04/06/2024 18:01:11

Charge Port (Busbar Type) (3-Phase) (Remove and Replace)

Correction code 44011652 0.66 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.

  • 2023-10-27: Update charge port to body bolt torque to 9 Nm.
  • 2023-10-10: Add a caution to not manually close the charge port door.
  • 1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
  • 1076927-00-A Hioki RM 3548
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 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.

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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.
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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 (Busbar Type) (3-Phase) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches 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
Bolt that attaches 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 windows.
  2. Open the trunk.
  3. Open the charge port door.
  4. Move the driver and front passenger seats fully forward.
  5. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  8. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  9. Remove the trunk garnish. See Garnish - Trunk (Remove and Replace).
  10. Remove the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  11. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  12. Disconnect the trunk light electrical connector.
  13. Release the clips (x2), and then move the LH trunk side trim aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid excessive creasing of the trunk side trim.
  14. Disconnect the LH taillight electrical connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not push down on the red tab. Pull the red tab to disengage lock, and then pull again to release connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Earlier vehicles may be equipped with different connector type.
  15. Remove the white locking tab, and then disconnect the logic connector from the charge port.
  16. Push the locking tab upward, and then disconnect the 3-phase connector from the charge port.
  17. 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.
  18. 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
  19. Release the charge port manual release cable from the vehicle body.
  20. Release the locking tab, and then disconnect the electrical connector from the charge port actuator.
    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.
  21. Remove the bolts 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 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
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the harness is routed out, and the adhesive pad with zip tie is properly mounted if it is installed.
  4. 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.
  5. Attach the charge port manual release cable barrel onto the vehicle body clip.
  6. If reinstalling the same charge port: 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.
    Tip: Use of the following tool(s) is recommended:
    • Torx T10 bit
    • 4 in extension
    • Ratchet/torque wrench
  7. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
    Figure 1. Busbar bracket design may vary
  8. 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 2. Busbar bracket design may vary
  9. Position the charge port busbars on the charge port, and then 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
  10. Put on HV insulating gloves and leather over gloves.
  11. 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.
  12. Remove the HV insulating gloves and leather over gloves.
  13. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  14. Connect the 3-phase connector on the charge port, and then slide the locking tab downward.
  15. Connect the logic connector on the charge port, and then install the white locking tab.
  16. Move the LH trunk side trim back into position, and then secure it with clips (x2).
  17. Connect the trunk light electrical connector.
  18. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  19. Install the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  20. Install the trunk garnish. See Garnish - Trunk (Remove and Replace).
  21. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  23. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  24. Restore the driver and front passenger seats back to their original position.
  25. Raise all windows and close all doors.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.