17/11/2024 18:09:37

Charge Port (NA) (Remove and Replace)

Correction code 44011602 0.60 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 wearing proper PPE when performing the below procedure.

  • 2023-10-27: Update charge port to body bolt torque to 9 Nm.
  • 2023-10-10: Added a caution to not manually close the charge port door.
  • 1076921-00-B Insulation Multimeter, Fluke 1507 (NA)
  • 1076921-00-A Insulation Multimeter, Fluke 1587 (EMEA)
  • 1076921-01-B Insulation Multimeter, Fluke 1508 (APAC)
  • 1076927-00-A Hioki RM 3548
  • 1130480-00-A Test Probes, Slim, Fluke TP38
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage 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 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 IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
Warning

Proper personal protective equipment (PPE) is required to perform this procedure:

  • High voltage insulating gloves
  • Leather glove protectors
  • High voltage glove tester
  • Safety glasses
  • Electrical hazard rated safety shoes
Warning IconA warning icon, calling your attention to a possibly risky situation
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 IconA warning icon, calling your attention to a possibly risky situation
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

Table 1. Torque Specifications: Charge Port (NA) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the charge port to the body
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Flex head ratchet/flex head torque wrench
Reuse
Nut that attaches the busbar to the charge port
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • ¼ in std flex head ratchet
  • ¼ in torque wrench (installation only)
Reuse

Remove

  1. Lower all windows.
  2. Open all doors and latch the rear doors.
  3. Move the driver seat and front passenger seat fully forward.
  4. Open the liftgate.
  5. Open the hood.
  6. Open the charge port door.
  7. Disconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  8. Perform the charge port voltage check procedure. See Charge Port Voltage Check.
  9. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  10. Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  11. Remove the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  12. Remove the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  13. Remove the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the LH trunk load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  16. Remove the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  17. Remove the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  18. Release the clips (x6) and tab (x1) that attach the LH upper C-Pillar trim to the vehicle, and then set the trim aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the foremost part of the LH upper C-Pillar trim from the headliner.
    Informational PurposesAn informational icon, calling your attention
    Note
    The LH upper C-Pillar trim will still be attached to the rear seatbelt.
  19. Remove the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  20. Disconnect the LH body harness connectors (x2) from the charge port ECU.
  21. Release the clip that attaches the LH body harness to the vehicle.
  22. Release the locking tabs from the charge port low voltage connectors (x2), and then disconnect the connectors (x2) from the charge port.
    Tip: Gently lift the black connector tab in order to remove the white locking tab from the 12-pin low voltage connector.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
  23. Remove the charge port busbar fastener cover from the charge port assembly.
  24. Remove the nuts that attach the charge port busbars to the charge port, and then slide the busbars off of the charge port studs.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  25. Remove the bolts that attach the charge port to the body, and then remove the charge port from the vehicle.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust)
  2. 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.
    Informational PurposesAn informational icon, calling your attention
    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.
  3. Position the charge port in the vehicle, and then install the bolts that attach the charge port to the body.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Flex head ratchet/flex head torque wrench
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure the harness is routed out, and the adhesive pad with zip tie is properly mounted if it is installed.
  4. If reinstalling the same charge port: Perform a torque check on the busbar studs on the back of the charge port.
    2 Nm (1.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly.
    Tip: Use of the following tool(s) is recommended:
    • Torx T10 bit
    • 4 in extension
    • Ratchet/torque wrench
  5. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.
  6. If reinstalling the same charge port, apply one drop of Penetrox A-13 electrical joint compound on each of the charge port busbar leads, on the side that makes contact with the charge port.
    Informational PurposesAn informational icon, calling your attention
    Note
    Skip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.
  7. Position the charge port busbars on the change port studs, and then install the nuts that attach the busbars to the charge port.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • ¼ in std flex head ratchet
    • ¼ in torque wrench (installation only)
  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.
    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 measured resistance is above 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, as appropriate.
    Informational PurposesAn informational icon, calling your attention
    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. Remove the HV insulating gloves and leather over gloves.
  11. Install the charge port busbar fastener cover on the charge port assembly.
  12. Install the charge port low voltage connectors (x2) on the charge port, and then engage the locking tabs on both connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the connector lock.
    Tip: Carefully insert the white locking tab in the 12-pin low voltage connector until it locks with the black connector tab.
  13. Install the clip that attaches the LH body harness to the vehicle.
  14. Connect the LH body harness connectors (x2) to the charge port ECU.
  15. Install the C-Pillar bracket. See Bracket - C-Pillar - LH (Remove and Replace).
  16. Position the LH upper C-Pillar trim on the vehicle, and then install the clips (x6) and tab (x1) that attach the trim to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the upper groove in the front portion of the C-Pillar trim with the headliner.
  17. Install the LH trunk side trim. See Trim - Side - Trunk - LH (Remove and Replace).
  18. Install the LH trunk pocket bracket. See Bracket - Trunk Pocket - LH (Remove and Replace).
  19. Install the LH load floor bracket. See Bracket - Trunk Load Floor - LH (Remove and Replace).
  20. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  21. Install the front trunk floor trim. See Trunk Load Floor - Front (Remove and Replace).
  22. Install the rear trunk floor trim. See Trunk Load Floor - Rear (Remove and Replace).
  23. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  24. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  25. Reconnect 12V power. See 12V/LV Power (Disconnect and Connect).
  26. Close the liftgate.
  27. Close the charge port door.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not try to manually close the charge port door.
  28. Place the driver and front passenger seats back to their previous positions.
  29. Unlatch and close all doors.