Tesla Model S: Handle and Cable Assembly - 40A Wall Connector (Remove and Replace)

Note: This procedure describes how to remove and replace the 40A Wall Connector handle and cable assembly. For instructions on how to remove and replace the 80A Wall Connector handle and cable assembly, refer to procedure 50022002 (refer to procedure).

Removal

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.

1. Turn off the electricity to the Wall Connector at the circuit breaker. Warning: Electricity must be turned off at the circuit breaker before continuing this procedure. Failure to follow this requirement might result in serious injury or death due to exposure to high voltage.
2. Remove the screws (x2) and washers (x2) that secure the front cover of the Wall Connector to the casing.

   

3. Lift the front cover and disconnect the white ribbon cable from the interior of the Wall Connector.

   Caution: When removing the front cover, do not damage the ribbon cable. Disconnect the ribbon cable before fully releasing the front cover.

   

4. Use a properly rated voltmeter or multimeter to check for AC voltage between terminals L1 and L2.

   

   1	L1 terminal
   2	L2 terminal

5. Loosen the screw that secures the yellow/green grounding wire (torque 2.3 Nm). Release the yellow/green grounding wire.

   

6. Loosen the screws (x2) that secure the red L1 and black L2 wires (torque 17.2 Nm).

   Caution: The ferrules on the ends of the L1 and L2 wires are one-time-use only. The ferrules or the handle and cable assembly must be replaced if they have been previously installed.

   

7. While holding the green terminal block in place with a finger, loosen the screws (x2) that secure the purple and blue wires (torque 1.1 Nm). Release the purple and blue wires from the terminal block.

   Caution: Make sure to hold the terminal block in place so it does not bend away from the printed circuit board.

   

8. Release the red and black L1 and L2 wires.
9. Use a diagonal cutter to cut the pinch clamp away from the cable.
10. Remove the screws (x2) that secure the plastic clamp to the casing.

    

11. Pull the cable through the bottom of the Wall Connector until the wires are free.

1. Insert the cable assembly through the grommet on the bottom of the Wall Connector. Caution: Do not unseat the grommet when inserting the cable assembly.
2. Slide a new pinch clamp over the wires to the end of the cable jacket.
3. Use a clamp pincer to install the pinch clamp approximately 5 mm from the end of the cable jacket.

   

4. Loosely install the screws (x2) that secure the plastic clamp to the casing. Note: Do not torque the screws yet.
5. Gently pull the cable jacket towards the bottom of the Wall Connector until the pinch clamp is flush with the plastic clamp.

   

   1	Pinch clamp
   2	Plastic clamp
   3	Cable jacket

6. Fully tighten the screws (x2) that secure the plastic clamp to the casing (torque 3.4 Nm).
7. Connect the wires in the same order as removal (steps 5-7 in the "Removal" section). Caution: The ferrules on the ends of the L1 and L2 wires are one-time-use only. The ferrules or the handle and cable assembly must be replaced if they have been previously installed.
8. Connect the white ribbon cable and reinstall the front cover of the Wall Connector.
9. Reinstall the screws (x2) that secure the cover of the Wall Connector to the casing (torque 1.1 Nm).
10. Turn on the electricity at the circuit breaker.
11. Check the front diagnostic lights on the Wall Connector cover. When it is not plugged into the vehicle, the topmost green LED should be steady (not flashing).
12. Charge the vehicle with the Wall Connector for 2-3 minutes to verify proper operation of the Wall Connector.

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