2025-06-04

Charge Port (GB) (Remove and Replace)

Correction code 4401011102 0.54 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 wearing proper PPE when performing the below procedure.

  • 2025-06-04: Added instruction to zero adjust the Hioki resistance meter prior to measurement.

Torque Specifications

Table 1. Torque Specifications:Charge Port (GB) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Fasteners securing charge port busbar to charge port
9 Nm (6.6 lbs-ft)
  • Insulated tools:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
  • Class 0 Electrical Protective Gloves
 Reuse
Bolts (X3) secure charge port assembly
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Cordless Ratchet/Impact Driver
  • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
 Reuse

Remove

  1. Remove the charge port safety cap See Charge Port Safety Cap - GB Standard (Remove and Replace).
  2. Remove fasteners securing charge port busbar to charge port and remove busbar leads from studs.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
    • Class 0 Electrical Protective Gloves
  3. Disconnect charge port logic connector.
  4. Disconnect AC inlet harness from charge port.
  5. Remove charge port assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
    • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA

Install

  1. Install charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
    • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
  2. Connect AC inlet harness from charge port.
  3. Connect charge port logic connector.
  4. Verify charge port studs are torqued to proper specification.
    2 Nm (1.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
    • WOBBLE EXTENSION, EXT .10.5\' NARROW 1/4DIA
    • 1/4in Dr T10 Socket
  5. Clean charge port busbar contact surface of residual penetrox.
  6. Apply penetrox to backside of busbar leads.
  7. Install charge port busbar leads to charge port assembly.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Insulated tools:
      • 10 mm deep socket
      • Cordless Ratchet/Impact Driver
    • Class 0 Electrical Protective Gloves
    Informational PurposesAn informational icon, calling your attention
    Note
    If excessive force is required to seat busbars, they may have been bent. Inspect for damage and replace if necessary.
  8. Perform a zero adjust of the Hioki resistance meter. See Resistance Meter (Zero Adjust).
  9. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port studs.
    Informational PurposesAn informational icon, calling your attention
    Note
    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), stop work and escalate the Toolbox session. 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.
  10. Install the charge port safety cap See Charge Port Safety Cap - GB Standard (Remove and Replace).