2026-05-12

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

Correction code 44013102 0.84 NOTA: Salvo explicitamente indicado em contrário no procedimento, o código de correção acima e o FRT refletem todo o trabalho necessário para a realização deste procedimento, incluindo os procedimentos associados. Não acumule códigos de correção, salvo se explicitamente instruído. NOTA: Consulte Tempos de taxa fixa para saber mais sobre FRT e sobre a respetiva criação. NOTA: Consulte Proteção pessoal para garantir que utiliza o EPI adequado durante a realização do procedimento abaixo. NOTA: Consulte para conhecer as práticas seguras e saudáveis de trabalho.

  • 2023-10-10: Added a caution to not manually close the charge port door.
Equipamento:
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
Aviso

Apenas os técnicos que tenham concluído todos os cursos obrigatórios de certificação estão autorizados a realizar este procedimento. A Tesla recomenda que os técnicos de outros prestadores de serviços frequentem uma formação equivalente antes de realizarem este procedimento. Para obter mais informações sobre os requisitos de técnicos Tesla, ou para ver descrições do assunto para terceiros, consulte Requisitos de certificação em alta tensão. Os técnicos devem usar equipamento de proteção individual (EPI) adequado e luvas isolantes de alta tensão com uma classe mínima de 0 (1000 V) sempre que manusearem cabos de alta tensão, barramentos ou encaixes. Para obter mais informações de segurança, consulte a nota técnica TN-15-92-003, Tópicos de cuidados e sensibilização para a alta tensão.

Warning IconA warning icon, calling your attention to a possibly risky situation
Aviso

Remova todas as joias (relógios, pulseiras, anéis, colares, brincos, chapas de identificação, piercings, etc.) e todos os objetos (chaves, moedas, canetas, lápis, ferramentas, fixadores, etc.) dos bolsos antes de realizar qualquer procedimento que o exponha a alta tensão.

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Aviso
Se tiver de usar óculos graduados para a realização segura de qualquer procedimento, certifique-se de que estão bem presos à cabeça e que não caem.
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Aviso

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
Warning IconA warning icon, calling your attention to a possibly risky situation
Aviso

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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Aviso
Certifique-se de que as luvas de alta tensão estão dentro da validade.
  • América do Norte: As luvas de alta tensão podem ser utilizadas até 12 meses depois da data de teste impressa na luva, mas apenas até 6 meses depois da primeira utilização, mesmo se as luvas ainda estiverem dentro do período de 12 meses. Se as luvas não forem utilizadas durante o período de 12 meses após a data de teste, devem ser novamente testadas antes de serem utilizadas.
  • Europa: As luvas de alta tensão de classe 0 (1000 V) não têm data de validade e podem ser utilizadas se obtiverem aprovação na avaliação pré-utilização e na inspeção periódica.
  • Ásia-Pacífico: Respeite a data de validade indicada pelo fabricante de luvas de alta tensão e:
    • o apenas na China: Teste as luvas a cada 6 meses, de acordo com GB/T 17622.

Torque Specifications

Tabela 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 #GUID-513C83FE-1D5B-4FC1-B3EA-FA796E158252.
  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 .
  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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the foremost part of the LH upper C-Pillar trim from the headliner.
    Informational PurposesAn informational icon, calling your attention
    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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    NÃO pressione a patilha de bloqueio vermelha para baixo. Afaste a patilha do conetor até este desbloquear. Em seguida, continue a puxar a estrutura principal do conetor até o libertar completamente.
  23. Release the locking tabs from the charge port low voltage connectors (x2), and then disconnect the connectors (x2) from the charge port.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    NÃO pressione a patilha de bloqueio vermelha para baixo. Afaste a patilha do conetor até este desbloquear. Em seguida, continue a puxar a estrutura principal do conetor até o libertar completamente.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Informational PurposesAn informational icon, calling your attention
    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)
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars into the vehicle through the liftgate.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Gently lift the rear half of the busbars to aid installation of the busbars on the HV header.
    Informational PurposesAn informational icon, calling your attention
    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)
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Informational PurposesAn informational icon, calling your attention
    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)
    Informational PurposesAn informational icon, calling your attention
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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)
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pressione a patilha de bloqueio vermelha para dentro do conetor para engatar o bloqueio do conetor.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pressione a patilha de bloqueio vermelha para dentro do conetor para engatar o bloqueio do conetor.
  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.
    Informational PurposesAn informational icon, calling your attention
    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 .
  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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    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.