Charger (Remove and Replace)

FRT No: 44100102

Warning: Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Special tool required for this procedure (North America and Japan):

Supplier Part Number Description
Tesla 1020288-00-A TOOL,INSTALLATION,EV INLET,MDLS

Remove

Tip: It is helpful, but not necessary, to have the vehicle on a lift while performing this procedure.

  1. Open both rear doors.
  2. Open the liftgate.
  3. Open the charge port.
  4. Perform the electrical isolation procedure (refer to procedure).
  5. Remove the LH parcel shelf support (refer to procedure).
  6. Remove the bolts that secure the LH tiedown bracket, then remove the bracket (torque 9 Nm).

    View large image.

  7. Remove the rear fascia (refer to procedure).
  8. Pull inboard on the tab on the rear of the charge port cover, then rotate the rear of the cover toward the front of the vehicle to remove it from the charge port.

    View large image.

  9. Release the bolts that secure the HV cables to the charge port (torque 9 Nm).

    View large image.

  10. If equipped, disconnect the rear PTC heater harness from the charger.

    View large image.

  11. Remove the nut and release the ground strap from the stud on the D-pillar (torque 9 Nm).

    View large image.

  12. Remove the bolt and release the green charge port ground cable from the charger (torque 6 Nm).

    View large image.

  13. Working under the vehicle, clamp the lower coolant hose.

    View large image.

  14. Disconnect the electrical connector from the bottom of the charger. Move the harness out of the work area.
  15. Remove the nuts that secure the charger to the body (torque 9 Nm).
  16. Position a container in order to catch spilled coolant.
  17. Release the coolant hose from the bottom of the charger.
  18. Release the barrel clip that holds the upper coolant hose to the body.
  19. Clamp the upper coolant hose.

    View large image.

  20. Release the hose from the charger, then plug the hose.
  21. Move the hose out of the work area.
  22. Remove the nuts that secure the charger bracket to the body (torque 7 Nm).

    View large image.

  23. Release the forward HV cable grommet from the body. This reduces tension on the forward HV cables, allowing easier access to the back of the charger.

    View large image.

  24. Rock the charger left and right, then pull it up partially and tilt it toward the center of the vehicle.

Caution: Take care not to damage the acoustic padding with the studs on the bottom of the charger.
Tip: Temporarily insert a spare floor mat under the charger to protect the acoustic padding from damage.

  1. Remove the bolts that secure the bracket to back of the charger.

    View large image.

  2. Loosen the fasteners that secure the cables to the HV Battery (torque 5 Nm).
    Note: It is not necessary to fully remove the fasteners.

    View large image.

Note: The next step requires an assistant.

  1. Remove the charger from the vehicle.
    Warning: The charger weighs approximately 85 pounds (40 kg).
  2. Remove the nuts and washers (x2) that secure the HV cables to the charger.
    Caution: Do not drop the washers or nuts inside the charger.

    View large image.

  3. Use a flathead screwdriver to release both HV inlet seals from the tabs on the charger inlets.

    View large image.

  4. Pull the both HV cables out from the top of the charger.
    Note: The rear HV cable has a slotted lug that surrounds a tab in the charger; use a suitable tool to pry the lug inboard to maneuver it around the tab before completly removing the cable out from the charger.

    View large image.

  5. Transfer the upper HV cables to the new charger.
    Warning: It is possible to install the upper HV cables in the wrong positions when they are transferred to the new charger. Install the cables on the new charger as shown.

    View large image.

  6. Install new nuts and washers (x2) to secure the HV cables to the new charger (torque 5 Nm).
  7. Transfer the bracket to the back of the new charger (torque 5 Nm).
  8. Transfer the foam seal from the bottom of the charger to the new charger.

Install

Installation procedure is the reverse of removal, except for the following:
Caution: Replace all Patchbolt(s).
Warning: The water slide bracket must be reinstalled on the rear of the charger to ensure proper performance in the event of a collision.
  • Clean the charger mounting area on the vehicle before installing the new charger.
  • Ensure that the new charger has a new foam gasket on the bottom of the charger. Do not reuse the foam gasket.
  • The forward HV cables must be inserted into the charger before it is permanently mounted. Place the charger in the approximate mounting position, tilted toward the center of the vehicle, then connect the forward HV cables.
  • The lugs of the forward HV cables must be positioned in front of the busbars.
  • Warning: The water slide bracket must be reinstalled on the rear of the charger to ensure proper performance in the event of a collision.
  • Note: The charger is difficult to position properly. Position the charger in the approximate position, then check under the vehicle to see the position of the coolant nipple, electrical connector, and studs relative to the holes in the body. Adjust the position of the charger accordingly.
  • Clean the adhesive residue on the charger and charger access panel with an alcohol wipe before installing a new warranty label.

    View large image.

  • Ensure that the forward HV cable grommet is fully seated on the body.
  • Tip: If the forward HV cable grommet is difficult to insert into the body, apply P-80 emulsion to the edges of the grommet.
  • Before securing the HV cables to the charge port, insert the charge port alignment tool into the charge port.

    View large image.

  • Perform a firmware update.
    Tip: Connect 12V power and start the firmware update before reinstalling the components that were removed for access.
  • Ensure that the vehicle charges as expected.