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.
- Open LH front door
- Lower LH and RH front windows
- Move LH front seat forward
- Open LH falcon wing door
- Move LH Monopost seat forward
-
Remove LH rear sill assembly
Note8x clips, 1x datum
-
Open charge port door using UI
NoteControl > Charging > Open Charge Port
-
Open hood
NoteVia center display > Controls > Frunk Open
-
Remove rear underhood apron
Note11x clips, 2x datums
-
Open liftgate
-
Remove trunk rear load floor
-
Remove trunk pocket load floor
-
Remove trunk tub floor insulator
-
Remove trunk carpet
-
Remove LH trunk sill side trim
Note4x clips, 1x datum
-
Remove RH trunk sill side trim
Note4x clips, 1x datum
-
Remove trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Discard patch bolts after removal
-
Remove rear wall load support
Note4x push clips, 2x clips
-
Remove LH crush can bracket
Note3x clips, 1 datum
-
Remove LH soft trim pocket bracket
Note1x push clip, 1 datum
-
Remove LH mid C-pillar trim
Note1x screw, T20, 2 Nm, 9x clips, 5x tabs
-
Remove LH lower C-pillar
Note1x patch bolt, T25, 2.5 Nm, 2x screws, T20, 2 Nm, Discard patch bolt after removal
-
Fold LH 3rd row seat back into down
position
-
Remove fasteners securing LH upper
C-pillar trim to bracket
Note3x screws, T20, 2 Nm, 1x patch bolt, T25, 3 Nm, Discard patch bolt after removal
-
Remove LH upper C-pillar trim
Note6x clips, 1x datum
-
Release charge port manual cable release
from LH mid C-pillar zone bracket
Note1x fir tree clip
-
Remove LH mid C-pillar zone
bracket
Note2x screws, T20, 2.5 Nm, 4x push clips
-
Remove LH trunk side trim carpet
Note4x push clips, 1x connector
-
Remove LH trunk side trim bracket
Note2x bolts, T30, 2.5 Nm, 1x push clip
-
Raise LH 3rd row seat back into the
upright position
- Disconnect LV power. See LV Power (Disconnect and Connect).
- Perform the charge port voltage check procedure. See Charge Port Voltage Check.
-
Release 3rd row seat harness trays from
seat frame
Note4x push clips
-
Disconnect 3rd row seat assembly
connections
Note11x connectors, Release tab and slide connector housing off tray to remove
-
Remove 3rd row seat cushion from
vehicle
Note2x 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
-
Remove LH inner reinforcement from
body
Note9x 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
-
Perform gap and flush inspection with
charge port door closed
NotePerformed 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
-
Release charge port latch
connection
Note1x connector, Take note of harness routing, Pull red locking tab outwards to release lock, pull again to release connector
-
Release charge port connection
Note1x 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
-
Remove charge port safety cap
Note2x hooks
-
Remove fasteners securing charge port
busbar to charge port and remove busbar leads from studs
Note2x nuts, 11mm, 9 Nm, Nuts have captured washers, Take caution of any tension present with the busbar
-
Remove bolts securing charge port
assembly and remove from vehicle
Note4x bolts, 10mm, 7 Nm, 2x datums, Note the charge port is bolted to the charge port door and lines up with 2 datums
-
Remove bolt securing charge port door to
vehicle body
Note1x bolt, 8mm, 1 Nm
-
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
Note1x 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
-
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
Note1x 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
-
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
Note1x 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
-
Install bolt securing charge port door
to vehicle body
Note1x bolt, 8mm, 1 Nm
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Install charge port assembly into
vehicle and secure bolts
Note4x 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
-
Clean charge port assembly busbar
contact surface of residual penetrox
NoteUse plastic trim tool to push IPA wipe down between plastic divider, Allow 1 minute dry time
-
Clean contact surfaces of busbar leads
to remove any residual Penetrox
NoteAllow 1 minute for IPA to dry
-
Apply Penetrox to backside of busbar
leads
NoteApply 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
-
Install charge port busbar leads to
charge port assembly
Note2x 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
-
Inspect HV insulating gloves
NoteCheck 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
-
Put on HV insulating gloves and leather
over gloves
-
Perform Hioki resistance test at each HV
joint from HV busbar lead to charge port stud
Note2x 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.
- Remove leather over gloves and HV insulating gloves
-
Install charge port safety cap
Note2x hooks, Safety cap will click into position
-
Secure charge port connection
Note1x connector, Fully engage connection and white locking tab, The connector is intended to lock the safety cap in place
-
Secure charge port latch
connection
Note1x connector, Return harness to original routing, Harness sits in front of busbar, Fully engage connector and red locking tab
-
Install LH inner reinforcement to
body
Note9x 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
-
Install 3rd row seat cushion
Note2x securing tabs, Feed cushion harness's below 3rd row seat backs
-
Connect 3rd row seat cushion connections
and secure to brackets
Note11x connectors, Secure connector housing onto tray
-
Connect First Responder Loop and LV
battery connector
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated
-
Install rear underhood apron
Note11x clips, 2x datums
- Close hood
- Verify operation of vehicle charging system
- Close charge port door
- Fold LH 3rd row seat back into down position
-
Install LH trunk side trim bracket
Note2x bolts, T30, 2.5 Nm, 1x push clip
-
Install LH trunk side trim carpet
Note4x push clips, 1x connector, Place Clip into trim tool to aide installation of lower clip.
-
Secure charge port manual release cable
onto LH mid C-pillar zone bracket
Note1x fir tree clip
-
Install LH mid C-pillar zone
bracket
Note2x screws, T20, 2.5 Nm, 4x push clips
-
Install LH upper C-pillar trim
Note6x clips, 1x datum
-
Raise LH 3rd row seat back into the
upright position
-
Install fasteners securing LH upper
C-pillar trim to bracket
Note3x screws, T20, 2 Nm, 1x patch bolt, T25, 2 Nm, Install new patch bolt
-
Install LH lower C-pillar
Note1x patch bolt, T25, 2.5 Nm, 2x screws, T20, 2 Nm, Install new patch bolt
-
Install LH mid C-pillar trim
Note9x clips, 5x tabs, 1x screw, T20, 2 Nm
-
Install LH soft trim pocket
bracket
Note1x push clip, 1 datum
-
Install LH crush can bracket
Note3x clips, 1 datum
-
Install rear wall load floor
support
Note4x push clips, 2x clips
-
Install rear trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
-
Install LH trunk sill side trim
Note4x clips, 1x datum
-
Install RH trunk sill side trim
Note4x clips, 1x datum
-
Install trunk carpet
-
Install trunk tub floor insulator
-
Install trunk pocket load floor
-
Install trunk rear load floor
- Close liftgate
- Move LH Monopost seat to original position
-
Install LH rear sill assembly
Note8x clips, 1x datum
-
Calibrate LH falcon wing door
NoteHold the upper B-pillar button in the down position to manually calibrate
-
Calibrate RH falcon wing door
NoteHold the upper B-pillar button in the down position to manually calibrate
- Move LH front seat to original position
- Raise LH and RH front windows
- Close LH front door