04/06/2024 18:03:19

Busbars - Charge Port to HV Battery (3-Phase) (Remove and Replace)

Correction code 44013152 0.84 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.

  • 2024-02-01: Removed steps for actuator pan and motor, and vehicle electrical isolation procedure.
  • 2023-07-10: Added steps to remove/install actuator pan and motor, and readded step for isolation procedure.
  • 2023-05-24: Replaced the vehicle electrical isolation procedure with the charge port voltage check procedure.
  • 1076927-00-A Hioki RM 3548
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 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.

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.

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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: Busbars - Charge Port to HV Battery (3-Phase) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nut that attaches 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
Reuse The nut has captured washers
Busbar access door bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Busbar to ancillary bay HV header bolt
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 bit
  • 4 in extension
  • Ratchet/torque wrench
N/A

Remove

  1. Open all the doors and lower all the windows.
  2. Move the front seats forward.
  3. Open the liftgate, hood and charge port door.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  6. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  7. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  8. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  9. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  10. Remove the front trunk load floor. See Trunk Load Floor - Front (Remove and Replace).
  11. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  12. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  13. Remove the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  14. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  15. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  16. Remove the LH C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  17. Carefully pull out the locking tab, and then disconnect the logic connector from the charge port.
  18. Push the locking tab upward, and then disconnect the AC cable from the charge port.
  19. Slide the red locking tab away from the LH taillight connector, and then disconnect the harness from the taillight.
  20. 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.
  21. Remove the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  22. Disconnect the harness from the electrical connector at the LH rear seat rail.
  23. Release the clip that attaches the electrical connector to the LH rear seat rail, and then move the connector aside.
  24. 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.
  25. Remove the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  26. Release the red locking tab, rotate the black lever upwards, and then disconnect the AC cable from the ancillary bay HV header.
  27. 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
    • Flex head ratchet/flex head torque wrench
  28. Remove the bolts (x2) that attach the charge port busbars to the HV header.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  29. 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.
  30. Remove the busbars from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance recommended. Guide the busbar and 3-phase AC harness through under the body harness rotating as needed for clearance, and then maneuver rearward through the liftgate

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. With assistance, position the charge port busbars for installation by inserting the busbars through the liftgate.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the busbars through the body harness, rotating the busbars as needed.
  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.
    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)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  7. Close the charge port busbar access door, and then install the bolt on the access door.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  8. Connect the AC cable to the ancillary bay HV header, rotate the black lever downward, and then engage the red locking tab.
  9. Install the clip that attaches the LH body harness to the vehicle near the LH rear door opening.
  10. Install the clips (x3) that attach the LH harness guide to the vehicle near the LH rear door sill area.
  11. Install the electrical connector harness clip to the LH rear seat rail.
  12. Connect the harness connector at the LH rear seat rail.
  13. Clean the charge port assembly busbar contact surface with an IPA wipe from any residual Penetrox.
  14. Apply two drops of Penetrox A-13 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.
    Figure 1. Busbar bracket design may vary
  15. 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.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
  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. Remove the HV insulating gloves and leather over gloves.
  19. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  20. Connect the AC cable harness connector to the charge port.
  21. Connect the electrical harness to the taillight connector, and then engage the connector lock.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the connector has a red locking tab: Push the red locking tab into the connector to engage the connector lock.
  22. Connect the logic connector to the charge port.
  23. Install the LH C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  24. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  25. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  26. Install the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  27. Install the LH load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  28. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  29. Install the front trunk load floor. See Trunk Load Floor - Front (Remove and Replace).
  30. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  31. Install the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  32. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  33. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  34. Close the liftgate.
  35. Move the front seats to the original positions.
  36. Verify the correct operation of the charging system.
  37. Close the charge port door.
  38. Raise all the windows and close all the doors.