Charge Port (Remove and Replace)

FRT No: 44011602

Warning: Only technicians who have been trained in High Voltage Awareness are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 00 (500V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Warning: The high voltage harness must be removed from the charge port before the charge port is removed from the vehicle. Never remove the charge port from the vehicle without first disconnecting the high voltage harness. Failure to follow this requirement may result in serious injury or death due to exposure to high voltage. Only Service Technicians that have received and completed high voltage training are authorized to perform this service.

Special tool required for this procedure:

Supplier	Part Number	Description
Tesla	1020288-00-A	TOOL,INSTALLATION,EV INLET,MDLS

Removal

Open the left rear door.
Open the liftgate.
Open the charge port.
Disconnect 12V power (refer to procedure).
Remove the LH rear trunk carpet and trim assembly (refer to procedure).
Remove the foam HVAC ducting.

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Pull inboard on the tab on the rear of the charge port cover, then rotate the rear of the cover toward the front of the vehicle to remove it from the charge port.

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Use a multimeter to check voltages on the lugs that secure the HV cables to the charge port:
- B+ to ground
- B- to ground
- B+ to B-
Warning: If any voltage reading is more than 10V, the contactors are not fully opened. Discontinue this procedure immediately. Contact a Field Service Engineer before performing any further work.
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Remove the bolts (x2) that secure the HV cables to the charge port (torque 9 Nm).
Release the HV cables from the charge port and move them out of the working area.
Disconnect the low voltage harnesses (x2) from the charge port.

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Release the bolts (x4) that secure the charge port to the body (torque 5 Nm).

Note: Do not attempt to remove the charge port at this time.

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Disconnect the harness that leads to the charge port door motor.

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Remove the charge port from the vehicle.

Installation

Installation procedure is the reverse of removal, except for the following:

Before installing the charge port, ensure that the grommet is fully seated in the door actuator.
Ensure that the wires for the charge port door motor are routed beneath the charge port.
Caution: Do not let the wires become pinched by the corner of the charge port.

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Ensure that the charge port is flush with the body panels.
Before securing the HV cables to the charge port, insert the charge port alignment tool into the charge port.

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Ensure that both low voltage harnesses are fully seated.
Ensure that both the upper and lower HV covers are fully seated.
Perform a vehicle firmware update if a new charge port was installed. This ensures that the charge port’s firmware is at the same revision as the vehicle firmware.