04/06/2024 18:01:25

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

Correction code 44011502 0.78 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 proper PPE is worn when performing the below procedure. 44011502

  • 2023-07-10: Cleaned up 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.
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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

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 glove and safety information.

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Note
This procedure is for the Original version of this part for North America. The procedure for the other versions of this part are here: Door Assembly - Charge Port (Global) (Remove and Replace) or Door Panel - Charge Port (Remove and Replace).

Remove

  1. Open the LH front door and lower the LH front window.
  2. Open the LH rear door and lower the LH rear window.
  3. Fold the LH 2nd row 60 split seat down.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat can be folded from the backrest button or trunk switch.
  4. Open the liftgate.
  5. Remove the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  6. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  7. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  8. Open the charge port door using the vehicle touchscreen.
  9. Open the hood.
  10. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  11. Disconnect LV power. See LV Power (Disconnect and Connect).
  12. Perform the charge port voltage check. See Charge Port Voltage Check.
  13. Remove the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  14. Remove the LH trunk side wall trim. See Trim - Side Wall - Trunk - LH (Remove and Replace).
  15. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  16. Remove the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  17. Remove the LH 2nd row seat outer bolster. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  18. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  19. Remove LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  20. Release the LH upper C-pillar trim, and then set it aside. See Trim - C-Pillar - Upper - LH (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the lower bolt that attaches the LH 2nd row seat belt retractor.
  21. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  22. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  23. Remove the nuts (x2) that attach the charge port busbar to charge port, and then remove the busbar leads from the studs.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 11 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers.
  24. Release the clip that attaches the manual release cable.
  25. Remove the nut that attaches the charge port harness ground to the body.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  26. Disconnect the charge port ECU electrical connectors (x2) as shown.
  27. Remove and discard the bolts (x4) that attach the charge port assembly to the body.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
  28. Disconnect the charge port door electrical connector from the charge port, and then remove the charge port assembly from the vehicle.
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    Note
    Disengage the locking tab, and then remove the connector body.
  29. Disconnect the LH taillight electrical connector.
  30. Remove the nuts (x3) that attach the LH taillight to the body.
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm 12-point deep socket
  31. Remove the LH taillight from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 studs
    Informational PurposesAn informational icon, calling your attention
    Note
    Be careful when maneuvering the door motor through the body.
  32. Remove the screws (x3) that attach the charge port door to the taillight.
    2.5 Nm (1.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Torx T20 socket

Install

  1. Install the screws (x3) that attach the charge port door to the taillight.
    2.5 Nm (1.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Torx T20 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the locating pins (x2) on the taillight align with the slots on the charge port door before installing the screws.
  2. Install the LH taillight to the vehicle body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the door motor into the body and line up the studs (x3).
  3. Install the nuts (x3) that attach the LH taillight to the body.
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm 12-point deep socket
  4. Connect the LH taillight electrical connector.
  5. Connect the charge port door electrical connector to the charge port, and then position the charge port assembly for installation.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully seat the electrical connector, and then engage locking tab. Harness should route beneath the charge port.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not pinch the electrical harness.
  6. Install the new bolts (x4) that attach the charge port assembly to the body.
    6 Nm (4.4 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    New charge port will come with Penetrox pre-applied to the HV joints.
  7. Verify that the charge port studs (x2) are torqued to specification.
    2 Nm (1.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • Torx T10 bit
  8. Install the clip that attaches the manual release cable.
  9. Install the nut that attaches the charge port electrical harness ground.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  10. Connect the charge port ECU electrical connectors (x2).
  11. Clean the charge port assembly busbar contact surface of residual Penetrox with an Isopropyl Alcohol (IPA) wipe
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to push the IPA wipe down between plastic divider. Allow 1 minute dry time before continuing.
  12. Clean the charge port busbar contact surface of residual Penetrox with an IPA wipe. Allow 1 minute to dry before continuing.
  13. Apply 2 drops of Penetrox A-13 approximately 5 mm in diameter to either side of the hole on both busbar leads. Spread evenly to verify the contact surface is fully covered.
  14. Install the nuts (x2) that attach the charge port busbar leads to charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 11 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers.
  15. Inspect the 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 for information on inspecting HV gloves: https://service.tesla.com/user/documents?searchText=TN-15-92-003
  16. Put on HV insulating gloves and leather over gloves.
  17. Perform a Hioki resistance test at each HV joint from the HV busbar lead to charge port stud.
    Informational PurposesAn informational icon, calling your attention
    Note
    When using the Hioki tester, verify that the meter has been properly adjusted and set prior to usage.
    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 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), the Hioki resistance test passed. Proceed to next step.
  18. Remove the leather glove protectors and HV insulating gloves.
  19. Install the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  20. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  21. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  22. Install LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  23. Install LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  24. Install the LH 2nd row seat side bolster. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  25. Install the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  26. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  27. Install the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  28. Install the trunk sill panel. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  29. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  30. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  31. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  32. Close the liftgate.
  33. Restore the LH 2nd row 60 seat into upright position.
  34. Raise the LH rear window and the LH rear door.
  35. Reconnect LV power. See LV Power (Disconnect and Connect).
  36. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  37. Close the hood.
  38. Verify the operation of vehicle charging system.
  39. Close the charge port door.
  40. Raise the LH front window and close the LH front door.