04/06/2024 18:03:16

Charge Port - BUSBar Chargeport Assembly (Remove and Replace)

Correction code 4401024042 FRT 0.96 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2024-03-06: Updated DC FC header greasing steps.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

  1. Open the tonneau cover.
  2. Open the tailgate.
  3. Open the LH front door and lower the LH front window.
  4. Use the touchscreen to open the charge port door.
  5. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  6. Disconnect MV power. See Disconnect MV Power.
  7. Perform the charge port voltage check. See Charge Port Voltage Check.
  8. Remove the LH aft rear fender flare. See Front and Rear Garnish - Rear Fender Flare Aft - LH (Remove and Install).
  9. Remove the LH fore rear fender flare. See Front and Rear Garnish - Rear Fender Flare Fore - LH (Remove and Install).
  10. Remove the LH rear fender flare aft carrier. See Front and Rear Garnish - Carrier - Rear Fender Flare Aft - LH (Remove and Install).
  11. Remove the LH rear fender flare fore carrier. See Front and Rear Garnish - Carrier - Rear Fender Flare Fore - LH (Remove and Install).
  12. Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  13. Remove the LH sail applique assembly. See Truck Bed Exterior Trim - Sail Applique Assembly - LH (Remove and Replace).
  14. Release the clip that attaches the LH tonneau rail seal to the vehicle, and then remove the rail seal from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull away the seal away from the rail to release it from the groove.
  15. Remove the LH upper bed side wall assembly. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
  16. Remove the LH rear bed closeout. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
  17. Remove the LH bed side wall. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
  18. Remove the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  19. Remove the bolts (x2) that attach the HV connector to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  20. Release the HV connector from the DC FC header, and then use an inflatable airbag to suspend the busbar assembly above the ancillary assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Upon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
  21. Disconnect the charge port assembly electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the white locking tab. Press the tab to release the connection from the charge port. Continue to pull off connector. The charge port connection is intended to disengage the safety cap when released.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not push down on the red tab. Pull the red tab to disengage lock. Pull again to release the electrical connector.
  22. Release the clip and disconnect the charge port door LV electrical connectors (x2).
  23. Remove the bolt that attaches the ground cable to the busbar assembly.
    6.5 Nm (4.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  24. Remove the bolt that attaches the charge port to the outer sail.
    6.5 Nm (4.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
  25. Remove the bolts (x2) that attach the charge port assembly onto the body.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only hand tools. Risk of galling if power tools are used on stainless bolts.
  26. Remove the charge port and busbar assembly from the vehicle.
  27. If grease was found around the inner perimeter of the DC FC header, use a disposable towel to wipe the grease off the header and the busbar connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not allow the grease to contact the busbar HV mating surfaces.

Install

  1. Inspect the HV busbar connector of the replacement busbar chargeport assembly.
    • If the gasket inside the connector is green, skip to step 3. Greasing of the DC FC header is not necessary.
    • If the gasket inside of the connector is purple, continue to step 2 and grease the DC FC header.
  2. Prepare the grease gun with Mobil XTCE grease, apply a 6 mm diameter continuous bead around the DC FC header inner perimeter, and then use a gloved finger wetted with alcohol to smear the grease up the inner wall to a height of 10 mm.
    Informational PurposesAn informational icon, calling your attention
    Note
    The grease is part number 1089958-00-A and is available from eProcurement.
  3. Clean the DC FC header contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with Penetrox applied to the HV connector.
  4. Position the busbar chargeport assembly onto the vehicle.
  5. Install the bolts (x2) that attach the busbar chargeport assembly to the DC FC header.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket (insulated)
  6. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 HV joints
    Informational PurposesAn informational icon, calling your attention
    Note
    When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
    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 resistance is greater than 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.
    • If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
    • If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed. proceed to the next step.
  7. Install the bolt that attaches the busbar HV connector lid.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  8. Install the bolts (x2) that attach the busbar chargeport assembly onto the body.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm 12-point deep socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only hand tools. Risk of galling if power tools are used on stainless bolts.
  9. Install the bolt that attaches the charge port to the outer sail.
    6.5 Nm (4.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
  10. Install the bolt that attaches the busbar ground to the body.
    6.5 Nm (4.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  11. Connect the charge port door electrical connectors (x2) and fasten the clip.
  12. Connect the charge port electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the connection and white locking tab. The electrical connector is intended to lock the safety cap in place.
  13. Install the LH bed side wall. See Bed Side Wall - Bed Side Wall - LH (Remove and Install).
  14. Install the LH rear bed closeout. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
  15. Install the LH upper bed side wall assembly. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
  16. Position the LH tonneau rail seal into the vehicle, push the seal into the rail groove, and then secure the clip.
  17. Install the LH sail applique assembly. See Truck Bed Exterior Trim - Sail Applique Assembly - LH (Remove and Replace).
  18. Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
  19. Install the LH rear fender flare aft carrier. See Front and Rear Garnish - Carrier - Rear Fender Flare Aft - LH (Remove and Install).
  20. Install the LH rear fender flare fore carrier. See Front and Rear Garnish - Carrier - Rear Fender Flare Fore - LH (Remove and Install).
  21. Install the LH fore rear fender flare. See Front and Rear Garnish - Rear Fender Flare Fore - LH (Remove and Install).
  22. Install the LH aft rear fender flare. See Front and Rear Garnish - Rear Fender Flare Aft - LH (Remove and Install).
  23. Reconnect MV power. See Disconnect MV Power.
  24. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  25. Raise the LH front window and close the LH front door.
  26. Close the tonneau cover.
  27. Close the tailgate.