HIGH VOLTAGE BUSBAR CHARGE PORT (Remove and Replace)
Correction code
4450010302
FRT
0.70
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.
- 1076921-00-B FLUKE DIGITAL MULTIMETER 1507
- 1130480-02-B Slim Test Probes, CAT III 1000V
- 1076927-00-A HIOKI RM 3548
- 1076928-00-A TEST PROBES - HIOKI 9461
- 1083188-01-B Digital Multimeter Unit, EXTECH 355
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.
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.
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
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.
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
Description | Torque Value | Recommended Tools | Reuse/Replace | Notes |
---|---|---|---|---|
Nuts (x2) that attach the charge port busbar leads to the charge port assembly |
![]() 9 Nm (6.6 lbs-ft) |
|
Reuse | |
Busbar access door bolt |
![]() 9 Nm (6.6 lbs-ft) |
|
Reuse | |
Bolts (x2) that attach the charge port busbars to the HV header |
![]() 9 Nm (6.6 lbs-ft) |
|
Reuse | |
Busbar studs at the back of the charge port |
![]() 2 Nm (1.5 lbs-ft) |
|
N/A |
Remove
- Open the trunk.
- Open all four doors and lower all windows.
- Remove the 2nd row lower seat cushion. See 2ND ROW SEAT CUSHION (Remove and Replace).
- Disconnect the LV power. See LV Power (Disconnect and Connect).
- Perform Vehicle HV Disablement Procedures. See Vehicle HV Disablement Procedure.
- Remove the LH lower C pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
- Remove the trunk sill trim. See TRUNK SILL LOWER TRIM (Remove and Replace).
- Remove the rear trunk load floor. See Bracket - Load Floor - LH (Remove and Replace).
- Remove the LH trunk side trim. See TRUNK SIDE TRIM LEFT HAND - REAR UNDER BODY (Remove and Replace).
- Release the white lock tab and then disconnect the DC logic connector from the charge port assembly.
- Put on HV insulating gloves and leather over gloves.
-
Use a pick to gently release
the tabs (x2) that attach the safety cap to the busbar brackets, and then
remove the safety cap.
NoteDo not pry with excessive force, as doing so could damage the safety cap.
-
Remove the nuts (x2) that
attach the charge port busbar leads to the charge port assembly.
TIpUse of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
- Ratchet/torque wrench
- Electrical Protective Gloves
-
Remove the bolt that closes the charge
port busbar access door at the ancillary bay HV header, and then open the access
door.
TIpUse of the following tool(s) is recommended:
- Insulated
tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm deep socket
- Electrical Protective Gloves
- Insulated
tools:
-
Remove the bolts (x2) that attach the
charge port busbars to the HV header.
TIpUse of the following tool(s) is recommended:
- Insulated
tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm deep socket
- Electrical Protective Gloves
- Insulated
tools:
-
Lift and remove the charge port busbar
connector from the HV header.
NoteWiggle the connector back and forth to ease removal.
- Release LH body harness from rear body and move aside.
- Remove the clips (x6) that attach the 3-phase electrical harness to the charge port busbar.
- Move the 2nd row LH seat back into the vertical position.
-
With assistance, remove the
charge port busbars out through the trunk.
NoteManeuver the busbars through the body harness, rotating the busbars as needed.
Install
-
With assistance, position
the charge port busbars for installation by inserting the busbars through
the trunk.
NoteManeuver the busbars through the body harness, rotating the busbars as needed.
- Fold up the LH 2nd row seat back and remove the protective covering from the 2nd row seat cushion area.
- Clean the HV header contact surface with an IPA wipe, and allow to dry for 1 minute.
- Apply 2 drops of Penetrox A-13 about 5mm in diameter onto either side of the holes on both leads of the HV header, and then spread evenly to ensure the contact surface is fully covered.
-
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.
TIpGently lift the rear half of the busbars to aid installation of the busbars on the HV header.NoteIf positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
-
Install the bolts (x2) that
attach the charge port busbars to the HV header.9 Nm (6.6 lbs-ft)TIpUse of the following tool(s) is recommended:
- Insulated
tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm deep socket
- Electrical Protective Gloves
- Insulated
tools:
-
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.
NoteThe 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.NoteIf 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.
-
Close the charge port busbar
access door, and then install the bolt on the access door.9 Nm (6.6 lbs-ft)TIpUse of the following tool(s) is recommended:
- Insulated
tools:
- Extension 1/4 Dr. Wobble 10.5"
- Ratchet/torque wrench
- 10 mm deep socket
- Electrical Protective Gloves
- Insulated
tools:
- Install LH body harness onto rear body.
- Clean the charge port busbar contact surface with IPA wipes, and then allow 1 minute to dry.
-
Perform a torque check on
the busbar studs on the back of the charge port.2 Nm (1.5 lbs-ft)NoteSkip this step if installing a new charge port assembly.TIpUse of the following tool(s) is recommended:
- Torx T10 socket
- 4 in extension
- Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
-
Apply two drops of Penetrox
A-13 about 5mm in diameter on each of the charge port busbar leads (x2), on
the side that makes contact with the charge port.
NoteSkip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.NoteMake sure the contact surfaces are completely covered with electrical joint compound.
-
Install the nuts (x2) that
attach the charge port busbar leads to the charge port assembly.9 Nm (6.6 lbs-ft)NoteIf positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.TIpUse of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
- Ratchet/torque wrench
- Electrical Protective Gloves
- Put on HV insulating gloves and leather over gloves.
-
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.
NoteThe 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.NoteIf 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.
- Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
- Remove the HV insulating gloves and leather over gloves.
- Connect the DC logic connector to the charge port assembly and then engage the white lock tab.
- Install the trunk side trim. See TRUNK SIDE TRIM LEFT HAND - REAR UNDER BODY (Remove and Replace).
- Install the LH trunk load floor bracket. See .
- Install the trunk sill trim. See TRUNK SILL LOWER TRIM (Remove and Replace).
- Install the LH lower C pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
- Connect the LV power. See LV Power (Disconnect and Connect).
- Install the LH 2nd row seat cushion bracket. See .
- Move the LH and RH front seats back to their original position.
- Raise all the windows and close all the doors.
- Close the trunk.