31/05/2024 11:04:31

HV Harness - Charger to Charge Port (Remove and Replace)

Correction Code 44500302

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage (HV) 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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Special tool required for this procedure (North America and Japan):

Supplier Part Number Description
Tesla 1020288-00-A TOOL,INSTALLATION,EV INLET,MDLS

Removal

  1. Open the charge port.
  2. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  3. For single-phase markets, follow these steps:
    1. Pull inboard on the tab on the rear of the charge port cover, then rotate the rear of the cover toward the front of the vehicle to remove it from the charge port.
      Figure 1. Single-phase shown, Three-phase
    2. Use a multimeter to check voltages on the lugs that secure the HV cables to the charge port:
      For Single Phase markets:
      • B+ to ground
      • B- to ground
      • B+ to B-
      Warning IconA warning icon, calling your attention to a possibly risky situation
      Warning
      If any voltage reading is more than 10V, the contactors are not fully opened. Discontinue this procedure immediately. Contact a Field Service Engineer before performing any further work.
    3. Remove the bolts that secure the HV cables to the charge port (torque 9 Nm).
  4. For three-phase markets, follow these steps:
    1. Remove the charge port cover.
    2. Remove the bolts (x3) that attach the HV harness to the charge port in the order shown.
    3. Remove the HV harness from the charge port assembly.
  5. Remove the nuts and washers (x2 for single-phase markets) (x4 for three-phase markets) that secure the HV cables to the charger (torque 6 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop the washers or nuts inside of the charger.
    Single Phase Markets Three Phase Markets
  6. Use a flathead screwdriver to release both HV inlet seals from the tabs on the charger inlets.
  7. Pull both charge port cables out from the top of the charger.
    Informational PurposesAn informational icon, calling your attention
    Note
    The rear HV cable has a slotted lug that surrounds a tab in the charger; use a suitable tool to pry the lug inboard to maneuver it around the tab before completely removing the cable out from the charger.

Installation

Installation procedure is the reverse of removal, except for the following:
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CAUTION
Replace all patchbolt(s).
  1. Clean the adhesive residue on the charger and charger access panel with an alcohol wipe before installing a new warranty label.
  2. For single-phase markets: ensure that the HV cables are installed in the correct locations. Before securing the HV cables to the charge port, insert the charge port alignment tool into the charge port.
  3. For three-phase markets: install the bolts (x3) that attach the HV harness to the charge port assembly (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    First hand tighten the bolts, then torque the bolts in the order shown.