2025-06-27

HV Connector - Busbar - Charge Port (Long Range) (Remove and Install)

Code de correction NEW REMARQUE : À moins d’indications explicites contraires dans la procédure, le code de correction et le temps forfaitaire ci-dessus représentent tout le travail à être fait pour cette procédure, notamment les procédures connexes. N’appliquez pas plusieurs codes de correction à la fois, à moins qu’il vous soit explicitement indiqué de le faire. REMARQUE : Consultez Temps forfaitaires pour en apprendre plus à propos des temps forfaitaires et de leur création. Vous pouvez transmettre par courriel vos commentaires relatifs aux valeurs des temps forfaitaires à ServiceManualFeedback@tesla.com. REMARQUE : Consultez Protection individuelle pour vous assurer de porter l’équipement de protection individuelle adéquat lors vous effectuez la procédure ci-dessous.

Warning IconA warning icon, calling your attention to a possibly risky situation
Avertissement
Cette procédure est une PREMIÈRE VERSION. Bien qu'elle ait été validée, des avertissements et des mises en garde pourraient manquer. Respectez les exigences de sécurité et faites preuve d’une extrême prudence lorsque vous travaillez sur ou près des systèmes et des composants haute tension. Transmettez toute correction ou remarque à ServiceDevelopment@teslamotors.com.
Warning IconA warning icon, calling your attention to a possibly risky situation
Avertissement
Les composants électroniques du Cybertruck sont alimentés par une architecture  moyenne tension » ou « MT » de 48 V conçue pour améliorer l'efficacité. L'entretien des composants MT nécessite des connaissances et des soins supplémentaires afin d'éviter tout dommage corporel ou au véhicule. Lisez et comprenez les précautions relatives à la MT dans Précautions en électricité et assurez-vous que tous les cours de formation requis liés à la MT ont été suivis, le cas échéant.
  • 2025-06-21: Released new procedure.
  1. Open LH front door
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Push LH B-pillar door trigger to release
  2. Lower LH front window
  3. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Set air suspension to "Jack Mode"
  4. Open tailgate
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Press button to release
  5. Remove fastener covers from bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Remarque
    14x covers
  6. Remove bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Remarque
    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Lift front edge with trim tool then remove panel, Recommend assistance
  7. Open powered front trunk
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Via exterior switch or UI
  8. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Remarque
    9x clips
  9. Power down vehicle via UI
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
  10. Disconnect FRL connector then disconnect MV battery connector
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x connectors, Release locking tab then disconnect FRL connector, Slide eCPA to left then lift lever to release MV battery connector, Early production trucks may have black FRL connector, Release eCPA by pushing down to unlock and slide red locking tab, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
  11. Verify operation of multimeter
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
  12. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  13. Remove rear skid plate
    Informational PurposesAn informational icon, calling your attention
    Remarque
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
  14. Remove all items from pockets and ensure not wearing metal items
  15. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Check gloves for damage prior to use, Refer to service document TN-15-92-003
  16. Put on HV insulating gloves and leather over gloves
  17. Verify no HV - Install amp clamp to RDU HV harness
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damagedMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  18. Secure RDU header connector to ancillary
    Informational PurposesAn informational icon, calling your attention
    Remarque
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
  19. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  20. Remove bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Remarque
    1x bolt, EP10, 9 Nm
  21. Remove bolts securing HV connector to DC FC header
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x bolts, 10mm, 9 Nm
  22. Release HV connector from DC FC header
    Informational PurposesAn informational icon, calling your attention
    Remarque
    1x connector, Use inflatable airbag to suspend busbar assembly above ancillary assembly
  23. Raise CP busbar connector
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x inflatable bags, Install bags, Do not open tonneau to prevent damage
  24. Remove screws securing HV connector to CP busbars
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x screws, T20, 1.5 Nm, Position mirror as needed
  25. Remove HV connector from CP busbars
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Gently pry between orange clips and primary heat sink, Pull evenly
  26. Position HV connector onto CP busbars
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Push evenly, Make sure orange clips are flush with primary heat sink
  27. Install screws securing HV connector to CP busbars
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x screws, T20, 1.5 Nm, Position mirror as needed
  28. Clean HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Allow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
  29. Apply Penetrox onto HV connector joints
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
  30. Clean busbar HV connector contact surface of residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Allow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
  31. Lower CP busbar connector
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x inflatable bags, Remove bags, Do not open tonneau to prevent damage
  32. Position busbar connector and lower onto HV header
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Release bungee cord
  33. Install bolts securing charge port busbar kit to HV Header
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x bolts, 10mm, 9 Nm
  34. Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usageThe 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), stop work and escalate the Toolbox session.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), hioki test passed, proceed to next step
  35. Install bolt securing busbar HV connector lid
    Informational PurposesAn informational icon, calling your attention
    Remarque
    1x bolt, EP10, 9 Nm
  36. Connect FRL connector then connect MV battery connector
    Informational PurposesAn informational icon, calling your attention
    Remarque
    2x connectors, Connect FRL connector then secure locking tab, Position lever to secure MV battery connector then slide eCPA to right, Early production trucks may have black FRL connector, If power cycling vehicle then ensure at least 60 seconds has passed since powering down
  37. Install bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Remarque
    10x short bolts, 15mm, 56 Nm, 2x long bolts, 15mm, 46Nm, Recommend assistance
  38. Install fastener covers onto bed floor assembly
    Informational PurposesAn informational icon, calling your attention
    Remarque
    14x covers
  39. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Remarque
    9x clips, Adjust windshield seal as required
  40. Close powered front trunk
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Via exterior switch or UI
  41. Close tonneau cover
  42. Close tailgate
  43. Raise vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
  44. Install rear skid plate
    Informational PurposesAn informational icon, calling your attention
    Remarque
    6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 to mid aero shield bolts and install fasteners
  45. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  46. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Remarque
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  47. Raise LH front window
  48. Close LH front door