09/10/2023 22:24:22

Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace)

Correction code 440151020.36NOTE: 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.

  • 2023-10-10: Added a caution to not manually close the charge port door.
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Lower all windows.
  2. Open all doors and latch the rear doors.
  3. Open the liftgate.
  4. Open the hood.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Open the charge port door.
  7. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  8. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  9. Remove the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  10. Remove the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  11. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  12. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  13. Remove the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  14. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  15. Release the clips (x6) and tab (x1) that attach the LH upper C-Pillar trim to the vehicle, and then set the trim aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the foremost part of the LH upper C-Pillar trim from the headliner.
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH upper C-Pillar trim will still be attached to the rear seatbelt.
  16. Remove the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  17. Release the locking tab from the charge port low voltage connector, and then disconnect the connector from the charge port.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Gently lift the black connector tab in order to remove the white locking tab from the 12-pin low voltage connector.
  18. Remove the charge port busbar safety cap from the charge port assembly.

Install

  1. Install the charge port busbar safety cap on the charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The charge port busbar safety cap will not be secure until the next step is performed.
  2. Connect the low voltage harness on the charge port, and then install the locking tab.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Carefully insert the white locking tab in the 12-pin low voltage connector until it locks with the black connector tab.
  3. Install the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  4. Position the LH upper C-Pillar trim on the vehicle, and then install the clips (x6) and tab (x1) that attach the trim to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the upper groove in the front portion of the C-Pillar trim with the headliner.
  5. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  6. Install the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  7. Install the LH load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  8. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  9. Install the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  10. Install the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  11. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  12. Close the liftgate.
  13. Close the charge port door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  14. Unlatch and close all doors.