04/06/2024 18:01:39

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

Correction code 44013122 0.78 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.
  • 2023-07-05: Cleaned up 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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Note
This procedure is for the Global Refresh version of this part. The procedure for the Original version of this part is here: Busbars - Charge Port to HV Battery (Remove and Replace).

Remove

  1. Open all four doors.
  2. Lower the LH and RH front windows.
  3. Move the driver and front passenger seats fully forward.
  4. Open the liftgate.
  5. Remove the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  6. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  7. Remove the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  8. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  9. Remove the LH and RH 2nd row seat outer bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  10. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  11. Fold the LH 2nd row 60 seat down.
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    Note
    Seat can be folded from the backrest button or trunk switch.
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    Note
    Since the seat cushion is not present, protect the seat as required.
  12. Open the charge port door using the vehicle touchscreen.
  13. Open the hood.
  14. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  15. Disconnect LV power. See LV Power (Disconnect and Connect).
  16. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  17. Remove the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  18. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  19. Remove the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  20. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  21. Remove the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  22. Release the LH upper C-pillar trim, and then set it aside. See Trim - C-Pillar - Upper - LH (Remove and Replace).
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    Note
    Do not remove the lower bolt that attaches the LH 2nd row seat belt retractor.
  23. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  24. Disconnect the 60 seat electrical connector.
  25. Release the harness clip for the 60 seat and the rear seat cushion.
  26. Disconnect the charge port latch electrical connector.
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    Note
    Take note of harness routing.
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    Note
    Pull the red locking tab outwards to release the lock, and then pull again to release the electrical connector.
  27. Disconnect the charge port electrical connector.
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    Note
    Carefully remove the white locking tab. Press the tab to release the electrical connector from the charge port. Continue to pull off the connector. The connector is intended to disengage the safety cap when released.
  28. Release the hooks (x2) that attach the charge port safety cap to the charge port, and then remove it from the vehicle.
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    Note
    2x hooks
  29. Remove the nuts (x2) that attach the charge port busbars to the charge port, and then remove the busbar leads from the studs.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 11 mm socket
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    Note
    Nuts have captured washers.
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    Note
    Take caution of any tension present with the busbars.
  30. Remove the LH 2nd row cushion support block. See Support Block - 2nd Row Cushion - LH (Remove and Replace).
  31. Remove the bolts (x2) that attach the busbars to the HV header, and then release the busbars.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
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    Note
    Make sure to set the busbars aside to prevent remating with the pack port.
  32. Remove the bolt that attaches the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
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    Note
    Use a small flat screwdriver to release the cover.
  33. Remove the busbars from the vehicle.
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    Note
    Recommend assistance.
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    Note
    Maneuver the busbars rearward, and then remove them through the liftgate. Rotate them 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 busbars come with Penetrox applied to the 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.
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    Note
    Allow 1 minute dry time after removing the Penetrox.
  3. Verify that the charge port studs (x2) are tightened to specification.
    2 Nm (1.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T10 bit
  4. Install the busbars into the vehicle.
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    Note
    Recommend assistance.
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    Note
    Maneuver the busbars forward through the liftgate, and then rotate to clear the seat bracket.
  5. Secure the busbars onto the HV header, and then install bolts (x2).
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
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    Note
    Make sure the busbars are seated flush onto the pack port to prevent arching.
  6. Apply Penetrox to the backside of the busbar leads.
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    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  7. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    11 Nm (8.1 lbs-ft)
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    Note
    Use of the following tool(s) is recommended:
    • 9 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers.
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    Note
    If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace it, if necessary.
  8. Inspect 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: https://service.tesla.com/user/documents?searchText=TN-15-92-003
  9. Put on the HV insulating gloves and leather over gloves.
  10. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the charge port stud (x2 HV joints).
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    Note
    When using the Hioki tester, verify that the meter has been properly adjusted and set prior to usage.
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    Note
    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 resistance test passed. Proceed to next step.
  11. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt head (x2 HV joints).
    Informational PurposesAn informational icon, calling your attention
    Note
    When using the Hioki tester, verify that the meter has been properly adjusted and set prior to usage.
    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 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 resistance test passed. Proceed to next step.
  12. Remove the leather glove protectors and HV insulating gloves.
  13. Install the bolt that attaches the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
  14. Install the LH 2nd row cushion support block. See Support Block - 2nd Row Cushion - LH (Remove and Replace).
  15. Secure the hooks (x2) that attach the charge port safety cap to the charge port assembly.
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    Note
    The safety cap will click into position.
  16. Connect the charge port electrical connector.
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    Note
    Fully engage the electrical connector and white locking tab. The connector is intended to lock the safety cap in place.
  17. Connect the charge port latch electrical connector.
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    Note
    Return the harness to its original routing: Harness sits in front of the busbars.
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    Note
    Fully engage the connector and red locking tab.
  18. Secure the harness clip for the 60 seat and rear seat cushion.
  19. Connect the 60 seat electrical connector.
  20. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  21. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  22. Install the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  23. Install the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  24. Install the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  25. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  26. Install the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  27. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  28. Install the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  29. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  30. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  31. Close the liftgate.
  32. Restore the LH 2nd row 60 seat into upright position.
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    Note
    Remove seat cushion protection.
  33. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  34. Install the LH and RH 2nd row seat outer bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  35. Reconnect LV power. See LV Power (Disconnect and Connect).
  36. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  37. Close the hood.
  38. Verify operation of the vehicle charging system.
  39. Close the charge port door.
  40. Raise the LH and RH front windows.
  41. Restore the driver and front passenger seats.
  42. Close all four doors.