2026-11-02

HV Harness - Charge Port Busbar (NACS) (Remove and Replace)

Código de corrección 4450010302 FRT 0.84 NOTA: Salvo que se indique lo contrario explícitamente en el procedimiento, el código de corrección y el FRT asociado reflejan todo el trabajo necesario para realizar este procedimiento, incluidos los procedimientos vinculados. No acumule códigos de corrección a menos que se le indique explícitamente que lo haga. NOTA: Consulte Tiempos de tarifa plana para obtener más información sobre los FRT y cómo se crean. NOTA: Consulte Protección personal para asegurarse de llevar el EPI adecuado al realizar el siguiente procedimiento. NOTA: Consulte Precauciones ergonómicas para ver prácticas de trabajo seguras.

  • 2026-11-02: Updated all HV busbar images to correct part and added missing steps to remove the charge port controller.
  • 2026-01-02: Added links to CCS safety cap removal procedure.
  • 2025-06-04: Added instruction to zero adjust the Hioki resistance meter prior to measurement.
Equipment:
  • 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

Solo los técnicos que hayan completado todos los cursos de certificación requeridos pueden realizar este procedimiento. Tesla recomienda que los técnicos de proveedores de servicios externos realicen una formación equivalente antes de ejecutar este procedimiento. Para obtener más información sobre los requisitos de los técnicos de Tesla o detalles del temario para terceros, consulte Requisitos de certificación de alta tensión. Siempre que se manipule un cable, barra colectora o conexión de alta tensión, deben llevarse equipos de protección individual (EPI) y guantes aislantes para alta tensión con una clasificación nominal mínima de 0 (1000 V). En la nota técnica TN-15-92-003sobre los puntos de peligro de alta tensión, encontrará más información sobre seguridad.

Warning

Quítese todos los artículos de joyería (relojes, pulseras, anillos, cadenas, pendientes, chapas, piercings, etc.) que lleve puestos y todos los objetos (llaves, monedas, bolígrafos, lápices, herramientas, tornillería, etc.) que lleve en los bolsillos antes de realizar cualquier procedimiento en el que se exponga a alta tensión.

Warning
Si necesita utilizar algún elemento de corrección de la visión para realizar con seguridad algún procedimiento, asegúrese de que esté bien sujeto a la cabeza y no pueda caerse.
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

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

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.

Especificaciones de apriete

Table 1. Especificaciones de apriete: HV Harness - Charge Port Busbar (NACS) (Remove and Replace)
Descripción Valor de apriete Herramientas recomendadas Reutilizar/Sustituir Notas
Bolt that secure the charge port controller
5 Nm (3.7 lbs-ft)
  • 10 mm socket
  • Cordless 1/4in Dr Ratchet
 Reutilizar
Nuts (x2) that attach the charge port busbar leads to the charge port assembly
9 Nm (6.6 lbs-ft)
  • Vaso de 10 mm de cuello largo
  • Llave dinamométrica de carraca de cabezal flexible/cabezal flexible
  • Llave de carraca/dinamométrica
  • Electrical Protective Gloves
 Reutilizar
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • Extension 1/4 Dr. Wobble 10.5"
    • Llave de carraca/dinamométrica
    • Vaso de 10 mm de cuello largo
  • Electrical Protective Gloves
 Reutilizar
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"
    • Llave de carraca/dinamométrica
    • Vaso de 10 mm de cuello largo
  • Electrical Protective Gloves
 Reutilizar
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Vaso Torx T10
  • Extensión de 4 pulg.
  • Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
 N/A

Retirar

  1. Open the trunk.
  2. Open all four doors and lower all windows.
  3. Remove the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  4. Disconnect the LV power. See LV Power (Disconnect and Connect) (Modify).
  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 Soporte - Suelo del maletero - Lado izquierdo (Desinstalación y sustitución).
  9. Remove the LH trunk side trim. See Trunk Side Trim LH - Rear Under Body (Remove and Replace).
  10. Remove the bolt and disconnect the connectors (x3) to disconnect the charge port controller.
    Note
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Cordless 1/4in Dr Ratchet
  11. Release the white lock tab and the disconnect the DC logic connector from charge port assembly.
  12. Use a plastic pry tool to gently release the tabs (x2) and clip that attach the safety cap to the busbar brackets, and then remove the safety cap.
  13. Remove the nuts (x2) that secure the charge port busbar to charge port and remove busbar leads from the studs.
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Insulated 10 mm socket
    • Cordless 1/4in Dr Ratchet
    Note
    Nuts have captured washers. You do not need to remove the bus bars; only clearance for the charge port assembly is required.
  14. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Insulated tools:
      • Extension 1/4 Dr. Wobble 10.5"
      • Llave de carraca/dinamométrica
      • Vaso de 10 mm de cuello largo
    • Electrical Protective Gloves
  15. Remove the bolts (x2) that attach the charge port busbars to the HV header.
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Insulated tools:
      • Extension 1/4 Dr. Wobble 10.5"
      • Llave de carraca/dinamométrica
      • Vaso de 10 mm de cuello largo
    • Electrical Protective Gloves
  16. Release LH body harness from rear body and move aside.
  17. Lift and remove the charge port busbar connector from the HV header.
    Note
    Use a inflatable air bag to suspend busbar away from HV header during removal and installation. Hold busbar firmly as there is tension on.
    CAUTION
    Avoid damaging the harness bracket.
  18. Release the clips (x4) that secure the body harness and move harness away from the body to give room to remove the busbar.
  19. Remove the charge port busbars out through the trunk.
    Note
    Recommend assistance. Guide the charge port busbar kit through the body harness, rotating as needed for clearance, then maneuver it rearward through the trunk.

Instalar

  1. Clean the HV connector contact surface with an IPA wipe, and allow to dry for 1 minute.
  2. Clean the busbar HV connector contact surface with an IPA wipe, and allow to dry for 1 minute.
    Note
    It is necessary to clean HV connector during re-use of busbar.
  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, position the charge port busbars for installation by inserting the busbars through the trunk.
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.
  5. Install the clips (x4) that secure the body harness.
  6. Remove the inflatable air bag from under HV header.
  7. 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.
    Tip
    Gently lift the rear half of the busbars to aid installation of the busbars on the HV header.
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
  8. Install the bolts (x2) that attach the charge port busbars to the HV header. Mark the bolts after torque.
    9 Nm (6.6 lbs-ft)
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Herramientas aisladas:
      • Extensión oscilante de 10,5", vaso de 1/4 pulg.
      • Llave de carraca/dinamométrica
      • Vaso de 10 mm de cuello largo
    • Guantes de protección eléctrica
  9. Perform a zero adjust of the Hioki resistance meter. See Medidor de resistencia (Ajuste a cero).
  10. 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. The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
    Note
    If the measured resistance is above 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Stop work and escalate the Toolbox session.
    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.
  11. Close the charge port busbar access door, and then install the bolt on the access door.
    9 Nm (6.6 lbs-ft)
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Herramientas aisladas:
      • Extensión oscilante de 10,5", vaso de 1/4 pulg.
      • Llave de carraca/dinamométrica
      • Vaso de 10 mm de cuello largo
    • Guantes de protección eléctrica
  12. Install LH body harness onto rear body.
  13. 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.
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Note
    Make sure the contact surfaces are completely covered with electrical joint compound.
  14. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Note
    If positioning the busbars requires excessive force, the busbars might be bent. Inspect for damage and replace the busbars if necessary.
    Tip
    Se recomienda utilizar las siguientes herramientas:
    • Vaso de 10 mm de cuello largo
    • Llave dinamométrica de carraca de cabezal flexible/cabezal flexible
    • Llave de carraca/dinamométrica
    • Electrical Protective 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. The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ).
    Note
    If the measured resistance is above 0.270 mΩ (270 μΩ), there is too much resistance in the High Voltage joint. Stop work and escalate the Toolbox session.
    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.
    Note
    For instructions on installing CCS charge caps, see Charge Port Safety Cap - CCS2 (Remove and Replace).
  17. Connect the DC logic connector to the charge port assembly and then engage the white lock tab.
  18. Install the bolt, the connectors (x3) and the datums (x2) to install the charge port controller.
    5 Nm (3.7 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 10 mm socket
    • Cordless 1/4in Dr Ratchet
  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) (Modify).
  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.