2025-10-21

Door Assembly - Charge Port (Global) (Remove and Replace)

Correction code 44011512 1.68 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: Added links to sub-procedures. Added steps to measure old charge port door and adjust new one to old door measurements if needed.

Remove

  1. Remove the rear sill panel. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  2. Open the charge port door.
  3. Open the liftgate.
  4. Remove the trunk side trim bracket. See:
  5. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  6. Disconnect LV power. See LV Power (Disconnect and Connect).
  7. Verify that high voltage is no longer available to the charge port. See Charge Port Voltage Check.
  8. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  9. Disconnect the LH tail lamp connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab.
  10. Remove the nuts (x2) that secure the LH tail lamp to the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    Informational PurposesAn informational icon, calling your attention
    TIp
    Be careful not to drop the fasteners into the vehicle body.
  11. Remove the LH body tail lamp from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x datums, Note one datum clips into charge port door assembly
  12. 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.
  13. 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.
  14. Remove the charge port safety cap.
  15. 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.
  16. 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
  17. Release the charge port door connection from the charge port ECU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the original routing.
  18. Release charge port door harness grommet from body and feed the harness out.
  19. Remove the bolt that secures the charge port door to vehicle body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
  20. Remove the charge port door from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x datums, Release single datum from vehicle body, Maneuver door assembly and motor out from rear of vehicle, Guide harness out
  21. If the charge port door was properly aligned, measure and note the adjustable mounting point settings.

Install

  1. If the previous charge port door was properly aligned and measurements are available, set the new charge port door's adjustable mounting points to those settings.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 5 mm hex
  2. Install the charge port door onto the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Guide the harness in, maneuver the door assembly and motor in from the rear of the vehicle, then secure the single datum into the body.
  3. 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
  4. Secure the charge port door harness grommet onto the body.
  5. Secure the charge port door connection onto the charge port ECU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Return to original routing
  6. 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.
  7. 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
  8. 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.
  9. 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
  10. 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.
  11. 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
  12. Put on HV insulating gloves and leather over gloves
  13. 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.
  14. Remove leather over gloves and HV insulating gloves
  15. Install the charge port safety cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage hooks (x2). The safety cap clicks into position.
  16. Secure the charge port connection.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully engage the connection and the white locking tab.
  17. 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.
  18. Install the LH body tail lamp onto the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    One datum clips into charge port door assembly.
  19. Install the nuts (x2) that secure the LH tail lamp to the body.
    3.5 Nm (2.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to drop the fasteners into the vehicle body.
  20. Connect the LH tail lamp connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Engage the red locking tab.
  21. Install the LH inner reinforcement to the body, and then install the bolts (x10) that attach the reinforcement to the body.
    27 Nm (19.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The bottom two bolts require improvising an 8 mm ratchet box-end wrench to turn the T40 socket.
  22. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  23. Reconnect LV power. See LV Power (Disconnect and Connect)
  24. Charge the vehicle to verify correct operation of the charging system.
  25. Close the charge port door.
  26. Fold LH 3rd row seat back into down position
  27. Install the trunk side trim bracket. See:
  28. Move the seats back to their original positions.
  29. Install the rear sill panel. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  30. Calibrate the LH and RH falcon wing doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the upper B-pillar button in the down position to manually calibrate.
  31. Move the LH front seat to its original position.