2025-10-23

Seal - HV Input Header (Remove and Replace)

Correction code 1630022302 FRT 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Torque Specifications

Remove

  1. Disconnect LV power. See LV Power (Disconnect and Connect) (Modify).
  2. Remove the LH and RH 2nd row seats. See 2nd Row Seat 5 Seater - LH (Remove and Install) and 2nd Row Seat 5 Seater - RH (Remove and Install).
  3. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  4. Remove the bolt securing the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  5. 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:
  6. Release the clip that attaches the LH body harness to the rear body, partially remove the LH B-pillar lower trim by releasing the push clip, and then partially pull out the harness for access.
  7. Use an inflatable air bag to lift the busbar kit connector away from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    During the process, note the following:
    • Hold the busbar firmly as there is tension on.
    • Avoid damaging the harness bracket.
  8. Remove the bolts (x4) that attach the input header seal to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  9. Release the location pins (x2) to remove the input header seal from the ancillary bay.

Install

  1. Align the location pins (x2) and install the input header seal to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the sealing ring for damage, and replace the input header seal if necessary.
  2. Install the bolts (x4) that attach the input header seal to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
  3. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox. Allow one minute of drying time for each surface.
    Informational PurposesAn informational icon, calling your attention
    Note
    A new busbar comes with Penetrox pre-applied to the HV connector; clean the contact surface of the busbar HV connector when reusing a busbar.
  4. Apply Penetrox onto the HV connector joints. Apply 2 drops of Penetrox A-13 (about 5mm in diameter) on each side of the hole on both leads, and spread evenly to ensure full coverage of the contact surface.
  5. Remove the inflatable air bag from under the HV header.
  6. Position the busbar kit connector, lower it onto the HV header while lifting the rear end of the busbar assembly to ease installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect for damage and replace if excessive force is needed to seat the busbar.
  7. Install 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:
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts after torque.
  8. Perform Hioki resistance test at each of the 2 HV joints from HV busbar lead to bolt head; acceptable resistance is 0.050 mΩ (50 μΩ) to 0.195 mΩ (195 μΩ).
    • If above 0.195 mΩ, stop work and escalate to Toolbox session;
    • If below 0.050 mΩ, reposition probes and remeasure;
    • If repeatedly between 0.00 mΩ and 0.050 mΩ, test passed, proceed to next step.
  9. Install the bolt securing the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
  10. Position the LH rear body harness under the LH lower C-pillar trim, secure the clip that attaches the harness to the rear body, and then partially by securing the push clip.
  11. Install the LH and RH 2nd row seats. See 2nd Row Seat 5 Seater - LH (Remove and Install) and 2nd Row Seat 5 Seater - RH (Remove and Install).
  12. Connect LV power. See LV Power (Disconnect and Connect) (Modify).