04/06/2024 18:00:47

Busbars - Charge Port to HV Battery (GB) (Remove & Replace)

Correction code 44013112 2.82 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.

Torque Specifications

Table 1. Torque Specifications: Busbars - Charge Port to HV Battery (GB) (Remove & Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that secures the busbar cover access door
9 Nm (6.6 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 10 mm deep socket
  • Small flat head screwdriver
 Reuse
Bolts (x2) that secure the busbar to the HV header
9 Nm (6.6 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 10 mm deep socket
  • 4 in extension
  • Ratchet/torque wrench
 Reuse
Nuts (x2) that secure the charge port busbar to the charge port
9 Nm (6.6 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 4 in extension
  • 11 mm deep socket
  • Ratchet/torque wrench
 Reuse
Charge port studs
2 Nm (1.5 lbs-ft)
  • Ratchet/torque wrench
  • Torx T10 socket
  • 4 in extension
 Reuse

Remove

  1. Open all doors and lower all windows.
  2. On the touchscreen, tap Control > Charging > Open Charge Port to open the charge port door.
  3. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  4. Open the liftgate.
  5. Remove the 2nd row mid floor board.
  6. Remove the LH and RH middle C-pillar trims. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  7. Remove the LH and RH lower C-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  8. Remove the 2nd row rear floor panel.
  9. Remove the busbar duct assembly. See Duct - Busbar - 3rd Row - LH (Remove and Replace).
  10. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  11. Remove the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  12. Remove the trunk carpet.
  13. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  14. Remove the LH crush can bracket. See Trim - Crush Can - Rear Trunk - LH (Remove and Replace).
  15. Remove the LH middle C-pillar zone bracket.
  16. Remove LH trunk trim bracket. See Bracket - Trim - Trunk - LH (Remove and Replace).
  17. Remove the 2nd row LH seat.
  18. Check the charge port voltage. See Charge Port Voltage Check.
  19. If equipped, remove the 3rd row seat cushion. See Cushion - Seat - 3rd Row (Remove and Replace).
  20. Remove the LH inner reinforcement from body. See Reinforcement - Inner - LH (Remove and Replace).
  21. Disconnect the AC inlet harness from the HV Battery.
  22. Release the clips (x2) that secure the AC inlet harness.
  23. Remove the bolt that secures the busbar cover access door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to damage the cover seal when prying.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
    • Small flat head screwdriver
  24. Remove the bolts (x2) that secure the busbar to the HV header, and release the busbar.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to set the busbar aside to prevent unintended re-mating with the pack port.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
    • 4 in extension
    • Ratchet/torque wrench
  25. Release the white locking tab, then disconnect the AC logic connector from the charge port assembly.
  26. Release the white locking tab, then disconnect the DC logic connector from the charge port assembly.
  27. Disconnect the charge port actuator logic connector from the charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not push down on the red tab. Pull the red tab to disengage the lock, then pull it again to release the connector.
  28. Remove the charge port safety cap.
  29. Remove the nuts (x2) that secure the charge port busbar to the charge port, and remove the busbar leads from the studs.
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captured the washers. Take caution of any tension present with the busbar.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
    • 11 mm deep socket
    • Ratchet/torque wrench
  30. Release the AC inlet harness from the charge port.
  31. With assistance, remove the busbar assembly from the LH falcon door opening.

Install

  1. Use IPA wipes to clean the charge port assembly busbar contact surface of residual penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to push the IPA wipe down between the plastic divider.
  2. Verify the charge port studs are torqued to specification.
    2 Nm (1.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Ratchet/torque wrench
    • Torx T10 socket
    • 4 in extension
  3. Use IPA wipes to clean the DC fast charge header contact surface of residual Penetrox, and allow 1 minute to dry.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar comes with penetrox applied to the HV connector.
  4. With assistance, maneuver the busbar assembly through the LH falcon door opening and position it properly for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    New busbar assembly comes with Penetrox A-13 applied on the HV connector side.
  5. Secure the busbar onto the HV header and install the bolts (x2).
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the busbar is seated flush onto the pack port to prevent arching.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
    • 4 in extension
    • Ratchet/torque wrench
  6. Secure the clips (x2) of the AC inlet harness.
  7. Connect the AC inlet harness to the HV battery.
  8. Secure the AC inlet harness onto the charge port.
  9. Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the holes on the backside of both busbar leads, and then spread evenly to verify the contact surface is fully covered.
  10. Install the nuts (x2) that secure the charge port busbar to the charge port.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captured washers. If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 4 in extension
    • 11 mm deep socket
    • Ratchet/torque wrench
  11. Inspect and put on the HV insulating gloves and leather over gloves.
  12. Perform Hioki resistance test at the highlighted locations of each HV joint from the HV busbar lead to the charge port stud.
    • 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), Hioki test passed, proceed to next step.
    • If the resistance is between 0.050 mΩ and 0.270 mΩ (50 μΩ), Hioki test passed, proceed to next step.
    • 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.
  13. Perform Hioki resistance test at each HV joint from the HV busbar lead to the bolt head.
    • 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), Hioki test passed, proceed to next step.
    • If the resistance is between 0.050 mΩ and 0.195 mΩ (50 μΩ), Hioki test passed, proceed to next step.
    • 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.
  14. Remove the leather over gloves and HV insulating gloves.
  15. Install the bolt that secures the busbar cover access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
    • Small flat head screwdriver
  16. Install the charge port safety cap and make sure it clicks into position.
  17. Connect the charge port actuator logic connector to the charge port assembly.
  18. Connect the DC logic connector to the charge port assembly.
  19. Connect the AC logic connector to charge port assembly.
  20. Install the LH inner reinforcement from body. See Reinforcement - Inner - LH (Remove and Replace).
  21. If removed, install the 3rd row seat cushion. See Cushion - Seat - 3rd Row (Remove and Replace).
  22. Install the 2nd row LH seat.
    Informational PurposesAn informational icon, calling your attention
    Note
    No need to run the Toolbox routines. Terminate after installing the LH 2nd row seat post inner and outer trims.
  23. Verify the operation of the vehicle charging system, and close the charge port door.
  24. Move 2nd row LH seat fully forward.
  25. If equipped, fold the 3rd row LH seatback into down position.
  26. Install the LH trunk trim bracket. See Bracket - Trim - Trunk - LH (Remove and Replace).
  27. Install the LH middle C-pillar zone bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pause before installing the LH and RH middle C-pillar trims. Install the busbar duct assembly. See Duct - Busbar - 3rd Row - LH (Remove and Replace). And then continue to install the LH middle C-pillar zone bracket.
  28. Install the RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  29. Install the RH middle C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  30. Close the liftgate.
  31. Move the 2nd row seats to original position.
  32. Install the 2nd row mid floor board.
  33. Hold the B-pillar button in the down position to manually calibrate the LH and RH falcon wing door.
    Informational PurposesAn informational icon, calling your attention
    Note
    The door must be calibrated and closed for firmware to pass.
  34. Move the front seats to original position.
  35. Raise all windows and close all doors.