31/08/2023 11:08:09

Charge Port (Remove and Replace)

Correction Code 44011602

  • 2023-08-31: Moved LV disconnect and charge port voltage check so that they are performed after the trunk side trim is removed.
  • 2023-05-24: Updated procedure to use Charge Port Voltage Check.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage (HV) Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper Personal Protective Equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
The high voltage harness must be removed from the charge port before the charge port is removed from the vehicle. Never remove the charge port from the vehicle without first disconnecting the high voltage harness. Failure to follow this requirement may result in serious injury or death due to exposure to high voltage. Only Service Technicians that have received and completed high voltage training are authorized to perform this service.

Special tool required for this procedure:

Supplier Part Number Description
Tesla 1020288-00-A TOOL,INSTALLATION,EV INLET,MDLS

Removal

  1. Open the left rear door.
  2. Open the liftgate.
  3. Open the charge port.
  4. Remove the LH rear trunk side trim (refer to procedure).
  5. Disconnect 12V power. See Disconnect 12V Power.
  6. Perform the charge port voltage check. See Charge Port Voltage Check.
  7. Remove the foam HVAC ducting.
  8. Pull inboard on the tab on the rear of the charge port cover, then rotate the rear of the cover toward the front of the vehicle to remove it from the charge port.
  9. Remove the bolts (x2) that secure the HV cables to the charge port (torque 9 Nm).
  10. Release the HV cables from the charge port and move them out of the working area.
  11. Disconnect the low voltage harnesses (x2) from the charge port.
  12. Release the bolts (x4) that secure the charge port to the body (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not attempt to remove the charge port at this time.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not over-tighten the bolts during installation to prevent water leaks inside the vehicle.
  13. Disconnect the harness that leads to the charge port door motor.
  14. Remove the charge port from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:

  1. Before installing the charge port, ensure that the grommet is fully seated in the door actuator.
  2. Ensure that the wires for the charge port door motor are routed beneath the charge port.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not let the wires become pinched by the corner of the charge port.
  3. Ensure that the charge port is flush with the body panels.
  4. Before securing the HV cables to the charge port, insert the charge port alignment tool into the charge port.
  5. Ensure that both low voltage harnesses are fully seated.
  6. Ensure that both the upper and lower HV covers are fully seated.
  7. Update the vehicle firmware. See Firmware Update.
  8. Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
  9. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
  10. Using Toolbox 3:
    1. Select the Actions tab and search for "Latch calibration".
    2. Select the ODIN routine PROC_CP_X_LATCH-CALIBRATIONSearch for routine in ToolboxCharge port latch calibration, and then click the link of the routine.
    3. Click RUN, and allow the routine to complete.
  11. Using Toolbox 3:
    1. Select the Actions tab and search for "Door sensor calibration".
    2. Select the ODIN routine PROC_CP_X_DOOR-SENSOR-CALIBRATIONSearch for routine in ToolboxCharge Port Door Calibration, and then click on the link of the routine.
    3. Click RUN, and allow the routine to complete.
  12. Perform a charging session and make sure that charging proceeds as intended.