25/08/2023 16:05:26

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

Correction code 44015102 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 proper PPE is worn when performing the below procedure.

  • 2023-08-25: Added link to charge port voltage check procedure.
  • 2023-07-20: Reorganized the procedure.
  • 1083188-00-A FLUKE DIGITAL MULTIMETER 179
  • 1130480-00-A Test Probes, Slim, Fluke TP38
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
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.
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.
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Warning
Make sure that the insulation meter and leads are capable of handling at least 500V DC.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Make sure that the HV gloves are not expired.
  • North America: 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. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: HV gloves have no expiration date and may be used if they pass the pressure assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Remove

  1. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  4. Remove the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  5. Remove the rear trunk floor NVH insulator. See NVH Insulator - Floor - Rear Trunk (Remove and Replace).
  6. Remove the trunk carpet.
  7. Remove the LH and RH side rear trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
  8. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  9. Remove the crush can bracket. See Trim - Crush Can - Rear Trunk - LH (Remove and Replace).
  10. Use a clip pry tool to release the clip that attaches the LH soft trim pocket bracket to the LH frame rail.
  11. Remove the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  12. Remove the LH lower C-pillar. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  13. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Release the clip that attaches the charge port manual cable release to the LH mid C-pillar zone bracket.
  15. Remove the LH mid C-pillar zone bracket. See:
  16. Remove the LH trunk trim carpet. See Carpet - Trim - Trunk - LH (Remove and Replace).
  17. Disconnect LV power. See LV Power (Disconnect and Connect).
  18. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  19. Remove and discard the bolt that attaches HV inlet safety cap to the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  20. Release the tabs (x2) to remove the HV inlet safety cap from the charge port.

Install

  1. Install the HV inlet safety cap onto the charge port.
  2. Install the bolt that attaches HV inlet safety cap to the vehicle.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  3. Connect LV power. See LV Power (Disconnect and Connect).
  4. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Install the LH trunk trim carpet. See Carpet - Trim - Trunk - LH (Remove and Replace).
  6. Install the clip that attaches the charge port manual release cable to the LH mid C-pillar zone bracket.
  7. Install the LH mid C-pillar zone bracket. See:
  8. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  9. Install the LH lower C-pillar. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  10. Install the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  11. Install the clip that attaches the LH soft trim pocket bracket to the LH frame rail..
  12. Install the crush can bracket. See Trim - Crush Can - Rear Trunk - LH (Remove and Replace).
  13. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  14. Install the LH and RH side rear trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
  15. Install the trunk carpet.
  16. Install the rear trunk floor NVH insulator. See NVH Insulator - Floor - Rear Trunk (Remove and Replace).
  17. Install the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  18. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  19. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  20. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  21. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, press and hold Calibrate to calibrate the rear doors.