2025-09-11

Insulator - Wheelhouse - Front - LH (Model YL) (Remove and Replace)

Correction code 15301000802 FRT 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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 safety information.

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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

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
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Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

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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: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use 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.

Torque Specifications

Table 1. Torque Specifications: Insulator - Wheelhouse - Front - LH (Model YL) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that secures the busbar cover access door
9 Nm (6.6 lbs-ft)
  • Insulated 10 mm socket
 Reuse
Bolts (x2) that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Insulated 10 mm socket
 Reuse

Remove

  1. Remove the LH 2nd row seat assembly. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).
  2. Perform the charge port voltage check. See Charge Port Voltage Check.
  3. Remove the LH trunk side trim. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  4. Remove the LH upper 3rd row B-section duct. See Duct - B Section - 3rd Row - Upper - LH (Model YL) (Remove and Replace).
  5. Carefully insert an inflatable air bag between the LH rear cabin carpet to the body, and then inflate it to support the LH rear carbin carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    This is to gain enough space to remove the busbar bolt.
  6. Put on HV insulating gloves and leather over gloves.
  7. Remove the bolt that secures the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  8. Remove the bolts (x2) that attach the charge port busbar kit to the HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  9. Release the LH body harness from the rear body, and move it aside.
  10. Lift the busbar kit connector to remove it from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use an inflatable airbag to suspend the busbar away from the HV header during removal and installation. Hold the busbar firmly, as there is tension on it. Avoid damaging the harness bracket.
  11. Remove the HV insulating gloves.
  12. Remove the clips (x3) that attach the LH body harness to the body, and move it aside.
  13. Remove the LH front wheel house insulator from the vehicle.

Install

  1. Install the LH front wheel house insulator to the vehicle.
  2. Install the clips (x3) that attach the LH body harness to the body.
  3. Put on HV insulating gloves and leather over gloves.
  4. Use IPA wipes to clean the HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with penetrox applied to the HV connector.
  5. Use IPA wipes to clean the busbar HV connector contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during the re-use of the busbar.
  6. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both HV connector joints. Spread it evenly to make sure the contact surface is fully covered.
  7. Remove the inflatable air bag from under the HV header.
  8. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift the rear end of the busbar assembly upward to help ease installation. If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  9. Install the bolts (x2) that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  10. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    • If the resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ), Hioki test passed, proceed to next step.
    • If the resistance is greater than 0.195 mΩ (195 μΩ), stop work and escalate the Toolbox session.
    • If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
    • If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), Hioki test passed, proceed to next step.
  11. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated 10 mm socket
  12. Remove the HV insulating gloves.
  13. Install the clip that attaches the LH body harness to the rear of the body.
  14. Install the LH upper 3rd row B-section duct. See Duct - B Section - 3rd Row - Upper - LH (Model YL) (Remove and Replace).
  15. Install the LH trunk side trim. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  16. Install the LH 2nd row seat assembly. See Seat Assembly - 2nd Row - LH (Model YL) (Remove and Install).