04/06/2024 18:01:36

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

Correction code 44013102 0.72 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 proper PPE is worn when performing the below procedure.

  • 2023-08-25: Added link to charge port voltage check procedure.
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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.
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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

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 glove and safety information.

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Note
This procedure is for the Original version of this part. An updated/region-specific Global Refresh version of this part is available for newer vehicles and that procedure is here: Busbars - Charge Port to HV Battery (Global) (Remove and Replace) or Busbars - Charge Port to HV Battery (EMEA) (Remove and Replace).

Remove

  1. Open all four doors.
  2. Lower the LH front window.
  3. Move the driver and front passenger fully forward.
  4. Open the liftgate.
  5. Remove the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  6. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  7. Fold down the LH rear seat.
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    Note
    Protect the seat backrest as needed.
  8. Open the charge port door through the touchscreen.
  9. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  10. Disconnect LV power. See LV Power (Disconnect and Connect).
  11. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  12. Remove the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  13. Remove trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  14. Remove the trunk sill panel. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  15. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  16. Remove the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  17. Remove LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  18. Remove LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  19. Release the clips (x7) that attach the LH upper C-pillar trim to the body, and then move the trim aside.
  20. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  21. Disconnect the seat 60 split electrical connector.
  22. Release the clip that attaches the harness clip for the 60 split seat and rear seat cushion.
  23. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  24. Remove the nuts (x2) that attach the charge port busbar to charge port, and then remove the busbar leads from the studs.
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    Note
    11mm. Torque 9 Nm.
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    Note
    Nuts have captured washers.
  25. Remove the busbar header foam block.
  26. Remove the bolt that attaches the busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    10mm. Torque 9 Nm.
  27. Remove the bolts (x2) that attach the busbar to the HV header, and then release the busbar.
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    Note
    10mm. Torque 9 Nm.
  28. With an assistant, remove the busbar from the vehicle.
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    Note
    Maneuver rearward to remove the busbar through the liftgate. Rotate the busbar to clear the seat bracket.

Install

  1. Clean the HV connector contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe.
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    Note
    Allow 1 minute dry time after removing Penetrox.
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    Note
    New busbar comes with Penetrox applied to HV connector.
  2. Clean the charge port assembly busbar contact surface of residual Penetrox with an IPA wipe
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    Note
    Use a plastic trim tool to push the IPA wipe down between plastic divider. Allow 1 minute dry time.
  3. Verify that the charge port studs are torqued to specifications.
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    Note
    T10. Torque 2 Nm.
  4. With an assistant, install the busbar into the vehicle.
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    Note
    Maneuver the busbar forward through the liftgate, and then rotate to clear the seat bracket.
  5. Secure the busbar onto the HV header, and install the bolts (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    10mm. Torque 9 Nm.
  6. Apply 2 drops of Penetrox A-13 approximately 5mm in diameter to either side of the hole on both busbar leads, and then spread evenly to verify the contact surface is fully covered..
  7. Install the nuts (x2) that attach the charge port busbar leads to charge port assembly.
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    CAUTION
    If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
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    Note
    11mm. Torque 9 Nm.
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    Note
    Nuts have captured washers.
  8. Inspect the HV insulating gloves.
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    Note
    Check gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
  9. Put on HV insulating gloves and leather over gloves.
  10. Perform a Hioki resistance test at each HV joint from the HV busbar lead to charge port stud.
    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. The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ). If the resistance is greater than 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. 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 and therefore proceed to the next step.
  11. Perform a Hioki resistance test at each HV joint from HV busbar lead to bolt head.
    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. 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 and therefore proceed to the next step.
  12. Remove the leather glove protectors and HV insulating gloves.
  13. Install the bolt that attaches busbar cover access door.
    Informational PurposesAn informational icon, calling your attention
    Note
    10mm. Torque 9 Nm.
  14. Install the busbar header foam block.
  15. Install the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  16. Attach the harness clip for the 60 split seat and rear seat cushion.
  17. Connect the 60 split seat electrical connector.
  18. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  19. Secure the clips (x7) that attach the LH upper C-pillar trim to the body.
  20. Install LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  21. Install LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  22. Install the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  23. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  24. Install the trunk sill panel. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  25. Install trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  26. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  27. Close the liftgate.
  28. Fold the 2nd row 60 split seat into vertical position.
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    Note
    Remove the seat cushion protection.
  29. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  30. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  31. Reconnect LV power. See LV Power (Disconnect and Connect).
  32. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  33. Verify the operation of vehicle charging system.
  34. Close the charge port door.
  35. Move the driver and front passenger seats to their original position.
  36. Close all four doors.