2026-08-09

Busbars - Charge Port to HV Battery (Remove and Replace)

Correction code 44013102 0.84 NOTA: Salvo diversa ed esplicita indicazione nella procedura, il codice modifica e il relativo FRT associato, riflettono tutto il lavoro richiesto per l'esecuzione di questa procedura, incluse le procedure collegate. Non cumulare i codici modifica a meno che non venga detto esplicitamente di farlo. NOTA: Consultare la Tempistica tariffe fisse per saperne di più sui tempi forfettari e su come essi vengono creati. NOTA: Consultare Protezione personale per assicurarsi di indossare i DPI adatti quando si esegue la procedura descritta di seguito. NOTA: Vedere per le pratiche di lavoro in sicurezza.

  • 2023-10-10: Added a caution to not manually close the charge port door.
Apparecchiatura:
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Avvertenza

Solo i tecnici che hanno completato tutti i corsi di certificazione richiesti sono autorizzati a eseguire questa procedura. Tesla raccomanda ai tecnici di fornitori di terze parti di seguire una formazione equivalente prima di svolgere la presente procedura. Per maggiori informazioni sui requisiti dei Tecnici Tesla, o per le descrizioni degli argomenti richiesti per i tecnici di fornitori terzi, vedere i Requisiti per certificazioni HV. Ogni volta che si maneggia un raccordo, una barra di distribuzione o un cavo ad alta tensione è necessario indossare idonei dispositivi di protezione individuale (DPI) e guanti isolanti per l'alta tensione con classe di protezione minima 0 (1000 V). Per ulteriori informazioni sulla sicurezza, fare riferimento alle Note tecniche relative ai rischi dell'alta tensione TN-15-92-003, "High Voltage Awareness Care Points".

Avvertenza

Togliere tutti i gioielli (orologi, bracciali, anelli, collane, orecchini, medagliette, piercing, ecc.) e tutti gli oggetti (chiavi, monete, penne, matite, strumenti, dispositivi di fissaggio, ecc.) dalle tasche prima di eseguire qualsiasi procedura in presenza di alta tensione.

Avvertenza
Se è necessario indossare occhiali da vista per eseguire in sicurezza qualsiasi procedura, assicurarsi che gli occhiali siano fissati saldamente alla testa e non possano cadere.
Avvertenza

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
Avvertenza

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.

Avvertenza
Assicurarsi che i guanti per l'alta tensione non siano scaduti.
  • Nord America: I guanti per l'alta tensione possono essere utilizzati fino a 12 mesi dopo la data di test stampata sui guanti stessi, ma solo 6 mesi dopo il primo utilizzo anche se i guanti ancora rientrano nel periodo di 12 mesi. Se i guanti non sono stati messi in servizio durante il periodo di 12 mesi successivo alla data di test, devono essere nuovamente testati prima di essere messi in servizio.
  • Europa: I guanti per alta tensione di Classe 0 (1000 V) non hanno una data di scadenza e possono essere utilizzati se superano la valutazione pre-utilizzo e l'ispezione periodica.
  • Asia Pacifico: Attenersi alla data di scadenza indicata dal produttore dei guanti per l'alta tensione e:
    • o Solo per la Cina: Testare i guanti ogni 6 mesi secondo GB/T 17622.

Torque Specifications

Tabella 1. Torque Specifications: Busbars - Charge Port to HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Busbar to charge port nut
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
 Reuse
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
 Reuse
Busbar to ancillary bay HV header bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
 Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 bit
 N/A Perform a torque check on the studs
Edge support bracket bolt
10 Nm (7.4 lbs-ft)
  • 10 mm socket
 Reuse

Remove

  1. Lower all windows.
  2. Open all doors and latch the rear doors.
  3. Move the driver seat and front passenger seat fully forward.
  4. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  5. Open the liftgate.
  6. Open the hood.
  7. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  8. Open the charge port door.
  9. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  10. Perform the charge port voltage check procedure. See .
  11. Remove the LH lower c-pillar trim. See .
  12. Remove the rear trunk floor trim. See .
  13. Remove the front trunk floor trim. See .
  14. Remove the trunk sill trim. See #GUID-65DAFEC6-8C71-450D-A401-8CD4EB2422E2.
  15. Remove the LH trunk load floor bracket. See .
  16. Remove the LH trunk pocket bracket. See .
  17. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  18. Release the clips (x6) and tab (x1) that attach the LH upper C-Pillar trim to the vehicle, and then set the trim aside.
    Note
    Carefully release the foremost part of the LH upper C-Pillar trim from the headliner.
    Note
    The LH upper C-Pillar trim will still be attached to the rear seatbelt.
  19. Remove the C-Pillar bracket. See .
  20. Disconnect the LH body harness connectors (x2) from the charge port ECU.
  21. Release the clip that attaches the LH body harness to the vehicle.
  22. Slide the red locking tab away from the LH taillight connector, and then disconnect the harness from the taillight.
    CAUTION
    NON premere sulla linguetta di blocco rossa. Tirare la linguetta allontanandola dal connettore fino a sbloccarlo, quindi continuare a tirare il corpo principale del connettore per scollegarlo completamente.
  23. Release the locking tabs from the charge port low voltage connectors (x2), and then disconnect the connectors (x2) from the charge port.
    CAUTION
    NON premere sulla linguetta di blocco rossa. Tirare la linguetta allontanandola dal connettore fino a sbloccarlo, quindi continuare a tirare il corpo principale del connettore per scollegarlo completamente.
    Tip
    Gently lift the black connector tab in order to remove the white locking tab from the 12-pin low voltage connector.
  24. Remove the charge port busbar fastener cover from the charge port assembly.
  25. Remove the nuts that attach the charge port busbars to the charge port.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  26. Disconnect the harness from the electrical connector at the LH rear seat rail.
  27. Release the clip that attaches the electrical connector to the LH rear seat rail, and then move the connector aside.
  28. Release the clips (x3) that attach the LH harness guide to the vehicle near the LH rear door sill area.
    Note
    Releasing these clips will loosen the LH body harness from the vehicle and facilitate removal of the charge port busbars.
  29. Remove the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  30. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  31. Remove the bolts (x2) that attach the charge port busbars to the HV header at the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  32. Position a fender cover or other protective material on the vehicle, underneath the charge port busbars.
  33. With assistance, lift the charge port busbars away from the HV header, and then carefully maneuver the busbars through the liftgate.
    Tip
    Gently lift the rear half of the busbars to aid removal of the busbars from the HV header.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See .
  2. Clean the charge port busbar HV header at the ancillary bay with an IPA wipe, and allow to dry for 1 minute.
  3. Clean the charge port busbar HV header at the back of the charge port assembly with an IPA wipe, and allow to dry for 1 minute.
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Tip
    Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  4. Perform a torque check on the busbar studs on the back of the charge port.
    2 Nm (1.5 lbs-ft)
    Note
    Skip this step if installing a new charge port assembly.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T10 bit
  5. Apply one drop of electrical joint compound on each of the charge port busbar HV header contacts (x2) at the ancillary bay.
    Note
    Skip this step if installing a new charge port busbar, as the new busbar has pre-applied electrical joint compound.
  6. If reinstalling the same busbar: Remove all residue/debris from the mating surfaces of both ends of the busbar using an IPA wipe.
  7. With assistance, position the charge port busbars in the vehicle.
    Note
    Maneuver the busbars into the vehicle through the liftgate.
    Note
    Make sure to position the busbars underneath the LH body harness guide near the LH rear seat rail.
  8. With assistance, align the guide tabs on the HV header with the charge port busbar connector, and then install the busbar connector on the HV header.
    Tip
    Gently lift the rear half of the busbars to aid installation of the busbars on the HV header.
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
  9. Install the bolts (x2) that attach the charge port busbars to the HV header at the ancillary bay.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  10. Install the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  11. Install the clips (x3) that attach the LH harness guide to the vehicle near the LH rear door sill area.
  12. Install the clip that attaches the electrical connector to the LH rear seat rail.
  13. Connect the harness to the electrical connector at the LH rear seat rail.
  14. Apply two drops of electrical joint compound on each of the charge port busbar leads (x2), on the side that makes contact with the charge port.
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Note
    Make sure the contact surfaces are completely covered with electrical joint compound.
  15. Position the charge port busbars on the charge port, and then install the nuts that attach the busbars to the charge port.
    9 Nm (6.6 lbs-ft)
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  16. Put on HV insulating gloves and leather over gloves.
  17. At the charge port, use the Hioki resistance meter to measure the resistance between the charge port busbar lead and the charge port busbar stud. Also perform this test on the other lead and stud.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ). If the measured resistance is above 0.270 mΩ (270 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again, as appropriate.
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  18. At the ancillary bay, use the Hioki resistance meter to measure the resistance between the charge port busbar lead and the ancillary bay HV header bolt head. Also perform this test on the other lead and bolt head.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ). If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again, as appropriate.
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  19. Remove the HV insulating gloves and leather over gloves.
  20. Close the charge port busbar access door, and then install the bolt that locks the access door in position.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  21. Install the charge port busbar fastener cover on the charge port assembly.
    Note
    The charge port busbar fastener cover will not be secure until the next step is performed.
  22. Connect the low voltage harness connectors (x2) on the charge port, and then install the locking tabs (x2) that secure the connectors.
    Note
    Premere la linguetta di blocco rossa nel connettore per inserire il blocco del connettore.
    Tip
    Carefully insert the white locking tab in the 12-pin low voltage connector until it locks with the black connector tab.
  23. Connect the electrical harness to the taillight, and then slide the red locking tab toward the connector.
    Note
    Premere la linguetta di blocco rossa nel connettore per inserire il blocco del connettore.
  24. Install the clip that attaches the LH body harness to the vehicle.
  25. Connect the LH body harness connectors (x2) to the charge port ECU.
  26. Install the C-Pillar bracket. See .
  27. 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.
    Note
    Align the upper groove in the front portion of the C-Pillar trim with the headliner.
  28. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  29. Install the LH trunk pocket bracket. See .
  30. Install the LH load floor bracket. See .
  31. Install the trunk sill trim. See #GUID-65DAFEC6-8C71-450D-A401-8CD4EB2422E2.
  32. Install the front trunk floor trim. See .
  33. Install the rear trunk floor trim. See .
  34. Install the LH lower c-pillar trim. See .
  35. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  36. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  37. Close the liftgate.
  38. Close the charge port door.
    CAUTION
    Do not try to manually close the charge port door.
  39. Place the driver and front passenger seats back to their previous positions.
  40. Unlatch and close all doors.