2025-03-12

WHEELHOUSE INSULATOR - FRONT - LEFT HAND (Remove and Replace)

Correction code 1530010502 FRT 0.50 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 wearing proper PPE when performing the below procedure.

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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 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
Warning IconA warning icon, calling your attention to a possibly risky situation
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: WHEELHOUSE INSULATOR - FRONT - LEFT HAND (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that closes the charge port busbar access door at the ancillary bay HV header
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm socket
 Reuse
Bolts (x2) that attach the charge port busbar to the ancillary bay HV header
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm socket
 Reuse

Remove

  1. Perform a charge port voltage check. See Charge Port Voltage Check.
  2. Remove the LH trunk side trim. See TRUNK SIDE TRIM LEFT HAND - REAR UNDER BODY (Remove and Replace).
  3. Put on safety glasses, High Voltage (HV) insulating gloves, and leather glove protectors.
  4. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm socket
  5. Remove the bolts (x2) that attach the charge port busbar to the ancillary bay HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm socket
  6. Release the clip that attaches the LH body harness to the body, and move it aside.
  7. Lift the rear half of the charge port busbar away from the HV header, and insert an inflatable air bag between the busbar and the HV header to prevent contact between the busbar and the HV header during subsequent operations.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care of not damaging the harness bracket.
  8. Remove the HV insulating gloves.
  9. Release the clips (x2) that attach the LH body harness to the body, and move it aside.
  10. Remove the LH front wheelhouse insulator from the vehicle.

Install

  1. Install the LH front wheelhouse insulator to the vehicle.
  2. Install the clips (x2) that attach the LH body harness to the body.
  3. Put on safety glasses, High Voltage (HV) insulating gloves, and leather glove protectors.
  4. Use IPA wipes to clean the HV connector contact surface and the busbar HV connector contact surface of the residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is necessary to clean the HV connector during the re-use of the busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time for each surface.
  5. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads on the HV connector joints, and then spread the liquid evenly until the contact surface is fully covered.
  6. Remove the airbag from the vehicle.
  7. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If excessive force is required to seat the busbar, they may have been bent. Inspect for damage and replace if necessary.
  8. Install the bolts (x2) that attach the charge port busbar to the ancillary bay HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Mark the bolts with paint pen after installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm socket
  9. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
    • If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Stop the work and escalate a 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 the next step.
  10. Close the charge port busbar access door, and then install the bolt that locks the access door in position.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm socket
  11. Install the clip that attaches the LH body harness to the body.
  12. Remove the HV insulating gloves.
  13. Install the trunk side trim. See TRUNK SIDE TRIM LEFT HAND - REAR UNDER BODY (Remove and Replace).
  14. Connect the LV power. See LV Power (Disconnect and Connect).