03/12/2020 14:44:05

30A Fuse - Charger - 3rd Generation (Remove and Replace)

Correction code 44103102

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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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Note
In three-phase markets, 4 cables connect the charger to the charge port instead of 2.
Special tool(s) recommended for this procedure:
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Note
If the dummy plug kit is not available, use electrical tape.
Part Number Description
1116814-00-A KIT, DUMMY PLUG, GEN 3 CHARGER
1076927-00-A HIOKI MODEL 3541 TESTER

Removal

  1. Remove the charger from the vehicle. See Charger (Remove and Replace).
  2. Remove and discard the bolts (x4) that attach the mounting bracket to the charger, and then remove the bracket from the charger.
  3. Prepare the ESD kit.
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    Note
    Refer to TN-14-92-003, "Electrostatic Discharge Tool".
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    CAUTION
    Improper use of ESD kit can result in damage to sensitive electronics.
  4. Make sure that the snap button connector of the ground cord is securely fastened to the ESD mat.
  5. Remove alligator clip adapter from the banana plug at the end of the wrist strap, and then connect the banana plug to the ground cord.
  6. Connect the ground cord to a ground source, and then put on the ESD wrist strap.
  7. Place the charger onto the ESD mat.
  8. Remove the tamper label from the charger.
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    Note
    Remember the location of the label over the housing screw.
  9. Remove and discard the screws (x22) that attach the charger cover, and then remove the cover from the charger.
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    Note
    Use a trim tool to help break the sealant at the cover perimeter.
  10. Remove the screws (x2) that attach the 30A PTC fuse to the busbars, and then remove the fuse.
  11. Use a plastic scraper to remove sealant from the perimeter of the charger cover and charger housing.
  12. Use the plastic scraper to remove the foam gasket from the charger.
  13. Use an ESD-safe vacuum cleaner to remove any loose sealant or gasket material from the charger.
  14. Use IPA wipes to clean the surfaces where the sealant and gasket were removed, and allow to dry.

Installation

  1. Ready the Hioki resistance meter for testing.
  2. Install the 30A PTC fuse to the busbars, and then install new screws (x2) to attach the fuse to the busbars (torque 1.5 Nm).
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    Note
    Install the fuse so that the label is facing up.
  3. Perform Hioki resistance test at the output end of the 30A PTC fuse.
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    Note
    The resistance of the joint should be between 0.025 mΩ and 0.265 mΩ.
  4. Perform Hioki resistance test at the input end of the 30A PTC fuse.
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    Note
    The resistance of the joint should be between 0.025 mΩ and 0.250 mΩ.
  5. Prepare the Loctite SI 5900 sealant.
    1. Remove the red plastic cap.
    2. Remove the clear plastic tab from the nozzle.
    3. Twist the nozzle 1/4 turn counter clockwise.
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      Note
      The nozzle is pre-cut to correct diameter.
  6. Apply an even bead of sealant, 1/16"-1/8" wide, to the charger housing perimeter.
  7. Install the charger cover to the charger housing.
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    CAUTION
    Make sure not to move the charger cover sideways after it has been set onto the charger housing.
  8. Install new screws (x22) to attach the charger cover to the charger housing, and tighten in the sequence shown (torque 2 Nm).
  9. Use an IPA wipe to remove any sealant that might have squeezed out, and to clean the location where the tamper label was removed.
  10. Apply a new tamper label to the charger over the location of the housing screw.
  11. Remove the ESD wrist strap.
  12. Install the mounting brackets onto charger, and then install new bolts (x4) to attach the brackets to the charger (torque 7 Nm).
  13. Install a new foam gasket onto the charger.
  14. Install the charger into the vehicle. See Charger (Remove and Replace).
  15. Verify the charging system operation, and PTC heater functionality.