04/06/2024 18:00:11

Busbars - Charge Port to HV Battery (Remove and Replace)

Correction code 44013102 0.90 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.

  • 2023-10-10: Added a caution to not manually close the charge port door.
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 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: Busbars - Charge Port to HV Battery (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Busbar to charge port nut
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • ¼ in std flex head ratchet
  • ¼ in torque wrench (installation only)
Reuse
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • ¼ in std flex head ratchet
  • ¼ in torque wrench (installation only)
Reuse
Busbar to ancillary bay HV header bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • ¼ in std flex head ratchet
  • ¼ in torque wrench (installation only)
Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 bit
  • Ratchet/torque wrench
  • 4 in extension
N/A Perform a torque check on the studs
Edge support bracket bolt
10 Nm (7.4 lbs-ft)
  • 10 mm socket
  • 4 in extension
  • Ratchet/torque wrench
Reuse

Remove

  1. Lower all windows.
  2. Open all doors and latch the rear doors.
  3. Move the driver seat and front passenger seat fully forward.
  4. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  5. Open the liftgate.
  6. Open the hood.
  7. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  8. Open the charge port door.
  9. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  10. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  11. Remove the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  12. Remove the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  13. Remove the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  16. Remove the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  17. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  18. Release the clips (x6) and tab (x1) that attach the LH upper C-Pillar trim to the vehicle, and then set the trim aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the foremost part of the LH upper C-Pillar trim from the headliner.
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH upper C-Pillar trim will still be attached to the rear seatbelt.
  19. Remove the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  20. Disconnect the LH body harness connectors (x2) from the charge port ECU.
  21. Release the clip that attaches the LH body harness to the vehicle.
  22. Slide the red locking tab away from the LH taillight connector, and then disconnect the harness from the taillight.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
  23. Release the locking tabs from the charge port low voltage connectors (x2), and then disconnect the connectors (x2) from the charge port.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
    Tip: Gently lift the black connector tab in order to remove the white locking tab from the 12-pin low voltage connector.
  24. Remove the charge port busbar fastener cover from the charge port assembly.
  25. Remove the nuts that attach the charge port busbars to the charge port.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  26. Disconnect the harness from the electrical connector at the LH rear seat rail.
  27. Release the clip that attaches the electrical connector to the LH rear seat rail, and then move the connector aside.
  28. Release the clips (x3) that attach the LH harness guide to the vehicle near the LH rear door sill area.
    Informational PurposesAn informational icon, calling your attention
    Note
    Releasing these clips will loosen the LH body harness from the vehicle and facilitate removal of the charge port busbars.
  29. Remove the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  30. Remove the bolt that closes the charge port busbar access door at the ancillary bay HV header, and then open the access door.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  31. Remove the bolts (x2) that attach the charge port busbars to the HV header at the ancillary bay.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  32. Position a fender cover or other protective material on the vehicle, underneath the charge port busbars.
  33. With assistance, lift the charge port busbars away from the HV header, and then carefully maneuver the busbars through the liftgate.
    Tip: Gently lift the rear half of the busbars to aid removal of the busbars from the HV header.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Clean the charge port busbar HV header at the ancillary bay with an IPA wipe, and allow to dry for 1 minute.
  3. Clean the charge port busbar HV header at the back of the charge port assembly with an IPA wipe, and allow to 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.
    Tip: Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  4. 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.
    Tip: Use of the following tool(s) is recommended:
    • Torx T10 bit
    • Ratchet/torque wrench
    • 4 in extension
  5. Apply one drop of electrical joint compound on each of the charge port busbar HV header contacts (x2) at the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port busbar, as the new busbar has pre-applied electrical joint compound.
  6. If reinstalling the same busbar: Remove all residue/debris from the mating surfaces of both ends of the busbar using an IPA wipe.
  7. With assistance, position the charge port busbars in the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars into the vehicle through the liftgate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to position the busbars underneath the LH body harness guide near the LH rear seat rail.
  8. 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.
    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.
  9. Install the bolts (x2) that attach the charge port busbars to the HV header at the ancillary bay.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  10. Install the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  11. Install the clips (x3) that attach the LH harness guide to the vehicle near the LH rear door sill area.
  12. Install the clip that attaches the electrical connector to the LH rear seat rail.
  13. Connect the harness to the electrical connector at the LH rear seat rail.
  14. Apply two drops of electrical joint compound 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.
  15. Position the charge port busbars on the charge port, and then install the nuts that attach the busbars to the charge port.
    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.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  16. Put on HV insulating gloves and leather over gloves.
  17. 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.
  18. 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.
  19. Remove the HV insulating gloves and leather over gloves.
  20. Close the charge port busbar access door, and then install the bolt that locks the access door in position.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  21. Install the charge port busbar fastener cover on the charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    The charge port busbar fastener cover will not be secure until the next step is performed.
  22. Connect the low voltage harness connectors (x2) on the charge port, and then install the locking tabs (x2) that secure the connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the connector lock.
    Tip: Carefully insert the white locking tab in the 12-pin low voltage connector until it locks with the black connector tab.
  23. Connect the electrical harness to the taillight, and then slide the red locking tab toward the connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the connector lock.
  24. Install the clip that attaches the LH body harness to the vehicle.
  25. Connect the LH body harness connectors (x2) to the charge port ECU.
  26. Install the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  27. Position the LH upper C-Pillar trim on the vehicle, and then install the clips (x6) and tab (x1) that attach the trim to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the upper groove in the front portion of the C-Pillar trim with the headliner.
  28. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  29. Install the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  30. Install the LH load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  31. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  32. Install the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  33. Install the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  34. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  35. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  36. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  37. Close the liftgate.
  38. Close the charge port door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  39. Place the driver and front passenger seats back to their previous positions.
  40. Unlatch and close all doors.