04/06/2024 18:03:57

Correction code 44011502 0.48 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.

  • 2023-10-25: Update charge port to body bolt torque to 9 Nm.
  • 2023-10-10: Add a caution to not manually close the charge port door.
  • 2023-06-06: Removed info on applying the Charging Identifier Label for Europe since there is an EMEA specific version of this topic: Door Assembly - Charge Port (Busbar Type) (EMEA) (Remove and Replace).
  • 1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
  • 1076927-00-A Hioki RM 3548
  • 1108272-00-B Cap, Logic Conn, Inv, 3DU
  • 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.

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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
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.

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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.

Remove

  1. Open the trunk.
  2. Open the hood.
  3. Open the charge port door.
  4. Open all four doors.
  5. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  6. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  7. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  8. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  9. Use the bump stop removal tool to remove the LH trunk stop.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use other tools to pry at the trunk stop as this could damage the taillight or trunk stop.
  10. Carefully pull back the trunk trim carpet to expose the taillight, and then disconnect the electrical harness from the taillight connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the connector has a red locking tab: 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.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the taillight must be replaced because of water ingress, place a shop towel under the taillight connector to prevent damage to other electrical components.
  11. Remove the nuts (x2) that attach the taillight to the body.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm 12-point deep socket
    • ¼ in std ratchet
    • ¼ in torque wrench (installation only)
  12. Remove the LH taillight assembly from the vehicle.
    Tip: Lift the trunk seal for better clearance.
  13. Apply masking tape around the charge port area.
  14. Release the locking tabs from the charge port low voltage connectors (x2), and then disconnect the connectors (x2) from the charge port.
    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.
    Tip: Gently lift the black connector tab in order to remove the white locking tab from the 12-pin low voltage connector.
  15. Remove the charge port busbar fastener cover from the charge port assembly.
  16. Remove the nuts that attach the charge port busbars to the charge port.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  17. Release the charge port manual release cable from the body clip.
  18. Remove the bolts that attach the charge port to the body, 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
  19. Disconnect the charge port door harness from the charge port ECU.
  20. Release the charge port door grommet from the body
  21. Release the clips that attach the charge port door to the vehicle, and then remove the charge port door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the bottom clips first, push the bottom of the charge port door out, and then down to release the upper tabs. Slide the charge port towards the rear of the vehicle to remove the charge port door.

Install

  1. Install the charge port door onto the vehicle, and then attach the charge port door with clips.
    Informational PurposesAn informational icon, calling your attention
    Note
    Position the charge port door, then push the electrical harness through the opening and push up to attach the upper tabs, and then inwards to attach the lower clips.
  2. Install the charge port door grommet onto 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.
  3. Connect the charge port door harness to the charge port ECU.
  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 then air 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. Position the charge port in the vehicle, and then install the bolts that attach the charge port to the body.
    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
  6. Secure the charge port manual release cable in the body clip.
  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 bit
    • 4 in extension
    • Ratchet/torque wrench
  8. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
  9. If reinstalling the same charge port, apply one drop of electrical joint compound on each of the charge port busbar leads, 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.
  10. Position the charge port busbars on the change port studs, and then install the nuts that attach the busbars to the charge port.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  11. Put on HV insulating gloves and leather over gloves.
  12. 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 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.
  13. Remove the HV insulating gloves and leather over gloves.
  14. Install the charge port busbar fastener cover on the charge port assembly.
  15. Connect the low voltage harness connectors (x2) on the charge port, and then install the locking tabs (x2) that secure the connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the connector lock.
    Tip: Carefully insert the white locking tab in the 12-pin low voltage connector until it locks with the black connector tab.
  16. If the taillight is to be reinstalled, replace the gaskets from around each taillight mounting bolt (x2) and the taillight electrical connector (x1).
  17. Install new grommets onto the vehicle.
  18. Position the LH taillight studs into the grommets, and then install the taillight onto the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Reseat the trunk seal over the LH taillight.
  19. Install the nuts that attach the taillight to the vehicle.
    3.2 Nm (2.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm 12-point deep socket
    • ¼ in std ratchet
    • ¼ in torque wrench (installation only)
  20. Connect the electrical harness to the taillight connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the connector has a red locking tab: Push the red locking tab into the connector to engage the connector lock.
  21. Install the LH liftgate bump stop.
  22. Remove the masking tape from around the charge port area.
  23. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  24. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  25. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  26. Move both front seats to their original positions.
  27. Connect a charging cable to the vehicle and make sure the charger is powered.
  28. 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.
  29. Close the charge port door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  30. Ensure all charging adapters are present.
  31. Close the hood and the trunk.
  32. Raise all windows.
  33. Close all doors.