2025-03-12

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
Warning IconA warning icon, calling your attention to a possibly risky situation
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 safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

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
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

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

Table 1. Torque Specifications: High Voltage Busbar Charge Port (Remove and Replace)
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)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
  • Ratchet/torque wrench
  • Electrical Protective Gloves
 Reuse
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
    • 10 mm deep socket
  • Electrical Protective Gloves
 Reuse
Bolts (x2) that attach the charge port busbars to the HV header
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Extension 1/4 Dr. Wobble 10.5"
    • Ratchet/torque wrench
    • 10 mm deep socket
  • Electrical Protective Gloves
 Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 socket
  • 4 in extension
  • Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
 N/A

Remove

  1. Open the trunk.
  2. Open all four doors and lower all windows.
  3. Remove the 2nd row lower seat cushion. See 2nd Row Seat Cushion (Remove and Replace).
  4. Disconnect the LV power. See LV Power (Disconnect and Connect).
  5. Perform Vehicle HV Disablement Procedures. See Vehicle HV Disablement Procedure.
  6. Remove the LH lower C pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  7. Remove the trunk sill trim. See Trunk Sill Lower Trim (Remove and Replace).
  8. Remove the rear trunk load floor. See Bracket - Load Floor - LH (Remove and Replace).
  9. Remove the LH trunk side trim. See Trunk Side Trim LH - Rear Under Body (Remove and Replace).
  10. Release the white lock tab and then disconnect the DC logic connector from the charge port assembly.
  11. Put on HV insulating gloves and leather over gloves.
  12. Use a pick to gently release the tabs (x2) that attach the safety cap to the busbar brackets, and then remove the safety cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not pry with excessive force, as doing so could damage the safety cap.
  13. Remove the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  14. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use 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
  15. Remove the bolts (x2) that attach the charge port busbars to the HV header.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use 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
  16. Lift and remove the charge port busbar connector from the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wiggle the connector back and forth to ease removal.
  17. Release LH body harness from rear body and move aside.
  18. Remove the clips (x6) that attach the 3-phase electrical harness to the charge port busbar.
  19. Move the 2nd row LH seat back into the vertical position.
  20. With assistance, remove the charge port busbars out through the trunk.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.

Install

  1. With assistance, position the charge port busbars for installation by inserting the busbars through the trunk.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.
  2. Fold up the LH 2nd row seat back and remove the protective covering from the 2nd row seat cushion area.
  3. Clean the HV header contact surface with an IPA wipe, and allow to dry for 1 minute.
  4. 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.
  5. 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.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Gently lift the rear half of the busbars to aid installation of the busbars on the HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
  6. Install the bolts (x2) that attach the charge port busbars to the HV header.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use 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
  7. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), the test has passed; continue to the next step.
  8. Close the charge port busbar access door, and then install the bolt on the access door.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use 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
  9. Install LH body harness onto rear body.
  10. Clean the charge port busbar contact surface with IPA wipes, and then allow 1 minute to dry.
  11. Perform a torque check on the busbar studs on the back of the charge port.
    2 Nm (1.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T10 socket
    • 4 in extension
    • Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
  12. 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the contact surfaces are completely covered with electrical joint compound.
  13. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  14. Put on HV insulating gloves and leather over gloves.
  15. 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.
    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 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), the test has passed; continue to the next step.
  16. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  17. Remove the HV insulating gloves and leather over gloves.
  18. Connect the DC logic connector to the charge port assembly and then engage the white lock tab.
  19. Install the trunk side trim. See Trunk Side Trim LH - Rear Under Body (Remove and Replace).
  20. Install the LH trunk load floor bracket. See .
  21. Install the trunk sill trim. See Trunk Sill Lower Trim (Remove and Replace).
  22. Install the LH lower C pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  23. Connect the LV power. See LV Power (Disconnect and Connect).
  24. Install the LH 2nd row seat cushion bracket. See .
  25. Move the LH and RH front seats back to their original position.
  26. Raise all the windows and close all the doors.
  27. Close the trunk.