05/07/2023 10:26:50

Charge Port (Remove and Replace)

Correction code 44011602 0.54 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.

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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. The procedures for the Global Refresh or the EMEA version of this part are here: This procedure is for the Original version of this part. An updated/region-specific Global Refresh version of this part is available for newer vehicles and that procedure is here: Charge Port (Global) (Remove and Replace) or Charge Port (EMEA) (Remove and Replace).

Torque Specifications

Table 1. Torque Specifications: Charge Port (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts that attach the charge port assembly to the body
6 Nm (4.4 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm deep socket
  • 4 in extension
 Replace
Nut that attaches the harness ground to the body
9 Nm (6.6 lbs-ft)
  • Ratchet/torque wrench
  • 13 mm socket
  • 4 in extension
 Reuse
Nuts that attach the charge port busbars to the charge port
9 Nm (6.6 lbs-ft)
  • Ratchet/torque wrench
  • 10 mm deep socket
 Reuse
Bolt that attaches the safety cover to the charge port assembly
6 Nm (4.4 lbs-ft)
  • Ratchet/torque wrench
  • 8 mm socket
  • 4 in extension
 Replace

Remove

  1. Open the LH front door and lower the LH front window.
  2. Open the LH rear door.
  3. Fold the LH 2nd row seatback to the down position.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the 2nd row seat cushion is not present, protect the seatback as required.
  4. Open the liftgate.
  5. Use the touchscreen to open the charge port door and the hood.
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Perform a charge port voltage check. See Charge Port Voltage Check.
  9. Remove the LH trunk side trim. See .Trim - Side - Trunk - LH (Remove and Replace).
  10. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  11. Remove the nuts (x2) that attach the charge port busbars to the charge port, and then remove the busbar leads from the charge port 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.
  12. Release the clip that attaches the charge port manual release cable.
  13. Remove the nut that attaches the charge port harness ground to the body, and then release the ground from the body.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  14. Disconnect the electrical harness from the charge port ECU connectors (x2).
  15. Remove and discard the bolts (x4) that attach the charge port assembly to the body, and then separate the charge port assembly from the body.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  16. Release the locking tab, disconnect the electrical harness from the charge port door connector, and then remove the charge port door assembly from the vehicle.
  17. If installed, cut the cable tie that attaches the manual release cable to the charge port assembly.
  18. Remove the manual release cable collar from the charge port assembly.
  19. Turn and slide the metal end of the manual release cable out of the charge port actuator arm opening.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure.
  2. Slide and turn the metal end of the manual release cable into the charge port actuator arm opening.
  3. Install the manual release cable collar into the charge port assembly.
  4. If previously removed, install a new cable tie to attach the manual release cable to the charge port assembly.
  5. Bring the charge port door assembly to the vehicle, connect the electrical harness to the charge port door connector, and then fasten the locking tab.
  6. Install the charge port assembly onto the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to route the electrical harness beneath the charge port, so that it is not pinched.
  7. Install new bolts (x4) to attach the charge port assembly to the body.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    New charge port has Penetrox pre-applied to HV joints.
  8. Connect the electrical harness to the charge port ECU connectors (x2).
  9. Install the charge port electrical harness ground to the body, and then install the nut that attaches the harness ground to the body.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
  10. Fasten the clip that attaches the charge port manual release cable.
  11. Use an IPA wipe to clean residual Penetrox from the charge port busbars' contact surface, and allow at least 1 minute to dry.
  12. Install the busbar leads to the charge port studs, and then 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
    If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  13. Inspect the HV insulating gloves for damage prior to use.
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    CAUTION
    Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  14. Put on the HV insulating gloves and leather over gloves.
  15. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud.
    Informational PurposesAn informational icon, calling your attention
    Note
    The acceptable resistance is between 0.050 mΩ and 0.270 mΩ. If the resistance is greater than 0.270 mΩ, stop work and escalate a Toolbox session. If the resistance is lower than 0.050 mΩ, reposition the probes and measure again. If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ, the resistance test has passed.
  16. Remove the leather glove protectors and HV insulating gloves.
  17. Install the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  18. Install the LH trunk side trim. See .Trim - Side - Trunk - LH (Remove and Replace)
  19. Connect LV power. See LV Power (Disconnect and Connect).
  20. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  21. Close the hood and liftgate.
  22. Verify that the vehicle charges properly, and then close the charge port door.
  23. Raise the LH front window, and then close the LH front door.