04/06/2024 18:03:42

Charge Port (Remove and Replace)

Correction code 44011602 1.56 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.
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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.
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Note
This procedure is for the Original version of this part. An updated/region-specific Global Refresh version of this part is available for newer vehicles and that procedure is here: Charge Port (EMEA) (Remove and Replace).

Remove

  1. Open the LH front and LH rear doors.
  2. Lower the LH and RH front windows.
  3. Move the driver seat fully forwards.
  4. Move the LH 2nd row seat fully forward, if equipped.
  5. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  6. Open the hood.
  7. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  8. Open the charge port door.
  9. Open the liftgate.
  10. Remove the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  11. Remove the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  12. Remove the trunk tub floor insulator.
  13. Remove the trunk carpet.
  14. Remove the LH and RH side rear trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
  15. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  16. Remove the rear trunk floor NVH insulator. See NVH Insulator - Floor - Rear Trunk (Remove and Replace).
  17. Remove the LH rear trunk crush can trim. See Trim - Crush Can - Rear Trunk - LH (Remove and Replace).
  18. Release the clip, and then remove the soft trim pocket bracket.
  19. Remove the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  20. Remove the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  21. Fold the LH 3rd row down, if equipped.
  22. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  23. Release the fur tree clip that attaches the charge port manual cable release to the LH mid C-pillar zone bracket.
  24. Remove the LH mid C-pillar zone bracket. See:
  25. Remove the LH trunk trim carpet. See Carpet - Trim - Trunk - LH (Remove and Replace).
  26. Raise the LH 3rd row seat back into the upright position, if equipped.
  27. Disconnect LV power. See LV Power (Disconnect and Connect).
  28. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  29. Remove the 3rd row seat cushion. See Cushion - Seat - 3rd Row (Remove and Replace).
  30. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  31. Remove the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  32. Remove the nuts (x2) that attach the busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 11 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers.
  33. Remove the nut that attaches the charge port electrical harness to the body stud.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  34. Disconnect the charge port harness electrical connectors (x2).
  35. Release the barrel clip that attaches the charge port harness to the body.
  36. Remove the bolts (x4) that attach the charge port assembly to the body.
    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to pull with force as the electrical harness routes to the charge port door and can be damaged.
  37. Release the locking tab, and then disconnect the charge port door harness electrical connector to the charge port assembly.

Install

  1. Connect the charge port door harness electrical connector to charge port, and then engage the locking tab.
  2. Remove the bolts (x4) that attach the charge port assembly to the body.
    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to pull with force as the electrical harness routes to the charge port door and can be damaged.
  3. Install the charge port assembly to body, and then attach the bolts (x4).
    5.5 Nm (4.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    New charge port assemblies come with Penetrox applied around the studs.
  4. Install the nut that attaches the charge port electrical harness onto the body stud.
    6 Nm (4.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  5. Secure the barrel clip that attaches the charge port harness to the body.
  6. Connect the charge port harness electrical connectors (x2).
  7. If the charge port is being reused, clean the charge port assembly busbar contact surface of residual penetrox with an Isopropyl Alcohol (IPA) wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to push the IPA wipe down between the plastic divider.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time before continuing.
  8. Clean the contact surfaces of the busbar leads to remove any residual Penetrox with an IPA wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time before continuing.
  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 5 mm in diameter to either side of the hole on both leads. Spread the Penetrox evenly to verify the contact surface is fully covered.
  10. Install the busbar leads onto the charge port assembly, and the install the nuts (x2).
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts have captured washers.
  11. Inspect the HV insulating gloves.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
  12. Put on the HV insulating gloves and leather over gloves.
  13. Perform a Hioki resistance test at each HV joint (x2) from the HV busbar lead to the charge port stud.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), the Hioki test passed. Proceed to the next step.
  14. Remove the leather over gloves and HV insulating gloves.
  15. Install the charge port to HV battery busbar safety cap. See Safety Cap - Busbar - Charge Port to HV Battery (Remove and Replace).
  16. Reconnect LV power. See LV Power (Disconnect and Connect).
  17. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  18. Close the hood.
  19. Verify operation of vehicle charging system.
  20. Close the charge port door.
  21. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  22. Install the 3rd row seat cushion. See Cushion - Seat - 3rd Row (Remove and Replace).
  23. Install the LH trunk trim bracket. See Bracket - Trim - Trunk - LH (Remove and Replace).
  24. Fold the LH 3rd row seat back in the down position, if equipped.
  25. Install the trunk side trim carpet.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push clips (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Fully seat the 12V outlet housing.
  26. Install the LH mid C-pillar zone bracket. See:
  27. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  28. Raise the LH 3rd row seat back into the upright position, if equipped.
  29. Install the LH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  30. Install the LH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  31. Fasten the push clip that attaches LH soft trim pocket bracket, and then install the bracket.
  32. Install the LH rear trunk crush can trim. See Trim - Crush Can - Rear Trunk - LH (Remove and Replace).
  33. Install the rear trunk floor NVH insulator. See NVH Insulator - Floor - Rear Trunk (Remove and Replace).
  34. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  35. Install the LH and RH side rear trunk garnishes. See Garnish - Rear Trunk - Side - LH (Remove and Replace).
  36. Install the trunk carpet.
  37. Install the trunk tub floor insulator.
  38. Install the side trunk load floor. See Trunk Load Floor - Side (Remove and Replace).
  39. Install the rear trunk load floor. See Trunk Load Floor - Rear (Remove and Replace).
  40. Close the liftgate.
  41. Restore the LH 2nd row LH seat back to its original position, if equipped.
  42. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  43. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  44. Restore the driver seat back to its original position.