01/02/2024 14:20:38

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
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. 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

  1. Remove the charge port assembly from the vehicle. See Charge Port (3-Phase) (Remove and Replace).
  2. Remove the LH taillight assembly. See Taillight - LH (Remove and Replace).
  3. Install protective tape around the charge port door.
  4. Disconnect the charge port door harness connector from the charge port ECU.
  5. Release the charge port door harness grommet from the body.
  6. Release the clips (x2) that attach the charge port door to the vehicle, and then remove the charge port door.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release clips and swing the bottom of the charge port door out. Maneuver the actuator around the body.

Install

  1. Install the charge port door to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the actuator around the body.
  2. Secure the grommet that attaches the charge port door harness to the body.
  3. Install the charge port door harness grommet to the body.
  4. Connect the charge port door harness connector to the charge port ECU.
  5. 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.
    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.
  6. Position the charge port on the vehicle, and then install the bolts that attach the charge port to the vehicle.
    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.
  7. Connect the electrical connector to the charge port actuator, and then engage the locking tab.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Push the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  8. 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
  9. Use an IPA wipe to clean all residue and debris from the charge port busbar leads, and then air dry for 1 minute.
    Figure 1. Busbar bracket design may vary
  10. 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.
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the contact surfaces are completely covered with electrical joint compound.
    Figure 2. Busbar bracket design may vary
  11. Position the charge port busbars on the charge port, and then install the nuts (x2) that attach the busbar leads to the charge port.
    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
  12. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  13. Install the safety cap on the busbar brackets, making sure to engage the two locking tabs.
  14. Connect the 3-phase connector on the charge port, and then slide the locking tab downward.
    Figure 3. Model 3 shown, Model Y similar
  15. If the same taillight is to be reinstalled, replace the gaskets from around each taillight mounting bolt (x2) and the taillight electrical connector (x1).
  16. Position the LH taillight studs into the grommets, and then install the taillight onto the body.
  17. Install the nuts (x2) that attach the taillight to the vehicle.
    3.2 Nm (2.4 lbs-ft)
    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)
  18. Connect the electrical harness to the taillight connector, and then engage the connector lock.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the connector has a red locking tab: Push the red locking tab into the connector to engage the connector lock.
  19. Continue installing the charge port assembly into the vehicle. See Charge Port (3-Phase) (Remove and Replace).
  20. Connect 12V power. See 12V/LV Power (Disconnect and Connect).
  21. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  23. Reinstall the vehicle software. See Software Reinstall - Touchscreen.
  24. Verify the operation of the charging system:
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the customer's charging equipment, if present.
    1. Open the charge port by lightly pushing on the lower RH corner of the charge port door, and then close the charge port door.
    2. Use a UMC or wall connector and press the button on the handle to open the charge port door.
      Informational PurposesAn informational icon, calling your attention
      Note
      There may be a brief timeout after closing the door until the door will open again.
    3. Connect the charge handle to the charge port and confirm that the vehicle is charging.
    4. Disconnect the charge handle and confirm that the charge port door closes.
  25. 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.