2025-10-21

Door - Charge Port (Global) (Adjust)

Correction code 44011500 1.02 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

  • 2025-10-21: Moved gap and flush inspection to beginning. Included links to sub-procedures.
  • 2023-08-25: Added link to charge port voltage check procedure.
Informational PurposesAn informational icon, calling your attention
Note
This procedure applies to the Global-style charge port door.

Remove

  1. Perform a gap and flush inspection with the charge port door closed. Note the measurements.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the measurements are within specification, do not continue with adjustment.
    Area (see figure) Specification Value
    1 Flush target to body N/A
    Flush target to lamp 0 mm
    2 Flush target to body 1.2 mm
    3 Flush target to body 1.2 mm
    Flush target to lamp 0 mm
  2. Remove the rear sill panel. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  3. Open the charge port door.
  4. Open the liftgate.
  5. Remove the trunk side trim bracket. See:
  6. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Verify that high voltage is no longer available to the charge port. See Charge Port Voltage Check.
  9. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  10. Release the charge port latch connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the harness routing.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red locking tab outwards to release lock, then pull again to release connector.
  11. Release the charge port connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully remove the white locking tab, depress the tab to release the connection from the charge port, then pull the connector out.
    Informational PurposesAn informational icon, calling your attention
    Note
    The connection is intended to disengage the safety cap when released.
  12. Remove the charge port safety cap.
  13. Remove the nuts (x2) that secure the charge port busbar to the charge port. Remove the busbar leads from the studs.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 11 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captive washers. Take caution of any tension present with the busbar
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The busbar may be under tension. Use caution to avoid damage upon removal.
  14. Remove the bolts (x4) that secure the charge port assembly, then remove the assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  15. Remove the bolt that secures the charge port door to the vehicle body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket

Adjust

  1. Turn the top hex insert clockwise to extend the insert or counter-clockwise to shorten the spacing to meet the desired flush measurement for the charge port door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 5 mm hex
    Informational PurposesAn informational icon, calling your attention
    Note
    The compensator is ~3 mm out from the back of the hex face to the top of the thread housing. It can be adjusted an additional 2 mm in either direction, leaving the total distance between 1 mm and 5 mm.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Push the datum slightly outwards for easier access to the hex insert.
  2. Turn the front hex insert clockwise to extend the insert or counter-clockwise to shorten the spacing to meet the desired flush measurement for the charge port door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 5 mm hex
    Informational PurposesAn informational icon, calling your attention
    Note
    The compensator is ~3 mm out from the back of the hex face to the top of the thread housing. It can be adjusted an additional 2 mm in either direction, leaving the total distance between 1 mm and 5 mm.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Push the datum slightly outwards for easier access to the hex insert.
  3. Turn the bottom hex insert clockwise to extend the insert or counter-clockwise to shorten the spacing to meet the desired flush measurement for the charge port door.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 5 mm hex
    Informational PurposesAn informational icon, calling your attention
    Note
    The compensator is ~3 mm out from the back of the hex face to the top of the thread housing. It can be adjusted an additional 2 mm in either direction, leaving the total distance between 1 mm and 5 mm.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Push the datum slightly outwards for easier access to the hex insert.

Install

  1. Install the bolt that secures the charge port door to vehicle body.
    1 Nm (.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm hex
  2. Install the charge port assembly into vehicle and torque the bolts (x4).
    7 Nm (5.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    New charge ports come pre-applied with Penetrox.
  3. Clean the charge port assembly busbar contact surfaces with isopropyl alcohol to remove any residual Penetrox. Allow 1 minute to dry.
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    TIp
    Use a plastic trim tool to push the alcohol wipe down between the plastic divider.
  4. Clean the busbar lead contact surfaces with isopropyl alcohol to remove any residual Penetrox.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute for IPA to dry.
  5. 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 5mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered
  6. Install the charge port busbar leads to the charge port assembly. Torque the nuts (x2).
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 11 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The nuts have captive washers.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  7. Inspect HV insulating gloves
  8. Put on HV insulating gloves and leather over gloves.
  9. Perform Hioki resistance test at each HV joint (x2) from the HV busbar lead to charge port stud.
    • If the resistance is greater than 0.270 mΩ (270 μΩ), remove the fastener, clean the areas with isopropyl alcohol, install fastener back, and retest.
    • If the resistance is less than 0.050 mΩ (50 μΩ), reposition the probe and measure again. If the measurement is under 0.050 mΩ again, proceed to the next step.
  10. Remove the leather over gloves and HV insulating gloves.
  11. Install the charge port safety cap.
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    Note
    Engage hooks (x2). The safety cap clicks into position.
  12. Secure the charge port connection.
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    Note
    Fully engage the connection and the white locking tab.
  13. Secure the charge port latch connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    Return harness to original routing. The harness sits in front of the busbar. Fully engage the connector and red locking tab.
  14. Install the LH inner reinforcement and all trim that was removed. See Reinforcement - Inner - LH (Remove and Replace).
  15. Reconnect LV power. See LV Power (Disconnect and Connect)
  16. Close the liftgate
  17. Install the rear sill panel. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  18. Calibrate the LH and RH falcon wing doors.
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    Note
    Hold the upper B-pillar button in the down position to manually calibrate.
  19. Move the LH front seat to the original position.