Tesla Model S: Charge Port - Single Phase - Non-Motorized (Remove and Replace) - Removal

Note: This procedure describes how to remove and install the single phase charge port. If the vehicle is equipped with a 3 phase charge port, refer to procedure 44012102 (refer to procedure).

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:

1. Perform the vehicle electrical isolation procedure (refer to procedure).
2. Remove the LH trunk trim (refer to procedure) .
3. Remove the screw and release the clips (x2) from the HV inlet cover (torque 4 Nm).
4. Remove the HV inlet cover. Note: When the HV inlet cover is in the proper position, a post on the cover presses a switch in the charge port that activates the HVIL. The vehicle indicates a HVIL fault if the cover is not properly installed or the post is damaged.

   

5. Remove and discard the bolts (x2) that secure the HV cables to the charge port. Discard any washers that are installed between the bolts and the high voltage lugs.
6. Disconnect the harness connectors (x2) from the charge port.

   

7. Remove the lower nut that secures the charge port cable clamp to the body (torque 6 Nm).
8. Remove the upper nut that secures the charge port cable clamp (torque 5 Nm).

   

9. Release the charge port clamp from the body and position the HV cables aside for access.
10. Remove and discard the bolts (x4) that secure the charge port.

    

11. Remove the charge port assembly.

    

READ NEXT: