2024-12-19

Cover - FastCharge (Remove and Replace)

Correction code 1630010082 FRT 1.44 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.

Torque Specifications

Table 1. Torque Specifications: Cover - FastCharge (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes

Bolts that secure the negative and positive fastcharge busbar DC link sides and inlet sides
15 Nm (11.1 lbs-ft) -180 degrees
5 Nm (3.7 lbs-ft) +60 degrees
  • Insulated Ratchet/torque wrench
  • Insulated 13 mm socket
  • Insulated Torque wrench with angle measurement
 Replace 1104475-00-F
Bolts that attach the fastcharge assembly to the ancillary bay
5.5 Nm (4.1 lbs-ft)
  • Insulated Ratchet/torque wrench
  • Insulated 10 mm socket
 Reuse

Bolt that secures the busbar cover access door

Bolts that attach the charge port busbar kit to the HV header
9 Nm (6.6 lbs-ft)
  • Insulated Ratchet/torque wrench
  • Insulated 10 mm socket
  • Insulated 10 mm 12-point deep socket
 Reuse
Bolts (x4) that attach the busbar DC input assembly to the ancillary bay
10 Nm (7.4 lbs-ft)
  • Insulated Ratchet/torque wrench
  • External Torx E10 5-Lobe
 Replace 1095042-00-C

Remove

  1. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  2. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  3. Partially remove the lower portion of the LH C-pillar trim.
  4. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  5. Remove the LH ancillary bay terminal cover. See .
  6. Disconnect the LV fastcharge contactor connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Press the tabs on both sides by hand and disconnect the connector upwards.
  7. Disconnect the connector that attaches the PCS to AC harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. Use a plastic trim tool to help lift the connector upward as needed.
  8. Remove the connector and the clip that attach the AC filter harness to the fastcharge contactor cover.
  9. Remove the harness clips from the fastcharge contactor cover, and move the wiring harness around the fastcharge cover aside.
  10. Remove and discard the bolts that secure the negative and positive fastcharge busbar DC link sides.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 13 mm socket
    • Insulated Torque wrench with angle measurement
  11. Disconnect the mega-harness connector from the DC input assembly.
  12. Remove the insulators from the DC input assembly to both fastcharge busbar inlet sides.
  13. Remove and discard the bolts that secure the negative and positive fastcharge busbar inlet sides.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 13 mm socket
    • Insulated Torque wrench with angle measurement
  14. Remove the bolts that attach the fastcharge assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 10 mm socket
  15. 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 Ratchet/torque wrench
    • Insulated 10 mm socket
    • Insulated 10 mm 12-point deep socket
  16. Remove the bolts 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 Ratchet/torque wrench
    • Insulated 10 mm socket
    • Insulated 10 mm 12-point deep socket
  17. Release the LH body harness from the rear body and move it aside.
  18. Partially remove the lower B-pillar trim.
  19. Partially pull out the LH rear body harness.
  20. Lift the busbar kit connector to remove it from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use inflatable air bag 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.
  21. Remove and discard the bolts that attach the busbar DC input assembly to the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • External Torx E10 5-Lobe
  22. Remove the busbar DC input assembly from the ancillary bay.
  23. Remove the fastcharge assembly from the ancillary bay.
  24. Remove and discard the fastcharge insulator cover from the fastcharge assembly.

Install

  1. Install a new fastcharge insulator cover to the fastcharge assembly.
  2. Position fastcharge assembly to the ancillary bay for installation.
  3. Install the bolts that attach the fastcharge assembly to the ancillary bay.
    5.5 Nm (4.1 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 Ratchet/torque wrench
    • Insulated 10 mm socket
  4. Install the busbar DC input assembly to ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the seal is not damaged and seated properly.
  5. Install the bolts (x4) that attach the busbar DC input assembly to the ancillary bay.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • External Torx E10 5-Lobe
  6. Install and torque new bolts that secure the negative and positive fastcharge busbar inlet sides.
    15 Nm (11.1 lbs-ft) -180 degrees
    5 Nm (3.7 lbs-ft) +60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 13 mm socket
    • Insulated Torque wrench with angle measurement
  7. Perform Hioki resistance test at both HV joints of the DC input assembly busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 60µΩ or less. Test from the negative fastcharge busbar to negative DC input busbar, and then positive fastcharge busbar to positive DC input busbar.
  8. Install the insulators for DC input assembly to both fastcharge busbar inlet sides.
  9. Connect the mega-harness connector to DC input assembly.
  10. Install and torque a new bolt that secures the negative fastcharge busbar DC link side.
    15 Nm (11.1 lbs-ft) -180 degrees
    5 Nm (3.7 lbs-ft) +60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 13 mm socket
    • Insulated Torque wrench with angle measurement
  11. Perform Hioki impedance test at the negative HV joint of the fastcharge busbar DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 55µΩ or less.
  12. Install and torque a new bolt that secures the positive fastcharge busbar DC link side.
    15 Nm (11.1 lbs-ft) -180 degrees
    5 Nm (3.7 lbs-ft) +60 degrees
    Informational PurposesAn informational icon, calling your attention
    Note
    Tighten the bolt to 15 Nm, back off 180 degrees, then torque to 5 Nm + 60 degrees. Mark after torque.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 13 mm socket
    • Insulated Torque wrench with angle measurement
  13. Perform Hioki impedance test at the positive HV joint of the fastcharge busbar DC link side.
    Informational PurposesAn informational icon, calling your attention
    Note
    The resistance should be 25µΩ or less.
  14. Install the LH ancillary bay terminal cover. See .
  15. Install the harness clips to the fastcharge contactor cover.
  16. Connect the LV fastcharge connector.
  17. Install the AC filter harness to fastcharge contactor cover.
  18. Connect the PCS to fastcharge contactor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the connector downward, then push the locking tab downward to install the connector. Make sure the connector is fully seated.
  19. 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 HV connector.
  20. 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 re-use of busbar.
  21. Apply Penetrox onto the HV connector joints.
    Informational PurposesAn informational icon, calling your attention
    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.
  22. Remove the Inflatable Air Bag from under the HV header.
  23. Position the busbar kit connector and lower it onto the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Shift rear end of 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.
  24. Install the bolts that attach the charge port busbar kit to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated Ratchet/torque wrench
    • Insulated 10 mm socket
    • Insulated 10 mm 12-point deep socket
  25. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    • If the resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ), Hioki test is 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 is passed, proceed to next step.
  26. 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 Ratchet/torque wrench
    • Insulated 10 mm socket
    • Insulated 10 mm 12-point deep socket
  27. Position the LH rear body harness under the LH lower C-pillar trim.
  28. Install the LH rear harness bracket to body.
  29. Partially install the B-pillar lower trim.
  30. Partially install the lower portion of LH C-pillar trim.
  31. Install the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  32. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).