05/07/2023 12:08:11

Connector - DC Input - Busbar - Charge Port to HV Battery (Remove and Replace)

Correction code 44018102 0.90 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.

  • 2023-07-05: 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.

Remove

  1. Open all four doors.
  2. Lower the LH front window.
  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 rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat can be folded from the backrest button or trunk switch.
    Informational PurposesAn informational icon, calling your attention
    Note
    Since the seat cushion is not present, protect the seat as required.
  12. Open the charge port door through the 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. 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 side wall trim. See Trim - Side Wall - Trunk - 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 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 seat 60 split electrical connector.
  25. Release the clip that attaches the harness clip for the 60 split seat and rear seat cushion.
  26. Disconnect the charge port latch electrical connector.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  29. Remove the charge port to HV battery busbars. See Busbars - Charge Port to HV Battery (Remove and Replace).
  30. Place the busbars on a safe work area.
  31. Remove the screws (x2) that attach the busbar leads to the HV connector.
    1.5 Nm (1.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 bit
  32. Release the busbar header connector clips (x2).
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    Note
    2 tabs per clip.
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    Note
    Release the orange clips, and then slide it backwards.
  33. Remove the busbar connector header from the busbar leads.
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    Note
    Carefully slide the header off from the leads.
  34. Remove the retainer clips (x2) and shielding (x2) from the busbar leads, and then remove the remaining components (x2 shielding holders) from the busbars.

Install

  1. Clean the busbar leads of residual Penetrox with an Isopropyl Alcohol (IPA) wipe. Allow 1 minute to dry before continuing.
  2. Install the HV connector header to the busbar leads.
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    Note
    Press firmly and evenly until the leads are fully seated and the holes align for fastener installation.
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    Note
    Perform push-pull-push test.
  3. Install the screws (x2) that attach the HV connector to the busbar leads.
    1.5 Nm (1.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T20 bit
  4. Install the charge port to HV battery busbars. See Busbars - Charge Port to HV Battery (Remove and Replace).
  5. Install the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  6. Connect the charge port electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the electrical connector, and then install the white locking tab. The connector is intended to lock the safety cap in place.
  7. Connect the charge port latch electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Return the harness to original routing: Harness sits in front of the busbars.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the connector and the red locking tab.
  8. Secure the harness clip for the 60 seat and rear seat cushion.
  9. Connect the 60 split seat electrical connector.
  10. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  11. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  12. Install LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  13. Install LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  14. Install the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  15. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  16. Install the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  17. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  18. Install the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  19. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  20. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  21. Close the liftgate.
  22. Restore the LH 2nd row 60 seat into upright position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection.
  23. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  24. Install the LH and RH 2nd row seat side bolsters. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  25. Reconnect LV power. See LV Power (Disconnect and Connect).
  26. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  27. Close the hood.
  28. Verify operation of the vehicle charging system.
  29. Close the charge port door.
  30. Raise the LH front window.
  31. Restore the driver and front passenger seats back to their original position.
  32. Close all four doors.