2026-09-04

Safety Cap - Charge Port to HV Battery (Remove and Replace)

Correction Code 44015102

  • 2026-09-04: Released new procedure.
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Warning

Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.

Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning

Proper Personal Protective Equipment (PPE) is required to perform this procedure:

  • High Voltage (HV) insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning

A glove inflator is the only recommended way to test HV gloves. Both HV gloves must pass testing before beginning this procedure. If either glove does not pass the air check, discard the pair.

Warning
Make sure that the HV gloves are not expired.
  • North America: HV gloves can be used up to 12 months after the testing date printed on the glove, but only 6 months after first use even if the gloves are still within the 12 month period. If the gloves were not put into service during the 12-month period following the testing date, they must be retested before being put into service.
  • Europe: Class 0 (1000V) HV gloves have no expiration date and may be used if they pass the pre-use assessment and the periodic inspection.
  • Asia Pacific: Follow the expiration date stated by the HV glove manufacturer, and:
    • o China only: Test the gloves every 6 months according to GB/T 17622.

Remove

  1. Open the LH front door and lower the window.
  2. In MCU, open LH falcon door, hood and liftgate and fold down the LH 3rd row seat.
  3. Remove the LH lower zone C-pillar bracket. See Bracket - C-Pillar - Lower Zone - LH (Remove and Replace).
  4. Disconnect 12V power. See Disconnect 12V Power.
  5. Perform the charge port voltage check. See Charge Port Voltage Check.
  6. Remove the rear body controller. See Module - Rear Body Controller - BCM (Remove and Replace).
  7. Move the NVH foam to gain access to the charge port.
  8. Remove the safety cap.
    • NA: Pull out the locking tab to disengage, then press the tab under the locking tab to release the cap from the charge port assembly.
    • EMEA: First remove the cover, then remove the bolts (x3, torque 5 Nm) in the order shown.

Install

Installation procedure is the reverse of removal.