04/06/2024 18:02:19

Door - Charge Port (NA) (Remove and Replace)

Correction code 4401010101 4401010102 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.

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.

Open trunk from exterior switch
Open all four doors
Lower all four windows
Move LH front seat forward
Move RH front seat forward
Open hood
Remove rear underhood apron

Note
14x clips
Place vehicle in service mode

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
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery and First Responder Loop

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
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

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
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Verify there is no high voltage present at the charge port

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
Remove HV insulating gloves
Remove load floor

Note
Use pull tab located at rear edge of panel
Remove trunk sill trim assembly

Note
4x clips, Pull corner upward to release clip on end then pull away from body for remaining clips
Remove LH load floor bracket

Note
4x clips, 2x locators, Release bracket front clips, then release clips at rear
Remove trunk garnish assembly

Note
6x clips, 4x locating tabs
Remove clip for LH trunk side trim

Note
1x clip
Disconnect LH trunk task light

Note
1x connector
Move LH trunk side trim to aside

Note
Take care not to cause excessive creasing
Remove LH trough trim

Note
3x clips, 1x bolt, T20, 1.2Nm
Release connectors from chargeport assembly

Note
1x clip, 2x connectors, Remove white locking tab before disconnecting, Pull red locking tab to release lock, pull again to release from connector
Remove charge port safety cap

Note
2x tabs
Remove charge port busbar leads from charge port assembly

Note
2x nuts, 10mm, 9 Nm, Nuts have captured washers
Release charge port manual release cable from body clip
Remove charge port assembly

Note
3x bolts, 10mm, 5.5 Nm
Disconnect charge port harness from charge port ECU

Note
1x connector
Release charge port door harness grommet from body

Note
1x grommet
Remove charge port door from vehicle

Note
2x tabs, 1x datum, Pull from the bottom rear to release, Pull the assembly towards the rear of the vehicle, when the door actuator reaches to the rear of the quarter panel pull the charge port down to clear the actuator mechanism then pull out and away from the body, Manipulating the charge door may be necessary to fully remove the assembly
Install charge port door onto vehicle

Note
2x clips, 1x datum, Install the part by pivoting the assembly so the actuator mechanism clears underneath the quarter panel, then slide the charge door forward toward the rear door, When in position push down on bottom rear to engage clips, Manipulating the charge door may be necessary to fully align the assembly to the body
Secure charge port door harness grommet to body

Note
1x grommet
Connect charge port door connector to charge port ECU

Note
1x connector
Install charge port assembly

Note
3x bolts, 10mm, 5.5 Nm
Secure charge port manual release cable to body clip
Clean charge port assembly busbar contact surface of residual penetrox

Note
Use plastic trim tool to push IPA wipe down between plastic divider, Allow 1 minute dry time
Verify charge port studs are torqued to proper specification

Note
2x studs, T10, 2 Nm
Apply Penetrox to backside of busbar leads

Note
Apply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
Install charge port busbar leads to charge port assembly

Note
2x nuts, 10mm, 9 Nm, Nuts have captured washers
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

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
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud

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.
Remove HV insulating gloves
Install charge port safety cap

Note
2x tabs
Connect chargeport assembly connectors

Note
1x clip, 2x connectors, Engage locking tab, Install white locking tab once connected,
Install LH trough trim

Note
3x clips, 1x bolt, T20, 1.2Nm
Connect LH trunk task light

Note
1x connector
Move LH trunk side trim to original position
Install clip for LH trunk side trim

Note
1x clip
Install trunk garnish assembly

Note
6x clips, 4x locating tabs, Align locating tabs to slot, Verify trunk seal is fully seated along garnish
Install LH load floor bracket

Note
4x clips, 2x locators
Install trunk sill trim assembly

Note
4x clips, Align striker with center slot then 2 locators to slots then press to secure clips, Manipulate seal to overlap trim
Install load floor
Close trunk via interior switch
Connect 2nd row seat harness and secure cushion

Note
2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test
Connect First Responder Loop and LV battery

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
Install rear underhood apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Reinstall Firmware via service UI

Note
Controls > Service Mode > Software Reinstall, Installation will begin immediately
Close LH rear door

Note
Release latch before closing if manually latched
Close RH rear door

Note
Release latch before closing if manually latched
Move RH front seat to original position
Close RH front door
Move LH front seat to original position
Raise all windows
Close LH front door