24/05/2023 18:13:18

Charge Port - Single Phase - Non-Motorized - Manual Release of Cable

FRT No: 44013005

Informational PurposesAn informational icon, calling your attention
Note
This procedure describes how to manually release a cable from the single phase charge port. If the vehicle is equipped with a 3 phase charge port, refer to procedure 44013205 (refer to procedure).
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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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Special tool required for this procedure:

Supplier Part Number Description
Tesla 1020288-00-A TOOL,INSTALLATION,EV INLET,MDLS
  • 2023-05-24: Updated procedure to use Charge Port Voltage Check.

Release Cable

  1. Disconnect 12V power. See Disconnect 12V Power.
  2. Perform the charge port voltage check. See Charge Port Voltage Check.
  3. Remove the LH trunk trim.(refer to procedure)
  4. Remove the screw and release the clips (x2) from the HV inlet cover (torque 4 Nm).
  5. Remove the HV inlet cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    When the HV inlet cover is in the proper position, a post on the cover presses a switch in the charge port that activates the HVIL. The vehicle indicates a HVIL fault if the cover is not properly installed or the post is damaged.
  6. Remove and discard the 2 bolts (torque 9 Nm) that secure the HV cables to the charge port. Discard any washers that are installed between the bolts and the high voltage lugs.
  7. Pull the tab outward to remove the pawl actuator cover from the back of the charge port.
  8. Push the pawl actuator tab to the left to release the pawl and hold it in place while an assistant removes the charge cable from the charge port. Once the charge cable is removed, release the pawl.

Reinstall Components

Installation of components is reverse of removal, except for the following:

  1. When reconnecting the HV cables to the charge port:

  2. Remove any adhesive patch residue from the mating surfaces of the high voltage cable lugs.
  3. Remove any adhesive patch residue from the surfaces of the terminals.
  4. Push the pawl actuator tab to the left to release the pawl, then insert the charge port alignment tool into the charge port.
    Informational PurposesAn informational icon, calling your attention
    Note
    The charge port alignment tool should only be used on vehicles manufactured for North America and Japan. Vehicles manufactured for all other countries include the European charge port and do not require use of the charge port alignment tool during this procedure.
  5. Install the bolts (x2) that secure the HV cables to the charge port (torque 9 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Replace all patchbolt(s).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not use any washers other than the captive washers that are part of the new bolts.
  6. Place a paint mark on each bolt to indicate that it has been properly tightened. Use one continuous motion to mark the bolt head, washer, and the surface of the lug.
  7. Push the pawl actuator tab to the left to release the pawl, then remove the charge port alignment tool from the charge port if used.
  8. Reinstall the pawl actuator cover.