04/06/2024 18:01:20

Charge Port (NA) (Remove and Replace)

Correction code 4401010061 4401010062 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.

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Warning
This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
  1. Open trunk from exterior switch
  2. Open all four doors
  3. Lower all four windows
  4. Move LH front seat forward
  5. Move RH front seat forward
  6. Open hood
  7. Remove rear underhood apron
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    Note
    14x clips
  8. Place vehicle in service mode
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    Note
    Via UI > Controls > Software, Touch and hold "Model 3" for 4 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
  9. Power off vehicle from center display
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    Note
    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
  10. Disconnect LV battery and First Responder Loop
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    Note
    2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
  11. Verify operation of multimeter
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
  12. Remove all items from pockets and ensure not wearing metal items
  13. Inspect HV insulating gloves
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
  14. Put on HV insulating gloves and leather over gloves
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    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  15. Verify there is no high voltage present at the charge port
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage components, Measure B+ to B-, B- to Ground, and B+ to Ground (use rear left door striker as a ground for the isolation check), If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
  16. Remove HV insulating gloves
  17. Remove load floor
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    Note
    Use pull tab located at rear edge of panel
  18. Remove trunk sill trim assembly
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    Note
    4x clips, Pull corner upward to release clip on end then pull away from body for remaining clips
  19. Remove LH load floor bracket
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    Note
    4x clips, 2x locators, Release bracket front clips, then release clips at rear
  20. Remove trunk garnish assembly
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    Note
    6x clips, 4x locating tabs
  21. Remove clip for LH trunk side trim
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    Note
    1x clip
  22. Disconnect LH trunk task light
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    Note
    1x connector
  23. Move LH trunk side trim to aside
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    Note
    Take care not to cause excessive creasing
  24. Remove LH trough trim
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    Note
    3x clips, 1x bolt, T20, 1.2Nm
  25. Release connectors from chargeport assembly
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    Note
    1x clip, 2x connectors, Remove white locking tab before disconnecting, Pull red locking tab to release lock, pull again to release from connector
  26. Remove charge port safety cap
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    Note
    2x tabs
  27. Remove charge port busbar leads from charge port assembly
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    Note
    2x nuts, 10mm, 9 Nm, Nuts have captured washers
  28. Release charge port manual release cable from body clip
  29. Remove charge port assembly
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    Note
    3x bolts, 10mm, 5.5 Nm
  30. Install charge port assembly
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    Note
    3x bolts, 10mm, 5.5 Nm
  31. Secure charge port manual release cable to body clip
  32. Install charge port busbar leads to charge port assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 9 Nm, Nuts have captured washers
  33. Remove all items from pockets and ensure not wearing metal items
  34. Inspect HV insulating gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
  35. Put on HV insulating gloves and leather over gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear Electrical Protective Gloves any time Hioki tester is used
  36. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ).If the resistance is greater than 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. If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step.
  37. Remove HV insulating gloves
  38. Install charge port safety cap
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    Note
    2x tabs
  39. Connect chargeport assembly connectors
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    Note
    1x clip, 2x connectors, Engage locking tab, Install white locking tab once connected,
  40. Install LH trough trim
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x bolt, T20, 1.2Nm
  41. Connect LH trunk task light
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  42. Move LH trunk side trim to original position
  43. Install clip for LH trunk side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  44. Install trunk garnish assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 4x locating tabs, Align locating tabs to slot, Verify trunk seal is fully seated along garnish
  45. Install LH load floor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 2x locators
  46. Install trunk sill trim assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, Align striker with center slot then 2 locators to slots then press to secure clips, Manipulate seal to overlap trim
  47. Install load floor
  48. Close trunk via interior switch
  49. Connect 2nd row seat harness and secure cushion
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    Note
    2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
  50. Connect First Responder Loop and LV battery
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    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
  51. Install rear underhood apron
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    Note
    14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
  52. Close hood
  53. Reinstall Firmware via service UI
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    Note
    Controls > Service Mode > Software Reinstall, Installation will begin immediately
  54. Close LH rear door
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    Note
    Release latch before closing if manually latched
  55. Close RH rear door
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    Note
    Release latch before closing if manually latched
  56. Move RH front seat to original position
  57. Close RH front door
  58. Move LH front seat to original position
  59. Raise all windows
  60. Close LH front door