01/02/2024 14:20:38

Door Assembly - Charge Port (EMEA) (Remove and Replace)

Correction code 44015302 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.

  • 2023-10-27: Update charge port to body bolt torque to 9 Nm.
  • 2023-06-06: Updated Charge Identifier Label TPN from 1691926-00-A to 1691926-00-B and updated related illustration.
  • 2023-05-24: Removed the vehicle electrical isolation procedure.
  • 1076921-01-B Insulation Multimeter, Fluke 1508
  • 1130480-00-A Test Probes, Slim, Fluke TP38
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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper personal protective equipment (PPE) is required to perform this procedure:

  • High voltage insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Open all doors and windows.
  2. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  3. Open the trunk.
  4. Apply masking tape around the charge port area.
  5. Move the driver and front passenger seats fully forward.
  6. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  7. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  8. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  9. Remove the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  10. Remove the trunk sill trim panel. See Trim - Sill - Trunk (Remove and Replace).
  11. Remove the trunk garnish. See Garnish - Trunk (Remove and Replace).
  12. Disconnect the LH liftgate task light connector.
  13. Release the edge of the trunk carpet, and then move the LH trunk side trim aside.
  14. Remove the LH taillight. See Taillight - LH (Remove and Replace).
  15. Release the edge clip that attaches the LV electrical harness to the charge port closeout panel.
  16. Slightly pull on the closeout panel. At the same time, insert a plastic trim tool inwards to start releasing the lower clips, and then pull the closeout panel towards the front of the vehicle while releasing the remaining clips.
  17. Remove the bolt that attaches the charge port harness bracket and ground cable to the body.
  18. Pull the manual release cable up and away from the cable hold down clip, or pull up the cable vertically away from the charge port assembly.
  19. Remove the bolts that attach the charge port to the body.
  20. Disconnect the Low Voltage (LV) electrical connectors from the charge port ECU.
  21. Pull the charge port assembly away from the body for access.
  22. Release the charge port door harness grommet from the body
  23. Release the lower clips that attach the charge port door assembly to the vehicle, then push the bottom of the assembly out, and then remove the assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    To ease the removal of the charge port door assembly:
    1. Pull the assembly towards the rear of the vehicle.
    2. When the assembly reaches the rear of the quarter panel, pull the assembly to clear the actuator mechanism, and then pull the assembly out and away from the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Manipulation of the charge port door assembly might be necessary to completely remove the assembly from the body.

Install

  1. Install the charge port door assembly on the vehicle: Pivot the assembly so that the actuator mechanism clears underneath the quarter panel, and then slide the assembly forward towards the rear door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Manipulation of the charge port door assembly might be necessary to fully align the assembly to the rear quarter.
  2. Push the charge port door assembly electrical harness through the opening, and then attach the charge port door assembly with lower clips (x2).
  3. Install the charge port door grommet on the body.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the harness is routed out, and the adhesive pad with zip tie is properly mounted if it is installed.
  4. Move the charge port assembly into position for installation.
  5. Connect the low voltage charge port ECU electrical connectors.
  6. Install the bolts that attach the charge port to the body.
    9 Nm (6.6 lbs-ft)
  7. Insert the manual release cable back into the locking tab; push down on the release back to secure it into the locking tab.
  8. Install the bolt that attaches the charge port harness bracket and ground cable to the body.
    6 Nm (4.4 lbs-ft)
  9. Install the clips that attach the charge port closeout panel.
  10. Install the edge clip that attaches the LV harness to the charge port closeout panel.
  11. Install the LH taillight. See Taillight - LH (Remove and Replace).
  12. Install the LH trunk stop.
  13. Remove the masking tape from the charge port door area.
  14. Move the LH trunk side trim back into position, and then install the clips (x2) that attach the side trim to the vehicle.
  15. Connect the LH liftgate task light connector.
  16. Install the trunk garnish. See Garnish - Trunk (Remove and Replace).
  17. Install the trunk sill trim panel. See Trim - Sill - Trunk (Remove and Replace).
  18. Install the trunk floor trim. See Trim - Floor - Trunk (Remove and Replace).
  19. Close the trunk.
  20. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  21. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  22. Move the driver and front passenger seats back to their original position.
  23. Verify the operation of the charging system:
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the customer's charging equipment, if present.
    1. Open the charge port by lightly pushing on the lower RH corner of the charge port door, and then close the charge port door.
    2. Use a UMC or wall connector and press the button on the handle to open the charge port door.
      Informational PurposesAn informational icon, calling your attention
      Note
      There may be a brief timeout after closing the door until the door will open again.
    3. Connect the charge handle to the charge port and confirm that the vehicle is charging.
    4. Disconnect the charge handle and confirm that the charge port door closes.
  24. Europe only: install a CKL charging identifier label (1691926-00-B) on the face plate of the charge port assembly as illustrated, if one was present on the original part.
  25. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  26. Close the hood and all doors and windows.