guides.

   

   

7. If the LH C-Pillar rear trim panel has a liftgate switch, reach behind the C-pillar rear trim panel and push the switch out from the back.
   Note

   1x electrical connection.

   

8. Remove LH rear C-pillar trim.
   Note

   1x screw, T25, 3 Nm, 4x clips.

   

   

9. Remove LH C-pillar upper trim.
   Note

   3x clips.

   

10. Remove LH trunk side garnish trim.
    Note

    2x clips, 1x guide.

    

    

11. Remove LH trunk side trim panel.
    Note

    1x fir clip.

    

12. Remove trunk floor carpet.
    Note

    4x fir tree clips.

    

    

13. Fold 2nd row seatbacks down.

    

14. Remove the LH side rear seat bolster from the vehicle.
    Note

    1x clip, Release clip from the rear, Do not pull the bolster because of risk of bending.

    

15. Release bottom portion of LH lower C-pillar trim .
    Note

    2x clips,Take care not to damage, Release the lower portion for access, Replace any damaged or missing clips.

    

    

    

16. Separate LH C-pillar mid from LH C-pillar lower.
    Note

    4x clips, Use caution to not damage any components with C-pillar mid.

    

17. Remove the mounting hardware for the LH lower C-pillar.
    Note

    2x push clips.

    

18. Use the air bag tool to push the LH lower C-pillar away from the body of the vehicle.

    

19. Remove LH lower C-pillar trim.
    Note

    4x clips.
20. Raise 2nd row seatbacks to upright position.
    Note

    Remove seat protection if used.

    

21. Remove rear underhood apron.
22. Remove RH underhood apron.
23. Remove LH underhood apron.
24. Release drainage hoses from HEPA filter inlet duct.
    Note

    2x hoses.

    

    

25. Remove clips securing HEPA filter inlet duct to cowl panel.
    Note

    3x push clips.

    

26. Remove HEPA filter inlet duct.
    Note

    2x clips on HEPA filter.
27. Remove HEPA filter outlet duct from vehicle.
    Note

    Lift up, pull towards front of vehicle, then rotate clockwise.

    

28. Using MCU open charge port door.
29. Disconnect 12V Power
30. Verify operation of multimeter.
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 12v battery.

    

31. Perform a charge port voltage check. See Charge Port Voltage Check.
32. Remove HV insulating gloves.

    

33. Remove nut securing charge port ground to body.
    Note

    1x nut, 13mm, 9 Nm.

    

34. Release edge clips securing manual release cables to charge port assembly.
    Note

    2x clips.

    

35. Remove screw securing latch release cables at center of charge port assembly housing and move cables aside.
    Note

    1x screw, T20, 1.5 Nm.

    

36. Disconnect both latch actuators.
    Note

    2x connectors.

    

37. Disconnect logic connector from charge port ECU.
    Note

    1x connector.

    

38. Release clips securing HV cables to body studs.
    Note

    2x clips.

    

39. Remove HV harnesses from charge port housing.
    Note

    3x bolts, 10mm, 6 Nm, Ensure that the cable is not tugged or pulled unnecessarily which can yield the C-clamp strain relief and cause a thermal ignition event at the GB charge port area while attempting to charge.

    

40. Release clips securing HV cables to body along LH rear.
    Note

    6x clips.

    

41. Disconnect charge port door connector from charge port ECU.
    Note

    1x connector.

    

42. Disconnect body harness connector from charge port ECU.
    Note

    1x connector.

    

43. Remove nut securing charge port ECU/bracket to vehicle and remove assembly.
    Note

    1x nut, 10mm, 2 Nm, 1x clip.

    

44. Remove 2nd row seat bottom cushion.
    Note

    2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side.

    

    

    

    

    

45. Remove NVH padding from underneath 2nd row seat cushion.
    Note

    If equipped .

    

46. Remove bolts securing seat bottom frame.
    Note

    8x bolts, 11mm, 26 Nm.

    

47. Lift up and support seat bottom frame.
    Note

    Release harness clips if necessary.

    

48. Remove tamper evident label from charger cover panel.

    

49. Remove the charger HV access panel cover and discard fasteners.
    Note

    11x bolts, T20, 2 Nm, Discard after removal.

    

    

50. Release tabs and open large access door.
    Note

    2x tabs, Number of tabs may vary.

    

51. Remove nuts securing charge port HV cables to charger.
    Note

    2x nuts, 10mm, 6 Nm, Do not drop fasteners into the charger.

    

52. Release tabs and remove HV cables from charger.
    Note

    4x tabs, Release tabs and pull cables up and out of charger, Cables may have to be turned slightly to release from charger.

    

    

53. Plug holes in top of charger where HV cables were installed.
    Note

    2x holes.

    

54. Close large access door.
    Note

    3x tabs.

    

55. Use a dummy plug or tape to cover the opening for the charger access panel.

    

56. Remove HV cable ground from charger.
    Note

    1x patch bolt, 8mm, 6 Nm, Discard bolt after removal.

    

57. Release Charge Port HV Harness clip from body at the lower C pillar.
    Note

    1x clip.

    

58. Disconnect Charge Port HV Harness CAN connector near coolant pump.
    Note

    1x connector.

    

59. Release clips securing charge port assembly to body along C-pillar.
    Note

    3x clips.

    

60. Feed charge port assembly through towards trunk area of vehicle until cables can be passed between seat pivot and body.

    

61. Remove charge port assembly from vehicle.

    

62. Remove E-Coat from the top face of the rivnut, the busbar grounds through the BIW.
    Note

    Clean area after rework with IPA and allow 1 minute dry time.

    

    

    

63. Install new charge port assembly and updated fasteners from kit to vehicle.
    Note

    3x bolts, 10mm, 6 Nm, 3x bolts, T30, 6 Nm.

    

    

64. Clean DC HV harness terminals and chargeport sockets.
    Note

    Use plastic trim tool to push IPA wipe down between plastic divider, Allow 1 minute dry time.

    

    

65. Apply Penetrox to backside of DC HV harness terminals.
    Note

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered.

    

66. Install DC HV harness into new charge port assembly.
    Note

    2x Nuts, 10mm, 9 Nm, Use nuts provided in chargeport retrofit kit (1521216-00-A).

    

    

67. Inspect HV insulating gloves.
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.

    

68. Put on HV insulating gloves and leather over gloves.

    

69. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud.
    Note

    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.150 mΩ (150 μΩ). If the resistance is not within this range, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed, proceed with the installation procedure. For more information on Hioki resistance testing, refer to Toolbox article 218200.

    

    

    

70. Remove leather over gloves and HV insulating gloves.

    

71. Install DC HV harness inlet safety cap.
    Note

    Ensure cap is fully seated to complete HVIL circuit.

    

72. Secure DC HV harness inlet harness connector to chargeport.
    Note

    Ensure white locking tab is engaged for connector x647.

    

73. Secure AC HV harness inlet to chargeport.
    Note

    Ensure lock is fully engaged.

    

74. Secure AC HV harness inlet harness connector to chargeport.
    Note

    Ensure white locking tab is engaged for connector x646.

    

75. Secure edge clips holding manual release cables to dual charge port assembly housing.
    Note

    2x clips.

    

76. Install nut securing charge port ground to body.
    Note

    1x nut, 13mm, 9 Nm.

    

77. Install nut securing charge port ECU/bracket to vehicle.
    Note

    1x nut, 10mm, 2 Nm, 1x clip.

    

78. Connect body harness connector to charge port ECU.
    Note

    1x connector.

    

79. Connect charge port door connector to charge port ECU.
    Note

    1x connector.

    

80. Connect logic connector to charge port ECU.
    Note

    1x connector.

    

81. Feed the Charge Port HV Harness in towards the front of the vehicle from the rear.
    Note

    The second row seat back can be released into the folding position to create additional room for Charge Port HV Harness install, Recommend assistance.

    

82. Connect Charge Port HV Harness CAN connector near coolant pump.
    Note

    1x connector.

    

83. Secure Charge Port HV Harness clip to body at the lower C pillar.
    Note

    1x clip.

    

84. Install HV cable ground strap to charger.
    Note

    1x patch bolt, 8mm, 6 Nm, Install new fastener.

    

85. Remove plugs at holes in top of charger where HV cables were installed.
    Note

    2x plugs.

    

86. Remove dummy plug or tape on cover to the opening for the charger access panel.

    

87. Release tabs and open large access door.
    Note

    2x tabs.

    

88. Install HV charge port cables into charger and secure tabs.
    Note

    4x tabs, Cables may have to be turned slightly to fit into charger.

    

89. Install nuts securing charge port cables.
    Note

    2x nuts, 10mm, 6 Nm, Do not drop fasteners into the charger, Install new fasteners.

    

90. Close large access door.
    Note

    2x tabs, Number of tabs may vary.

    

91. Install charger cover panel and torque screws.
    Note

    11x bolts, T20, 2 Nm, Install new patch bolts.

    

92. Install new warranty label onto charger cover panel.
    Note

    Wipe charger with IPA prior to installation.

    

93. Secure clips holding charge port assembly to body along LH rear.
    Note

    6x clips.

    

94. Fold 2nd row seatbacks down.
    Note

    Protect the seat cushion if necessary.

    

95. Install LH lower C-pillar.
    Note

    4x clips, 2x push clips, Replace any damaged clips.

    

    

96. Install the LH mid C-Pillar trim.
    Note

    4x clips.

    

97. Install the LH rear seat back bolster.
    Note

    1x clip.

    

98. Raise 2nd row seatbacks to upright position.
    Note

    Remove seat protection if used.

    

99. Lower seat frame into position and secure harness clips to frame.
    Note

    8x clips.

    

100. Install and torque bolts securing seat frame to vehicle.
     Note

     8x bolts, 11mm, 26 Nm.

     

101. Place NVH padding onto seat frame.

     

102. Reinstall seat bottom cushion.
     Note

     2x clips, 7x connectors if equipped, Replace clips if necessary.

     

     

     

103. Install trunk floor carpet.
     Note

     4x clips.

     

     

104. Install the LH side trunk carpet trim.
     Note

     1x fir tree clip.

     

105. Install LH trunk side garnish trim.
     Note

     2x clips.

     

     

106. Install LH C-pillar upper trim.
     Note

     3x clips.

     

107. Install trunk sill panel.
     Note

     4x clips, 4x guides.

     

     

108. Install trunk load floor.

     

109. Install LH rear C-pillar trim.
     Note

     1x screw, T25, 3 Nm, 4x clips.

     

     

110. If the LH C-Pillar rear trim panel has a liftgate switch, reach behind the C-pillar rear trim panel and connect the trunk switch from the back.
     Note

     1x electrical conection.

     

111. Install parcel shelf.

     

112. Close liftgate.

     

113. Connect 12V power. See Disconnect 12V Power.
114. Install HEPA filter outlet duct.

     

115. Install HEPA filter inlet duct.
     Note

     2x tabs, One on each side.

     

116. Install clips securing HEPA filter inlet duct to cowl panel.
     Note

     3x push clips.

     

117. Secure drainage hoses to HEPA filter inlet duct.
     Note

     2x hoses.

     

     

118. Install LH underhood apron.
     Note

     9x clips.
119. Install RH underhood apron.
     Note

     9x clips.
120. Install rear underhood apron.
     Note

     8x clips.
121. Close hood .
122. Connect vehicle to WiFi connection.
     Note

     Connect vehicle to WiFi or Tesla WiFi if available, Maintain WiFi connection for profile functions and firmware download.

     

123. Place vehicle in service mode with touchscreen.
     Note

     Pre-FW 2020.48.25 hold Tesla "T" icon at top of center display for four seconds and then type "service" into Access Code box, Post-FW 2020.48.25 The Tesla T has been removed from the top bar of the UI, Press and hold for 2sec the vehicle's badge icon in Controls > Software for Access Code box.

     

     

     

     

124. Select "Service Mode" on the Control Panel menu, then select "Software Reinstall".

     

125. Select "Request" to initiate software installation.
     Note

     Vehicle will send a request to Tesla server for the re-installation of the current firmware, yellow clock installation icon should appear within 5 minutes.

     

126. Select the clock on the center display, then select "Install Now" to start firmware update.
     Note

     Tap center display next to software update window until clock runs down to 0, After displayed installation time, Check the center display and ensure the firmware package was successfully installed.

     

     

     

127. Unlock the gateway. See Gateway Unlock..
128. Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect)..
129. Using Toolbox 3:
     1. Select the Actions tab and search for "Door sensor calibration".
     2. Select the ODIN routine PROC_CP_X_DOOR-SENSOR-CALIBRATIONSearch for routine in ToolboxCharge Port Door Calibration, and then click on the link of the routine.
     3. Click RUN, and allow the routine to complete.
        Note

        If the routine fails with the message "Unmotorized Gen1 charge ports are not supported in this routine", the vehicle might have a non-motorized charge port door with an older revision door sensor that does not require calibration. This is expected behavior and the repair can be considered complete.
130. Disconnect Toolbox from vehicle and install cubby under the MCU.
     Note

     1x connector, 2x clips.
131. Exit Service Mode.
     Note

     Select "Service Mode" on the Control Panel menu, then select "Exit Service Mode".

     

132. Verify charging system operation.
     Note

     Charge vehicle using known good UMC and verify vehicle charges without issue.

     

133. Move both front seats to their original positions.