Correction code 4401010401, 4401010402 FRT 0.60 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.

1. Open LH front door

   

2. Lower LH front window

   

3. Open hood

   

   

4. Use UI open liftgate

   

   

5. Use UI open charge port door

   

   

6. Power off vehicle from center display
   Note

   Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

   

   

7. Remove rear apron
   Note

   16x trim clips, 3x datums, 2x clips

   

   

   

   

8. Remove HEPA filter assembly
   Note

   2x bolts, 10mm, 10 Nm, Pivot rear edge up past brake reservoir then lift up to clear frunk assembly

   

   

   

   

9. Disconnect LV battery and first responder loop
   Note

   2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

   

   

   

   

   

10. Verify operation of multimeter
    Note

    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

    

11. Remove all items from pockets and ensure not wearing metal items

    

12. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003, For information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

    

13. Put on HV insulating gloves and leather over gloves

    

14. Verify there is no high voltage present at AC charge inlet
    Note

    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Be sure to place the positive test lead on the side of the HV pin just past the plastic protective covers, Touch the probe to the insides of the terminals, not the centers. If the terminals are from left to right, a, b, c, and d, then measure ab, ac, ad, bc, bd, and cd, Then measure a and ground, b and ground, c and ground, and d and ground. (use rear left door striker as a ground for the isolation check), If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

15. Verify there is no high voltage present at DC charge inlet
    Note

    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Be sure to place the positive test lead on the side of the HV pin just past the plastic protective covers, Touch the probes to the insides of the terminals, not the centers. Measure B+ to B-, B- to Ground, and B+ to Ground (use rear left door striker as a ground for the isolation check), If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

    

16. Remove leather over gloves and HV insulating gloves

    

17. Remove rear load floor

    

    

18. Remove front load floor

    

    

19. Remove trunk sill trim from vehicle
    Note

    4x clips, 2x loaction pins

    

    

20. Remove LH load floor bracket
    Note

    4x tabs, 2x clips, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly later

    

    

    

21. Remove LH trunk pocket bracket
    Note

    2x clips

    

    

    

22. Remove LH trunk side trim
    Note

    1x connector, 1x push clip, 4x clips, 7x tabs, 6x location pins, guide front clip stanchions around LH C-pillar, trim part may slightly differ by vehicle build location, and the number of clips may also vary, Adjust the position of the 60 seat backrest as needed

    

    

    

    

    

23. Partially remove LH upper C-pillar trim

    

24. Remove charge port release cable from LH upper C-pillar trim
    Note

    1x clip

    

    

    

25. Put on HV insulating gloves and leather over gloves

    

26. Disconnect DC logic connector from charge port assembly
    Note

    1x connector, Remove white locking tab before disconnecting

    

27. Disconnect charge port actuator logic connector from charge port assembly
    Note

    1x connector, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector

    

28. Remove charge port safety cap
    Note

    2x tabs, 1x clip, Gently release tabs to avoid damage, Do not apply excess force

    

    

29. Remove charge port busbar leads from charge port assembly
    Note

    2x nuts, 10mm, 9 Nm, Nuts have captured washers

    

30. Disconnect charge port logic connector
    Note

    1x connector, Carefully remove white locking tab, Depress tab to release connection from the charge port, Continue to pull off connector, The connection is intended to disengage the safety cap when released

    

31. Disconnect AC inlet harness from charge port
    Note

    1x connector, Release dual step locking tab

    

    

32. Remove charge port assembly
    Note

    3x bolts, 10mm, 9 Nm

    

    

33. Disconnect charge port harness from charge port ECU
    Note

    1x connector

    

34. Release charge port door harness grommet from body
    Note

    1x grommet

    

35. Release lower clips securing charge port door from vehicle
    Note

    2x clips, Release bottom clips, then push bottom of charge port door out

    

36. Gently pull the charge port door away from the body to remove the assembly
    Note

    1x tab, Pull the assembly towards the rear of the vehicle, when the door actuator reaches to the rear of the quarter panel pull the charge port down to clear the actuator mechanism then pull out and away from the body. Manipulation the charge door may be necessary to fully remove the assembly

    

    

37. Install charge port door onto vehicle
    Note

    2x clips, 1x tab, Install the part by pivoting the assembly so the actuator mechanism clears underneath the quarter panel, then slide the charge door forward toward the rear door. Manipulation the charge door may be necessary to fully align the assembly to the body

    

    

    

38. Secure charge port door harness grommet to body
    Note

    1x grommet

    

39. Connect charge port door connector to charge port ECU
    Note

    1x connector

    

40. Install charge port assembly
    Note

    3x bolts, 10mm, 9 Nm

    

    

41. Connect AC inlet harness onto charge port
    Note

    1x connector, Secure dual step locking tab

    

    

42. Connect charge port logic connector
    Note

    1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place

    

43. Verify charge port studs are torqued to proper specification
    Note

    2x studs, T10, 2 Nm

    

44. Clean charge port busbar contact surface of residual Penetrox
    Note

    Allow 1 minute dry time

    

    

45. Apply Penetrox to backside of busbar leads
    Note

    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered

    

46. Install charge port busbar leads onto charge port assembly
    Note

    2x nuts, 10mm, 9 Nm, Nuts have captured washers, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary

    

47. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port studs
    Note

    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ). If the resistance is greater than 0.270 mΩ (270 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

    

    

48. Install charge port safety cap
    Note

    2x tabs, 1x clip, Push firmly to lock into place

    

    

49. Connect DC logic connector onto charge port assembly
    Note

    1x connector, 1x white locking tab

    

50. Connect charge port actuator logic connector onto charge port assembly
    Note

    1x connector, Engage locking tab

    

51. Remove leather over gloves and HV insulating gloves

    

52. Install charge port release cable to LH upper C-pillar trim
    Note

    1x clip, Make sure to install the chargeport cable in place

    

    

53. Install LH upper C-pillar trim

    

54. Install LH trunk side trim
    Note

    1x connector, 1x push clip, 4x clips, 7x tabs, 6x location pins, guide front clip stanchions around LH C-pillar, trim part may slightly differ by vehicle build location, and the number of clips may also vary

    

    

    

    

    

    

55. Install LH trunk pocket bracket
    Note

    2x clips

    

    

    

56. Install LH load floor bracket
    Note

    4x tabs, 2x clips, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, If clip position is changed or push-pull action shows bracket not secure, Remove clip from tab and seat clip into doghouse on bracket and reinstall

    

    

    

57. Install trunk sill trim onto vehicle
    Note

    4x clips, 2x location pins, Seat seal around edge of trim

    

    

    

58. Install front load floor

    

    

59. Install rear load floor

    

    

60. Connect first responder loop and LV battery
    Note

    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

    

    

    

    

    

61. Install HEPA filter assembly
    Note

    2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct, Do not pinch washer hose inbetween HEPA filter assembly and body

    

    

    

    

    

    

62. Install rear apron
    Note

    16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron

    

    

    

63. Close hood

    

    

64. Close liftgate

    

    

65. Raise LH front window

    

66. Close LH front door