04/06/2024 18:00:29

Chargeport (EU) (Remove and Replace)

Correction code 4401010072 FRT 0.66 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-A FLUKE DIGITAL MULTIMETER 1587
  • 1130480-02-A Slim Test Probes
  • 1076927-00-A Hioki RM 3548
  • 1076928-00-A Test Probes, Hioki 9461
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.
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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
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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: Chargeport (EU) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts (x2) that attach 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
  • Ratchet/torque wrench
  • Electrical Protective Gloves
 Reuse
Bolts (x3) that attach the charge port assembly to the vehicle
5.5 Nm (4.1 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
  • Ratchet/torque wrench
  • Electrical Protective Gloves
 Reuse
Busbar studs at the back of the charge port
2 Nm (1.5 lbs-ft)
  • Torx T10 socket
  • 4 in extension
  • Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
 N/A

Remove

  1. Open the LH front door and lower the LH front window.
  2. Open the trunk from exterior switch.
  3. Open the charge port door manually.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect the LV power. See LV Battery - Li-lon (Disconnect and Connect).
  6. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  7. Remove the trunk load floor. See Load Floor - Trunk (Remove and Replace).
  8. Remove the trunk garnish. Garnish - Trunk (Remove and Replace).
  9. Remove the trunk sill trim. See Trim - Trunk Sill (Remove and Replace).
  10. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  11. Disconnect the LH trunk task light electrical connector.
  12. Remove the clip that secures the LH trunk side trim to the vehicle, and then move the side trim aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to cause excessive creasing when moving the side trim.
  13. Remove the white locking tab, and then disconnect the DC logic connector from the charge port assembly.
  14. Release the locking tab, and then disconnect the electrical connector from the charge port actuator.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not push down on the red tab. Pull the red tab away to disengage lock, and then pull again to release the connector.
  15. Remove the white locking tab, and then disconnect the AC logic connector from the charge port assembly.
  16. Release the charge port manual release cable from the cable bracket.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Gently release the clip to avoid damage. Do not apply excess force.
  17. Remove the harness clip from vehicle body with a clip prytool.
  18. Inspect and put on HV insulating gloves and leather gloves.
  19. Pull the locking tab upward to release, and then disconnect the AC 3-phase connector from the charge port assembly.
  20. Remove the charge port safety cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Gently release the tabs and clip to avoid damage. Do not apply excessive force.
  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
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  22. Remove the bolts (x3) that attach the charge port assembly to the vehicle, and remove the charge port assembly from the vehicle.
    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

Install

  1. Position the charge port on the vehicle, and then install the bolts (x3) that attach the charge port to the vehicle.
    5.5 Nm (4.1 lbs-ft)
    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
  2. If reinstalling the same charge port: 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.
  3. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
  4. If reinstalling the same charge port: 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.
  5. If reinstalling the same charge port: 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 socket
    • 4 in extension
    • Torque Wrench 1/4in Dr Hexagon - 1060071-00-A
  6. Position the charge port busbars on the charge port, and then install the nuts (x2) that attach the busbar leads to the charge port.
    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
    • Ratchet/torque wrench
    • Electrical Protective Gloves
  7. Put on HV insulating gloves and leather gloves.
  8. 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.
  9. Install the safety cap on the busbar brackets, making sure to engage the tabs and clip.
  10. Connect the AC 3-phase connector to the charge port, and then slide the locking tab downward to engage.
  11. Remove the HV insulating gloves and leather gloves.
  12. Install the harness clip to vehicle body.
  13. Secure the charge port manual release cable onto the cable bracket.
  14. Connect the AC logic connector on the charge port, and then install the white locking tab.
  15. Connect the electrical connector to the charge port actuator, and then engage the locking tab.
  16. Connect the DC logic connector on the charge port, and then install the white locking tab.
  17. Move the LH trunk side trim back into position.
  18. Connect the LH trunk task light electrical connector.
  19. Secure the LH trunk side trim with the clip.
  20. Install the trunk garnish. Garnish - Trunk (Remove and Replace).
  21. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  22. Install the trunk sill trim. See Trim - Trunk Sill (Remove and Replace).
  23. Install the trunk load floor. See Load Floor - Trunk (Remove and Replace).
  24. Connect the LV power. See LV Battery - Li-lon (Disconnect and Connect).
  25. Reinstall the software. See Software Reinstall - Touchscreen.
  26. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  27. Close the trunk.
  28. Close the charge port door.
  29. Verify operation of the charging system.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lightly push on the lower corner of the charge port door, close the door once opening is confirmed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Press the button on the charge handle, there can be brief time out. Once the charge port door is open, confirm the vehicle is charging by connecting the charge handle to the vehicle. Then disconnect the charge handle and confirm the charge port door closes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  30. Raise the LH front window and close the LH front door.