Tesla Model S Owners & Service Manuals

Tesla Model S: 200A Fuses - Wall Connector (Remove and Replace) - 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.

Note: This procedure describes how to replace the fuses in the Wall Connector. For information on upgrading the fuses from 100A to 200A, refer to SB-13-50-004, High Power Wall Connector Fuse Upgrade.

  1. Turn off the electricity to the Wall Connector at the circuit breaker. Verify that the breaker was not already tripped (which would also explain the Wall Connector not functioning). 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) that secure the cover of the Wall Connector to the casing (torque 1.1 Nm).

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  3. Release the front cover by pulling it forward far enough to disconnect the ribbon cable from the cover. Disconnect the ribbon cable from inside the main enclosure to fully remove the front cover.

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

    Caution: Do not service the area from the utility input to the left terminal blocks. This wiring is considered house wiring, and must be connected and serviced by a certified electrician.

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  4. Use a properly rated HV voltmeter or multimeter to check for AC voltage between terminals L1 and L2. Ensure that the correct power breaker has been turned off to de-energize the Wall Connector.

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  5. Inspect the wiring near the fuses for evidence of heat damage, abrasion, or corrosion. Caution: If the wiring is damaged, the entire Wall Connector must be replaced; close the unit and call a certified electrician to remove the unit.
  6. Remove the screws that connect the bus bars to terminals L1 and L2.

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  7. Use a 13 mm socket wrench to remove the nuts that fasten the bus bars.

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  8. Before removing the fuse/bus bar assemblies completely, note the order of the components from bottom to top: nut, split washer, wire lug, bus bar.

    Caution: Take note of the color configuration of the wiring to the contactor before removal. Ensure that all wiring is installed to the same location it was before removal.

    200A Fuses - Wall Connector (Remove and Replace) - Removal

  9. Remove the insulator sheet and fuse/bus bar assemblies.
  10. Ensure that the green ground wire is secured to the back of the Wall Connector. If it is not, use wire harness tape or other high temperature resistant tape to secure it to the back of the Wall Connector.

    200A Fuses - Wall Connector (Remove and Replace) - Removal


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