04/06/2024 18:02:07

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

Correction code 44011512 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.

  • 2024-04-04: Added the installation step of the busbar to the charge port nuts.
  • 2023-07-06: Cleaned up procedure.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
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
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.
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 glove and safety information.

Informational PurposesAn informational icon, calling your attention
Note
This procedure is for the Global Refresh version of this part. The procedure for the Original version of this part is here: Door Assembly - Charge Port (NA) (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 seat down.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat can be folded from the backrest button or trunk switch.
    Informational PurposesAn informational icon, calling your attention
    Note
    Since the seat cushion is not present, protect the seat as required.
  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 side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  8. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  9. Open the charge port door using the vehicle touchscreen.
  10. Open the hood.
  11. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  12. Disconnect LV power. See LV Power (Disconnect and Connect).
  13. Perform the charge port voltage check. See Charge Port Voltage Check.
  14. Remove the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (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. 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.
  19. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  20. Remove the LH taillight. See Taillight - LH (Global) (Remove and Replace).
  21. Disconnect the charge port latch electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of harness routing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red locking tab outwards to release the lock, and then pull again to release the electrical connector.
  22. Disconnect the charge port electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully remove the white locking tab. Press the tab to release the electrical connector from the charge port. Continue to pull off the connector. The connector is intended to disengage the safety cap when released.
  23. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Global) (Remove and Replace).
  24. Remove the nuts (x2) that attach the charge port busbars to the 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take caution of any tension present with the busbars.
  25. Remove the charge port. See Charge Port (Global) (Remove and Replace).
  26. Disconnect the charge port door connection from the charge port ECU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the original harness routing.
  27. Release the charge port door harness grommet from the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the grommet and feed harness out.
  28. Remove the bolt that attaches the charge port door to the body.
    1 Nm (.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm deep socket
  29. Remove the charge port door assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 datums
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the single datum from vehicle body. Maneuver the charge port door assembly and motor out from the rear of vehicle and guide the harness out.

Install

  1. Install the charge port door assembly to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 datums
    Informational PurposesAn informational icon, calling your attention
    Note
    Guide the harness in, then maneuver the charge port door assembly and motor in from the rear of vehicle. Secure the single datum onto the body.
  2. Install the bolt that attaches the charge port door to the body.
    1 Nm (.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm deep socket
  3. Fully secure the charge port door harness grommet onto the body.
  4. Connect the charge port door electrical connector onto the charge port ECU.
  5. Install the charge port assembly into the vehicle and attach bolts (x4).
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 datums.
    Informational PurposesAn informational icon, calling your attention
    Note
    Start by lining up the datums on the charge port with the charge port door, and then proceed to thread in all bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    New charge port will come pre-applied with Penetrox.
  6. Secure the charge port manual release cable onto the body.
  7. Verify that the charge port studs (x2) are tightened to specification.
    2 Nm (1.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T10 bit
  8. Clean the charge port assembly busbar contact surface of residual Penetrox with an IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to push the IPA wipe down between plastic divider.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time after removing the Penetrox.
  9. Clean the charge port busbar contact surface of residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time.
  10. Apply Penetrox to the backside of the busbar leads.
    Informational PurposesAn informational icon, calling your attention
    Note
    Apply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
  11. Install the nuts (x2) that attach the charge port busbars to the charge port.
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    If excessive force is required to seat the busbars, they may have been bent. Inspect for damage and replace if necessary.
  12. Inspect 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
  13. Put on the HV insulating gloves and leather over gloves.
  14. Perform a Hioki resistance test at each HV joint from the HV busbar lead to the charge port stud (x2 HV joints).
    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.
  15. Remove the leather glove protectors and HV insulating gloves.
  16. Install the busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Global) (Remove and Replace).
  17. Connect the charge port electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the electrical connector and white locking tab. The connector is intended to lock the safety cap in place.
  18. Connect the charge port latch electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Return the harness to its original routing: Harness sits in front of the busbars.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the connector and red locking tab.
  19. Install the LH taillight. See Taillight - LH (Global) (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 the LH 2nd row seat outer bolster. See Bolster - Outer - Seat - 2nd Row - LH (Remove and Replace).
  23. Install the trunk floor front trim. See Trim - Front - Floor - Trunk (Remove and Replace).
  24. Install the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  25. Install the rear wall rear trunk trim. See Trim - Rear Trunk - Rear Wall (Remove and Replace).
  26. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  27. Install the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  28. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  29. Install the rear trunk parcel shelf. See Parcel Shelf - Rear Trunk (Remove and Replace).
  30. Close the liftgate.
  31. Restore the LH 2nd row 60 seat into upright position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove seat cushion protection.
  32. Raise the LH rear window and the LH rear door.
  33. Reconnect LV power. See LV Power (Disconnect and Connect).
  34. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  35. Close the hood.
  36. Verify operation of the vehicle charging system.
  37. Close the charge port door.
  38. Raise the LH front window and close the LH front door.