04/06/2024 18:01:58

Charge Port (EU) (Remove and Replace)

Correction code 4401010112 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: Charge Port (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
 Reuse

Remove

  1. Disconnect LV power, perform the charge port voltage check, and remove the charge port safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (3-Phase) (Remove and Replace).
  2. Remove the white locking tab, and then disconnect the logic connector from the charge port.
  3. Push the locking tab upward, and then disconnect the 3-phase connector from the charge port.
  4. 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
  5. 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 locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
  6. Release the charge port manual release cable from the vehicle body.
  7. Remove the bolts that attach the charge port to the vehicle, and then remove the charge port 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

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
  2. Secure the charge port manual release cable onto the cable bracket.
  3. Connect the electrical connector to the charge port actuator, and then engage the locking tab.
  4. 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.
  5. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
  6. 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.
  7. 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
  8. 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
  9. Put on HV insulating gloves and leather gloves.
  10. 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.
  11. Remove the leather gloves and HV insulating gloves.
  12. Install the charge port safety cap.
  13. Connect the AC 3-phase connector to the charge port, and then slide the locking tab downward to engage.
  14. Connect the logic connector on the charge port, and then install the white locking tab.
  15. Move the LH trunk side trim back into position.
  16. Connect LV power. See LV Battery - Li-lon (Disconnect and Connect).
  17. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  18. Reinstall the vehicle firmware. See Software Reinstall - Touchscreen.
  19. Connect the LH trunk task light electrical connector.
  20. Secure the LH trunk side trim with the clip.
  21. Install the trunk garnish. Garnish - Trunk (Remove and Replace).
  22. Install the trunk sill trim. See Trim - Trunk Sill (Remove and Replace).
  23. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  24. Install the trunk load floor. See Load Floor - Trunk (Remove and Replace).
  25. 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.