03/07/2024 15:59:20

Charge Port Housing Assembly

Repair Information

Review all collision repair general practices and safety documentation and wear the appropriate PPE (Personal Protective Equipment) before beginning this procedure.
This procedure can be completed without using a frame bench.

Parts List


Quantity	Description	Image / Notes
1	M3 CHARGE PORT HOUSING ASSY SVC (Charge Port Housing Bracket)
1	Rivnut,M6x1,4.0mm GRP,STL,ZnNi	Tesla part number 1038174-00-A. Note Required only if the vehicle has a Rivnut to attach the ground wire to the Charge Port Housing Assembly.

When ordering parts, refer to the Parts Catalog and enter the VIN of the vehicle being repaired to find the correct parts (and the part numbers) for the vehicle. Alternatively, use the search function in the Parts Catalog to find a specific part for the vehicle.

Repair Procedure

Remove the original component.
or Factory Spot Welds
Prepare for installation.

Note
If the original component had a Rivnut in the location circled in red, install a Rivnut in that location.

or Installation Spot Welds

or Steel Plug Welds

Rivnut (if needed)
Apply seam sealer in the area where the Charge Port Housing Bracket makes direct contact to the Quarter Panel skin and the factory foam baffle (shown here in yellow).

CAUTION
This procedure calls for a seam sealer with a cured elongation rating of greater than 150%. This is to prevent visible distortion of the quarter panel’s exterior surface where the Charge Port Housing Bracket is bonded to the inside of the panel.

CAUTION
If using a seam sealer not designed for application over bare metal surfaces, the mating surface on the inside of the quarter panel will require refinishing prior to installing the Charge Port Housing Assembly. Refer to the technical data sheet for the seam sealing product being used.
Apply structural adhesive to the mating surfaces on the vehicle and the new component or components.
Install the new component or components.

Note
If needed, install the Rivnut.
Perform resistance spot welding.
or Installation Spot Welds
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.

CAUTION
Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.
Perform GMA welding.
or Steel Plug Welds
Warning
Failure to follow all welding safety precautions, including the use of personal protective equipment, could result in serious injury or property damage. Only technicians who have completed Tesla’s approved welding training are authorized to weld structural components on Tesla vehicles.

Warning
To maintain vehicle crash integrity, use only approved welding wire and an approved GMA welder to perform GMA welding on Tesla vehicles. Refer to Approved Gas Metal Arc (GMA) Welders and Welding Wire for information on approved GMA welders and welding wire.

CAUTION
Do not weld on a Tesla vehicle before performing the Vehicle Electrical Isolation Procedure (refer to the vehicle-specific Service Manual for more information on the Vehicle Electrical Isolation Procedure). Welding on a Tesla vehicle with an energized high or low voltage system might damage vehicle components.

Note
Before GMA welding, a test weld using material of the same gauge and type should be performed to make sure that the welding equipment settings produce a satisfactory joint.
If a Rivnut was installed, use a multimeter to check continuity between the rivnut and the charge port housing.

Note
Resistance not to exceed 0.2mΩ.
Perform any necessary post-repair operations.