04/06/2024 17:59:58

Charge Port (China) (Busbar Type) (Remove and Replace)

Correction code 44012712 0.60 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.

  • 2024-02-02: Updated the cover image.
  • 2023-10-27: Updated charge port to body bolt torque to 9 Nm.
  • 2023-07-06: Added videos in step 12, 14, 15 of Remove part and step 9 in Install part.
  • 2024-04-02: Changed the steps of removing the LH trunk side trim to steps of releasing some clips and moving the trim aside.
  • 1076928-00-A Hioki 9461
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

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

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

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Warning

If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.

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

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
Warning

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.

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Warning

Make sure that the HV gloves are not expired. HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12-month period.

Torque Specifications

Table 1. Torque Specifications: Charge Port (China) (Busbar Type) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts (x2) that attach the charge port busbar leads to the charge port assembly
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Bolts (x3) that attach the charge port to the vehicle
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse

Remove

  1. Open all four doors and lower all four windows.
  2. Open the trunk.
  3. Open the charge port door.
  4. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  5. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  6. Remove the trunk garnish. See Garnish - Trunk (Remove and Replace).
  7. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  8. Disconnect the electrical connector from the puddle lamp.
  9. Release the edge of the trunk carpet and move the LH trunk side trim aside. Tuck the carpet under the trim and take care not to cause excessive creasing.
  10. Release the locking tab, and then disconnect the electrical connector from the charge port assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
    Figure 1. Model 3 shown, Model Y similar
  11. Remove the white locking tab, and then disconnect the DC logic connector from the charge port.
    Figure 2. Model 3 shown, Model Y similar
  12. Remove the white locking tab, and then disconnect the AC logic connector from the charge port.
    Figure 3. Model 3 shown, Model Y similar
  13. Push the locking tab upward, and then disconnect the 3-phase connector from the charge port.
    Figure 4. Model 3 shown, Model Y similar
  14. Use a pick to gently release the tabs (x2) that attach the safety cap to the busbar brackets, and then remove the safety cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not pry with excessive force, as doing so could damage the safety cap.
  15. Inspect and put on the HV insulating gloves and leather over gloves.
  16. Remove the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  17. Remove the HV insulating gloves and leather over gloves.
  18. Release the charge port manual release cable from the vehicle body.
  19. Remove the bolts (x3) that attach the charge port to the vehicle, and then remove the charge port from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. If reinstalling the same charge port: 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.
    Tip: Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  3. Position the charge port on the vehicle, and then install the bolts (x3) that attach the charge port to the vehicle.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  4. Attach the charge port manual release cable barrel onto the vehicle body clip.
  5. Inspect and put on the HV insulating gloves and leather over gloves.
  6. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
    Figure 5. Busbar bracket design may vary
  7. If reinstalling the same charge port: 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.
    Figure 6. Busbar bracket design may vary
  8. Install the nuts (x2) that attach the busbar leads to the charge port.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  9. 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 0.325 mΩ (325 μΩ). If the measured resistance is above 0.325 mΩ (325 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.
  10. Remove the HV insulating gloves and leather over gloves.
  11. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  12. Connect the 3-phase connector on the charge port, and then slide the locking tab downward.
    Figure 7. Model 3 shown, Model Y similar
  13. Connect the AC logic connector on the charge port, and then install the white locking tab.
    v
    Figure 8. Model 3 shown, Model Y similar
  14. Connect the DC logic connector on the charge port, and then install the white locking tab.
    Figure 9. Model 3 shown, Model Y similar
  15. Connect the electrical connector to the charge port actuator, and then engage the locking tab.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Push the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  16. Move the LH trunk side trim back into position, and secure the clips onto body.
  17. Connect the electrical connector to the puddle lamp.
  18. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  19. Install the trunk garnish. See Garnish - Trunk (Remove and Replace).
  20. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  21. Raise all windows and close all doors.