04/06/2024 18:01:54

Door - Charge Port (Global) (Adjust)

Correction code 44011500 0.96 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.

  • 2023-08-25: Added link to charge port voltage check 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.
Informational PurposesAn informational icon, calling your attention
Note
This procedure applies to the Global-style charge port door.
  1. Open LH front door
  2. Lower LH and RH front windows
  3. Move LH front seat forward
  4. Open LH falcon wing door
  5. Move LH Monopost seat forward
  6. Remove LH rear sill assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, 1x datum
  7. Open charge port door using UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Control > Charging > Open Charge Port
  8. Open hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Via center display > Controls > Frunk Open
  9. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  10. Open liftgate
  11. Remove trunk rear load floor
  12. Remove trunk pocket load floor
  13. Remove trunk tub floor insulator
  14. Remove trunk carpet
  15. Remove LH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x datum
  16. Remove RH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x datum
  17. Remove trunk sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 2x patch bolts, T25, 2.5 Nm, Discard patch bolts after removal
  18. Remove rear wall load support
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x clips
  19. Remove LH crush can bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1 datum
  20. Remove LH soft trim pocket bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 1 datum
  21. Remove LH mid C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2 Nm, 9x clips, 5x tabs
  22. Remove LH lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, T25, 2.5 Nm, 2x screws, T20, 2 Nm, Discard patch bolt after removal
  23. Fold LH 3rd row seat back into down position
  24. Remove fasteners securing LH upper C-pillar trim to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T20, 2 Nm, 1x patch bolt, T25, 3 Nm, Discard patch bolt after removal
  25. Remove LH upper C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 1x datum
  26. Release charge port manual cable release from LH mid C-pillar zone bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  27. Remove LH mid C-pillar zone bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2.5 Nm, 4x push clips
  28. Remove LH trunk side trim carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 1x connector
  29. Remove LH trunk side trim bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 2.5 Nm, 1x push clip
  30. Raise LH 3rd row seat back into the upright position
  31. Disconnect LV power. See LV Power (Disconnect and Connect).
  32. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  33. Release 3rd row seat harness trays from seat frame
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips
  34. Disconnect 3rd row seat assembly connections
    Informational PurposesAn informational icon, calling your attention
    Note
    11x connectors, Release tab and slide connector housing off tray to remove
  35. Remove 3rd row seat cushion from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, While pushing down on cushion, feel for rocket clips and disengage locking tabs, Clips located on both ends of seat cushion, Feed cushion harnesses below 3rd row seat backs, Place cushion on protected surface
  36. Remove LH inner reinforcement from body
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, T40, 27 Nm, Use a T40 socket with 8mm wrench to loosen the lower 2 bolts to avoid removal of 3rd row seat frame, Then use hex bit ratchet to remove bolts fully, All other bolts can be removed with 1/4in. Dr. ratchet and 1/4in. Dr. T40 socket
  37. Perform gap and flush inspection with charge port door closed
    Informational PurposesAn informational icon, calling your attention
    Note
    Performed gap and flush inspection with charge port door closed to determine which insert need adjustmentsArea 1:CPD to body flush target is no flush requirementCPD to lamp flush target is 0 mmArea 2:CPD to body flush target is - 1.2 mmArea 3: CPD to Body flush target is - 1.2 mmCPD to lamp flush target is 0 mm
  38. Release charge port latch connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Take note of harness routing, Pull red locking tab outwards to release lock, pull again to release connector
  39. Release charge port connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Carefully remove white locking tab, Depress tab to release connection from the charge port, Continue to pull off connector, The connection is intended to disengage the safety cap when released
  40. Remove charge port safety cap
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hooks
  41. Remove fasteners securing charge port busbar to charge port and remove busbar leads from studs
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 11mm, 9 Nm, Nuts have captured washers, Take caution of any tension present with the busbar
  42. Remove bolts securing charge port assembly and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 7 Nm, 2x datums, Note the charge port is bolted to the charge port door and lines up with 2 datums
  43. Remove bolt securing charge port door to vehicle body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 8mm, 1 Nm
  44. Rotate the top hex insert CLOCKWISE to extend the insert or COUNTER-CLOCKWISE to shorten the spacing to meet the desired flush requirement for charge port door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hex insert, 5mm, 1x datum, Slightly push datum outwards to ease access to hex insert, Compensator is nominally 3mm out from the back of the hex face to the top of the thread housing, It can be adjusted an additional 2mm either out or in, leaving the total distance between 1mm and 5mm
  45. Rotate the front hex insert CLOCKWISE to extend the insert or COUNTER-CLOCKWISE to shorten the spacing to meet the desired flush requirement for charge port door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hex insert, 5mm, Compensator is nominally 3mm out from the back of the hex face to the top of the thread housing, It can be adjusted an additional 2mm either out or in, leaving the total distance between 1mm and 5mm
  46. Rotate the bottom hex insert CLOCKWISE to extend the insert or COUNTER-CLOCKWISE to shorten the spacing to meet the desired flush requirement for charge port door
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hex insert, 5mm, Compensator is nominally 3mm out from the back of the hex face to the top of the thread housing, It can be adjusted an additional 2mm either out or in, leaving the total distance between 1mm and 5mm
  47. Install bolt securing charge port door to vehicle body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 8mm, 1 Nm
  48. Install charge port assembly into vehicle and secure bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 7 Nm, 2x datums, Start by lining up the datums on charge port with the charge port door, Then proceed to thread in all bolts, New charge port will come pre-applied with penetrox
  49. Clean charge port assembly busbar contact surface of residual penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Use plastic trim tool to push IPA wipe down between plastic divider, Allow 1 minute dry time
  50. Clean contact surfaces of busbar leads to remove any residual Penetrox
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute for IPA to dry
  51. Apply Penetrox to backside of 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
  52. Install charge port busbar leads to charge port assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 11mm, 9 Nm, Nuts have captured washers, If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary
  53. 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.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
  54. Put on HV insulating gloves and leather over gloves
  55. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud
    Informational PurposesAn informational icon, calling your attention
    Note
    2x HV joints, Measure both joints at the highlighted locations, 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), Hioki test passed, proceed to next step.
  56. Remove leather over gloves and HV insulating gloves
  57. Install charge port safety cap
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hooks, Safety cap will click into position
  58. Secure charge port connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place
  59. Secure charge port latch connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Return harness to original routing, Harness sits in front of busbar, Fully engage connector and red locking tab
  60. Install LH inner reinforcement to body
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, T40, 27 Nm, To avoid removal of 3rd row seat frame, Use hex bit ratchet to fully seat bottom 2 bolts prior to torque
  61. Install 3rd row seat cushion
    Informational PurposesAn informational icon, calling your attention
    Note
    2x securing tabs, Feed cushion harness's below 3rd row seat backs
  62. Connect 3rd row seat cushion connections and secure to brackets
    Informational PurposesAn informational icon, calling your attention
    Note
    11x connectors, Secure connector housing onto tray
  63. Connect First Responder Loop and LV battery connector
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
  64. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  65. Close hood
  66. Verify operation of vehicle charging system
  67. Close charge port door
  68. Fold LH 3rd row seat back into down position
  69. Install LH trunk side trim bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 2.5 Nm, 1x push clip
  70. Install LH trunk side trim carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 1x connector, Place Clip into trim tool to aide installation of lower clip.
  71. Secure charge port manual release cable onto LH mid C-pillar zone bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  72. Install LH mid C-pillar zone bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2.5 Nm, 4x push clips
  73. Install LH upper C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips, 1x datum
  74. Raise LH 3rd row seat back into the upright position
  75. Install fasteners securing LH upper C-pillar trim to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T20, 2 Nm, 1x patch bolt, T25, 2 Nm, Install new patch bolt
  76. Install LH lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, T25, 2.5 Nm, 2x screws, T20, 2 Nm, Install new patch bolt
  77. Install LH mid C-pillar trim
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, 5x tabs, 1x screw, T20, 2 Nm
  78. Install LH soft trim pocket bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip, 1 datum
  79. Install LH crush can bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1 datum
  80. Install rear wall load floor support
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x clips
  81. Install rear trunk sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
  82. Install LH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x datum
  83. Install RH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x datum
  84. Install trunk carpet
  85. Install trunk tub floor insulator
  86. Install trunk pocket load floor
  87. Install trunk rear load floor
  88. Close liftgate
  89. Move LH Monopost seat to original position
  90. Install LH rear sill assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips, 1x datum
  91. Calibrate LH falcon wing door
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the upper B-pillar button in the down position to manually calibrate
  92. Calibrate RH falcon wing door
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the upper B-pillar button in the down position to manually calibrate
  93. Move LH front seat to original position
  94. Raise LH and RH front windows
  95. Close LH front door