04/06/2024 18:03:19

Busbars - Charge Port to HV Battery (3-Phase) (Remove and Replace)

Correction code 44013152 0.84 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.

  • 2023-10-10: Add a caution to not manually close the charge port door.
  • 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.

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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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: Busbars - Charge Port to HV Battery (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 The nut has captured washers
Bolt that attaches the 2nd row seat cushion edge support bracket to the vehicle
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • 4 in extension
  • Ratchet/torque wrench
Reuse
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Busbar to ancillary bay HV header bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 bit
  • 4 in extension
  • Ratchet/torque wrench
N/A

Remove

  1. Open all four doors and lower all windows.
  2. Open the trunk.
  3. Open the charge port door.
  4. Move the driver seat and front passenger seat 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 LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  10. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  11. Remove the trunk garnish. See Garnish - Trunk (Remove and Replace).
  12. Remove the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  13. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  14. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  15. 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.
  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. Release the clip that attaches the electrical harness to the 2nd row seat cushion edge support bracket.
  18. Remove the bolts that attach the 2nd row seat cushion edge support bracket to the vehicle, and then remove the bracket from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  19. Release the clips (x7) that attach the LH body harness to the vehicle, near the charge port busbar.
  20. Remove the clips (x6) that attach the 3-phase electrical harness to the charge port busbar.
  21. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  22. Remove the bolts (x2) that attach the charge port busbars to the HV header.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  23. Lift and remove the charge port busbar connector from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wiggle the connector back and forth to ease removal.
  24. Fold the LH 2nd row seat back down, and place the 12V foam cap under the seat back for clearance.
  25. With assistance, remove the charge port busbars out through the trunk.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.

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. 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.
    Tip: Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  4. With assistance, position the charge port busbars for installation by inserting the busbars through the trunk.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.
  5. Fold up the LH 2nd row seat back and remove the protective covering from the 2nd row seat cushion area.
  6. 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.
    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.
  7. Install the bolts (x2) that attach the charge port busbars to the HV header.
    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
  8. Install the clips (x6) that attach the 3-phase electrical harness to the charge port busbar.
  9. Install the clips (x7) that attach the LH body harness to the vehicle, near the charge port busbar.
  10. Position the 2nd row seat cushion edge support bracket on the vehicle, and then install the bolts that attach the bracket to the vehicle.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  11. Install the clip that attaches the electrical harness to the 2nd row seat cushion edge support bracket.
  12. 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
  13. 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 1. Busbar bracket design may vary
  14. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    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.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  15. Put on HV insulating gloves and leather over gloves.
  16. 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.
  17. 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.
  18. Remove the HV insulating gloves and leather over gloves.
  19. Close the charge port busbar access door, and then install the bolt on the access door.
    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
  20. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  21. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  22. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  23. Install the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  24. Install the trunk garnish. See Garnish - Trunk (Remove and Replace).
  25. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  26. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  27. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  28. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  29. Restore the driver seat and front passenger seat back to their original position.
  30. Verify the operation of the charging system.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  31. Close all doors and close all windows.