2026-08-09

Charge Port (GB) (Model Y L) (Remove and Replace)

Correction code 44010102602 FRT 1.02 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Torque Specifications

Table 1. Torque Specifications: Charge Port (GB) (Model Y L) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts (x2) that attach the charge port busbar leads to the charge port assembly
9 Nm (6.6 lbs-ft)
  • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
 Reuse
Bolts (x3) that attach the charge port assembly to the vehicle
9 Nm (6.6 lbs-ft)
  • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
 Reuse

Remove

  1. Perform a charge port voltage check. See Charge Port Voltage Check.
  2. Remove the LH trunk side trim from the vehicle. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).
  3. Release the clips (x10), locator pins (x4), and tabs (x2) that attach the LH C-pillar upper trim to the body, and then disconnect the seat dump switch connector and release the charging port release cable.
    Note
    Do not pull the trim too far from the vehicle, as it is still attached by the connector and charging port release cable.
  4. Put on HV insulating gloves and leather over gloves.
  5. Locate the charge port actuator logic connector on the charge port assembly, pull the red tab to disengage the lock, then pull again to release the connector.
    Note
    Avoid pushing down on the red tab.
  6. Remove the white locking tab, then disconnect the DC logic connector from the charge port assembly.
  7. Release the tabs (x2) and clip that attach the charge port safety cap to the charge port assembly, and then remove the safety cap.
    Note
    Avoid excess force to prevent damage.
  8. Remove the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
    Note
    The nuts come with captured washers.
  9. Carefully depress the white locking tab to release the charge port logic connector from the charge port, and pull off the connector.
  10. Release the dual step locking tab, then disconnect the charge port AC cable kit from the charge port.
  11. Release the clip that attaches the harness to the charge port assembly.
  12. Remove the bolts (x3) that attach the charge port assembly to the vehicle.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm

Install

  1. Install the bolts (x3) that attach the charge port assembly to the vehicle.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
  2. Release the clip that attaches the harness to the charge port assembly.
  3. Secure the dual step locking tab, then connect the charge port AC cable kit to the charge port.
  4. Connect the charge port logic connector to the charge port and fully engage the white locking tab.
  5. Verify charge port studs are torqued to proper specification.
    2 Nm (1.5 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 1/4in Dr T10 Socket
    • TQRQUE WRENCH, 1/4" DR, INSULATED, 2-10NM. TPN 1785247-00-A
  6. Clean the charge port busbar contact surface of residual penetrox, and allow 1 minute to dry.
  7. Apply 2 drops of Penetrox A-13 (about 5mm in diameter) to either side of the hole on the backside of both busbar leads, spreading evenly to ensure full coverage of the contact surface.
  8. Install the nuts (x2) that attach the charge port busbar leads to the charge port assembly.
    9 Nm (6.6 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Insulated Socket 1/4in Dr. 12pt. Deep x 10mm
    Note
    • The nuts come with captured washers.
    • Inspect for damage or bending if excessive force is needed; replace if necessary.
  9. Perform Hioki resistance test at each HV joint from HV busbar lead to charge port stud. The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.270 mΩ (270 μΩ).
    • If the resistance is greater than 0.270 mΩ (270 μΩ), stop work and escalate the Toolbox session.
    • If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
    • If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step.
  10. Secure the tabs (x2) and clip that attach the charge port safety cap to the charge port assembly, then push the cap firmly to lock it into place.
    Note
    Avoid excess force to prevent damage.
  11. Secure the white locking tab, then connect the DC logic connector to the charge port assembly.
  12. Engage the red locking tab, then connect the charge port actuator logic connector onto the charge port assembly.
  13. Remove the leather over gloves and HV insulating gloves.
  14. Connect the seat dump switch connector and install the charging port release cable, and then install the clips, locator pins, and tabs that attach the LH C-pillar upper trim to the body.
    Note
    While installing the upper trim, make sure that the air vent is properly installed.
    Note
    After installation, make sure that the seal fully covers the edge of the trim.
  15. Install the LH trunk side trim to the vehicle. See Trunk Side Trim - LH (Model Y L) (Remove and Replace).