2025-01-21

High Voltage System - Charge System Inlet - Charge Port - Charge Port Door

Correction code44010105020.5 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-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1130480-00-A Test Probes, Slim, Fluke TP38
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.

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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.

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Warning
Make sure that the HV gloves are not expired.
  • North America: 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. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Torque Specifications

Table 1. Torque Specifications: High Voltage System - Charge System Inlet - Charge Port - Charge Port Door
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (X3) that attach charge port assembly to vehicle
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
 Reuse
Nuts (X2) secure charge port busbar leads to charge port assembly
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
  • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
  • Electrical Protective Gloves
 Reuse Nuts have captured washers, if excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.

Remove

  1. Remove the charge port controller. See High Voltage System - Charge System Inlet - Charge Port - Charge Port Controller.
  2. Remove charge port safety cap.
  3. Remove fasteners securing charge port busbar to charge port, and remove busbar leads from studs.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
    • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
    • Electrical Protective Gloves
  4. Release LH body harness from rear body and move aside.
  5. Remove charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
  6. Remove charge port door.

Install

  1. If reinstalling the same charge port, clean the charge port busbar HV header at the back of the charge port assembly with an IPA wipe, and then air dry for 1 minute.
    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
    TIp
    Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  2. Remove charge port door.
  3. Install charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
  4. Install LH body harness onto rear body.
  5. Apply Penetrox to backside of busbar leads.
  6. Install charge port busbar leads to charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
    • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
    • Electrical Protective Gloves
  7. Put on HV insulating gloves and leather over gloves.
  8. 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 270 mΩ (270 μΩ), escalate a Toolbox session, 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.
  9. Install charge port safety cap.
  10. Install the charge port controller. See High Voltage System - Charge System Inlet - Charge Port - Charge Port Controller.