Tesla Model S Owners & Service Manuals

Tesla Model S: Reinstall Components

Tesla Model S (2012-2024) Service Manual / High Voltage System / Charge Port - Single Phase - Non-Motorized - Manual Release of Cable / Reinstall Components

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

When reconnecting the HV cables to the charge port:

  1. Remove any adhesive patch residue from the mating surfaces of the high voltage cable lugs.
  2. Remove any adhesive patch residue from the surfaces of the terminals.

    Release Cable

  3. Push the pawl actuator tab to the left to release the pawl, then insert the charge port alignment tool into the charge port.

    Note: The charge port alignment tool should only be used on vehicles manufactured for North America and Japan. Vehicles manufactured for all other countries include the European charge port and do not require use of the charge port alignment tool during this procedure.

    Release Cable

  4. Install the bolts (x2) that secure the HV cables to the charge port (torque 9 Nm). Caution: Do not use any washers other than the captive washers that are part of the new bolts.
  5. Place a paint mark on each bolt to indicate that it has been properly tightened. Use one continuous motion to mark the bolt head, washer, and the surface of the lug.

    Release Cable

  6. Push the pawl actuator tab to the left to release the pawl, then remove the charge port alignment tool from the charge port if used.
  7. Reinstall the pawl actuator cover.

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