Tesla Model S: Charge Port - 3 Phase (Remove and Replace)

Note: This procedure describes how to remove and install the 3 phase charge port. If the vehicle is equipped with a single phase charge port, refer to procedure 44012202 (refer to procedure).

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. Removal

1. Open the charge port.
2. Remove the LH trunk trim (refer to procedure).
3. Release the 12V harness connection from the charge port.

   

4. Remove the grounding bracket by releasing the nut that secures it to the body (torque 6 Nm).

   

5. Disconnect the harness that connects the tail light to the charge port.

   

6. Remove the cover from the cable connector by using a trim tool or similar non-conductive tool to bend the 3 tabs that secure the cover to the cable connector.

   Note: The locations of the tabs are marked by arrows on the face of the cover.

   Caution: Do not lose or damage the magnet on the outboard side of the cable connector.

   

7. Remove the 3 bolts that secure the cable connector to the charge port in the order shown (torque 4 Nm). Remove the cable connector.

   

8. Remove the LH taillight assembly (refer to procedure) .
9. Remove the bolts in the order shown (torque 3 Nm). Remove the charge port.

   

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

• When securing the charge port to the body, install all 4 bolts loosely, then tighten them in the order shown.

  Note: Insert all 4 bolts loosely before tightening them in the proper sequence.

  

• Before installing the cable connector, close the charge port door and verify that it is 0-2 mm underflush to the body. If necessary, turn the screw to adjust the magnet that secures the charge port door.

  

• When reinstalling the cable connector, ensure that the HV cables and data harness do not touch or interfere with the latch on the inside of the charge port.

  

• When securing the cable connector to the charge port, loosely install all 3 bolts, then tighten them in the order shown. Note: Insert all 3 bolts loosely before tightening them in the proper sequence.

  

• After reinstalling all components, perform a firmware update.

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