2026-10-08

Charge Port Door - NACS (Model Y L) (Remove and Replace)

Correction code 44010101102 FRT 1.02 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-09-24: 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.

Torque Specifications

Remove

  1. Remove the trunk tub. See Trunk Tub (Model YL) (Remove and Replace).
  2. Remove the LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  3. Perform the charge port voltage check. See Charge Port Voltage Check.
  4. Remove the LH trunk side trim. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  5. Release the clips (x10), locator pins (x4), and tabs (x2) that attach the LH C-pillar upper trim to the body, and then disconnect the seat dump switch connector and release the charging port release cable.
    Note
    Do not pull the trim too far from the vehicle, as it is still attached by the connector and charging port release cable.
  6. Put on the HV insulating gloves and leather over gloves.
  7. Remove the bolt that attaches the charge port controller to the vehicle, and disconnect the connectors (x3).
    Tip
    Use of the following tool(s) is recommended:
  8. Disconnect the DC logic connector from the charge port assembly.
    Note
    Remove white locking tab before disconnecting.
  9. Remove the charge port safety cap.
    Note
    Gently release the tabs to avoid damage; do not apply excess force.
  10. Remove the nuts (x2) that attach the charge port busbar to the charge port, and remove busbar leads from studs.
    Note
    Use of the following tool(s) is recommended:
  11. Release the LH body harness from the rear body and move aside.
  12. Remove the charge port assembly.
    Tip
    Use of the following tool(s) is recommended:
  13. Remove the charge port door.

Replace

  1. If reinstalling the same charge port, clean the charge port busbar HV header at the back of the charge port assembly with an IPA wipe, and then air dry for 1 minute.
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
    Tip
    Use a plastic trim tool to push the IPA wipe into the crevices of the charge port busbar HV header.
  2. Install the charge port door.
  3. Install the charge port assembly.
    Tip
    Use of the following tool(s) is recommended:
  4. Install the LH body harness onto the rear body.
  5. Apply Penetrox to backside of busbar leads.
  6. Install charge port busbar leads to charge port assembly.
    Tip
    Use of the following tool(s) is recommended:
  7. Perform a zero adjust of the Hioki resistance meter. See Resistance Meter (Zero Adjust).
  8. Put on HV insulating gloves and leather over gloves.
  9. At the charge port, use the Hioki resistance meter to measure the resistance between the charge port busbar lead and the charge port busbar stud. Also perform this test on the other lead and stud.
    Note
    The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ). If the measured resistance is above 270 mΩ (270 μΩ), escalate a Toolbox session, as appropriate.
    Note
    If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again. If after 4 attempts the resistance is consistently lower than 0.050 mΩ (50 μΩ), the test has passed; continue to the next step.
  10. Install charge port safety cap.
  11. Connect the DC logic connector to the charge port assembly.
  12. Install the bolt that attaches the charge port controller to the vehicle, and connect the connectors (x3).
    Tip
    Use of the following tool(s) is recommended:
  13. Remove HV insulating gloves and leather over gloves.
  14. Secure the clips (x10), locator pins (x4), and tabs (x2) that attach the LH C-pillar upper trim to the body, and then connect the seat dump switch connector and secure the charging port release cable.
    Note
    Do not pull the trim too far from the vehicle, as it is still attached by the connector and charging port release cable.
  15. Connect the LV power. See LV Power (Disconnect and Connect) (Modify).
  16. Install the LH trunk side trim. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  17. Install the LH and RH seat cushion bolsters. See Bolster - Seat Cushion - 3rd Row - LH (Model YL) (Remove and Replace) and Bolster - Seat Cushion - 3rd Row - RH (Model YL) (Remove and Replace).
  18. Install the trunk tub. See Trunk Tub (Model YL) (Remove and Replace).