Door Assembly - Charge Port (EMEA) (Remove and Replace)
Correction code 44015302 0.84 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.
- 2024-02-01: Removed steps for actuator pan and motor, and vehicle electrical isolation procedure.
- 2023-10-27: Update charge port to body bolt torque to 9 Nm.
- 2023-07-11: Added vehicle electrical isolation procedure back into charge port assembly link, and updated install steps for more detail.
- 2023-06-06: Updated Charge Identifier Label TPN from 1691926-00-A to 1691926-00-B and updated related illustration.
- 1076921-01-B Insulation Multimeter, Fluke 1508
- 1130480-00-A Test Probes, Slim, Fluke TP38
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.
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.
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
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.
Make sure that the HV gloves are not expired. 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.
Remove
- Remove the charge port assembly from the vehicle. See Charge Port (3-Phase) (Remove and Replace).
- Remove the LH taillight assembly. See Taillight - LH (Remove and Replace).
- Install protective tape around the charge port door.
-
Disconnect the charge port
door harness connector from the charge port ECU.
-
Release the charge port door
harness grommet from the body.
-
Release the clips (x2) that
attach the charge port door to the vehicle, and then remove the charge port
door.
NoteRelease clips and swing the bottom of the charge port door out. Maneuver the actuator around the body.
Install
-
Install the charge port door
to the vehicle.
NoteManeuver the actuator around the body.
-
Secure the grommet that attaches the charge port door harness to the
body.
-
Install the charge port door
harness grommet to the body.
-
Connect the charge port door
harness connector to the charge port ECU.
-
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 allow to dry for 1
minute.
NoteSkip 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.
-
Position the charge port on
the vehicle, and then install the bolts that attach the charge port to the
vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
WarningMake sure the harness is routed out, and the adhesive pad with zip tie is properly mounted if it is installed. -
Connect the electrical
connector to the charge port actuator, and then engage the locking
tab.
CAUTIONPush the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
-
If reinstalling the same
charge port: Perform a torque check on the busbar studs on the back
of the charge port.NoteSkip 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
-
Use an IPA wipe to clean all
residue and debris from the charge port busbar leads, and then air dry for 1
minute.
-
If reinstalling the same
charge port: Apply two drops of electrical joint compound on each of
the charge port busbar leads (x2), on the side that makes contact with the
charge port.
NoteSkip this step if installing a new charge port assembly, as the new charge port has pre-applied electrical joint compound.NoteMake sure the contact surfaces are completely covered with electrical joint compound.
-
Position the charge port
busbars on the charge port, and then install the nuts (x2) that attach the
busbar leads to the charge port.Tip: Use of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
- Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
- Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
-
Connect the 3-phase
connector on the charge port, and then slide the locking tab downward.
- If the same taillight is to be reinstalled, replace the gaskets from around each taillight mounting bolt (x2) and the taillight electrical connector (x1).
- Position the LH taillight studs into the grommets, and then install the taillight onto the body.
-
Install the nuts (x2) that
attach the taillight to the vehicle.Tip: Use of the following tool(s) is recommended:
- 8 mm 12-point deep socket
- ¼ in std ratchet
- ¼ in torque wrench (installation only)
-
Connect the electrical
harness to the taillight connector, and then engage the connector
lock.
CAUTIONIf the connector has a red locking tab: Push the red locking tab into the connector to engage the connector lock.
- Continue installing the charge port assembly into the vehicle. See Charge Port (3-Phase) (Remove and Replace).
- Connect 12V power. See 12V/LV Power (Disconnect and Connect).
- Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Reinstall the vehicle software. See Software Reinstall - Touchscreen.
-
Verify the operation of the
charging system:
NoteUse the customer's charging equipment, if present.
- Europe only: install a CKL charging identifier label (1691926-00-B) on the face plate of the charge port assembly as illustrated, if one was present on the original part.