Tesla Model X: HV Harness - Charger to Charge Port (Remove and Replace)

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):

1. Open the charge port.
2. Perform the electrical isolation procedure (refer to procedure).
3. 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.

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4. Use a multimeter to check voltages on the lugs that secure the HV cables to the charge port:
   • B+ to ground
   • B- to ground
   • B+ to B-
   Warning: If any voltage reading is more than 10V, the contactors are not fully opened. Discontinue this procedure immediately. Contact a Field Service Engineer before performing any further work.

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5. Remove the bolts that secure the HV cables to the charge port (torque 9 Nm).
6. Remove the nuts and washers that secure the HV cables to the charger (torque 5 Nm).

   Caution: Do not drop the washers or nuts inside of the charger.

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

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8. Pull the both HV cables out from the top of the charger and remove them from the vehicle.

Note: The rear HV cable has a notch in the connector; use a suitable tool to pry the connector inboards before pulling the cable out from the charger.

Installation procedure is the reverse of removal, except for the following:

Caution: Replace all Patchbolt(s).

• Clean the adhesive residue on the charger and charger access panel with an alcohol wipe before installing a new warranty label.

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• Ensure that the HV cables are installed in the correct locations. Before securing the HV cables to the charge port, insert the charge port alignment tool into the charge port.

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