2025-03-13

Charge Port - Combine Charging Standard 2 (CCS2) (Remove and Replace)

Correction code 4401010102 FRT 0.50 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:Charge Port - Combine Charging Standard 2 (CCS2) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Charge port controller
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • Cordless Ratchet/Impact Driver
 Reuse
Fasteners (X2) securing charge port busbar to charge port
9 Nm (6.6 lbs-ft)
  • 10 mm socket
  • Cordless Ratchet/Impact Driver
 Reuse
Fastener (X1) securing busbar cover access door
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) securing charge port busbar kit to HV header
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
  • Ratchet/torque wrench
  • Electrical Protective Gloves
 Reuse

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. Put on HV insulating gloves and leather over gloves.
  11. Disconnect charge port controller.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  12. Disconnect DC logic connector from charge port assembly.
  13. Remove charge port safety cap.
  14. Remove fasteners (X2) securing charge port busbar to charge port and remove busbar leads from studs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers, you do not need to remove the bus bars, only clearance for charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  15. 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
  16. 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:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  17. Release LH body harness from rear body and move aside.
  18. Lift busbar kit connector to remove from HV header.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wiggle the connector back and forth to ease removal.
  19. Remove HV busbar assembly from vehicle

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. Clean the HV header contact surface with an IPA wipe, and allow to dry for 1 minute.
  3. 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.
  4. 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.
  5. 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:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  6. 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.
  7. 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
  8. Install LH body harness onto rear body.
  9. Clean the charge port busbar contact surface with IPA wipes, and then allow 1 minute to dry.
  10. Install charge port busbar leads to charge port assembly.
    9 Nm (6.6 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:
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  11. Install charge port safety cap.
  12. Connect DC logic connector from charge port assembly.
  13. Install charge port controller.
    10 Nm (7.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Cordless Ratchet/Impact Driver
  14. Install the trunk side trim. See Trunk Side Trim LH - Rear Under Body (Remove and Replace).
  15. Install the LH trunk load floor bracket. See .
  16. Install the trunk sill trim. See Trunk Sill Lower Trim (Remove and Replace).
  17. Install the LH lower C pillar trim. See Trim - C-Pillar - Lower - LH (5-Seat) (Remove and Replace).
  18. Connect the LV power. See LV Power (Disconnect and Connect).
  19. Install the LH 2nd row seat cushion bracket. See .
  20. Move the LH and RH front seats back to their original position.
  21. Raise all the windows and close all the doors.
  22. Close the trunk.