Charge Port Door Actuator

Replace the charge port door actuator on a 2024 Tesla Model S Long Range. The actuator controls the soft-open/close motion of the charge port door on the left rear quarter panel and is accessed by removing trim from inside the trunk wheel arch area.

Warnings

Tools required

Parts

• Charge port door actuator assembly (Model S 2021+ refresh) × 1 — Tesla OEM charge port actuator — verify by VIN at parts counter
• Replacement trim clips (in case any break during removal) × 4 — Generic OEM-style push-pin retainers

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Open the charge port door from the touchscreen (Controls > Charging > Open Charge Port) BEFORE powering down — this gives access to the actuator without forcing the door.
3. Exit ALL doors with the key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
4. Open the frunk and disconnect the 12V low-voltage battery (negative terminal first) located under the front trunk nose cowl panel. Refer to the architecture notes for your specific build.
5. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
6. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
7. Apply painter's tape around the perimeter of the charge port opening to protect paint.
8. Open the rear trunk and remove items from the cargo area. Pull back the left-side trunk trim panel to expose the rear quarter panel inner cavity behind the charge port.

Procedure

1. 1

   Access the charge port cavity
   From inside the trunk, release the left-side trunk side trim using plastic trim tools. Pull back the carpet/felt liner to expose the back side of the charge port assembly. The actuator is mounted to the charge port housing on the inboard side of the door hinge.
   ⚠Trim clips on Model S are brittle in cold weather — warm the cabin before removal to reduce breakage.
2. 2

   Identify the actuator and verify HV clearance
   Locate the small electric actuator attached to the charge port door hinge mechanism. Confirm visually that you see only low-voltage (typically black, 2-3 wire) connectors going to the actuator. If you see ANY orange cable in your work area, STOP — those serve the HV charge inlet and must not be disturbed.
   ⚠️Orange cables = high voltage. Do not touch, move, or cut. Stop the job if you cannot work around them safely.
3. 3

   Disconnect the actuator electrical connector
   Release the locking tab on the low-voltage connector going to the actuator and disconnect it. Inspect the connector for corrosion or moisture intrusion (a known cause of charge port door faults on Model S).
4. 4

   Support the charge port door
   With the door in the open position, support it by hand or with a soft-padded prop. Once the actuator is unbolted, the door will be free to swing — do not let it strike the painted quarter panel.
5. 5

   Remove the actuator mounting fasteners
   Remove the fasteners securing the actuator to the charge port housing bracket. Note the exact orientation and any shims or alignment features before removal — the actuator must be reinstalled in the same orientation for proper door travel.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
6. 6

   Remove the actuator
   Carefully withdraw the actuator from the charge port housing. The actuator output arm engages a lever on the door hinge — disengage this linkage gently. Do not pry against the painted door or the plastic charge port housing.
7. 7

   Compare old and new actuators
   Place the old and new actuators side by side. Verify part numbers/connectors match, output arm orientation matches, and any pre-set position of the output shaft is identical. Tesla actuators sometimes ship in a 'home' position that must not be rotated by hand before installation.
8. 8

   Install the new actuator
   Engage the new actuator's output arm with the door hinge linkage in the same orientation as removed. Seat the actuator flush against its mounting bracket and start the fasteners by hand to avoid cross-threading into the housing.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Torque the actuator fasteners
   Torque the actuator mounting fasteners to the manufacturer-specified bracket bolt value. Do not overtighten — the housing surrounding the charge port is partially plastic and can crack.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Reconnect the electrical connector
    Plug the low-voltage connector back into the actuator until the locking tab clicks. Route the wiring exactly as found, ensuring no pinching against sheet metal edges or interference with the door hinge sweep.

Reassembly

1. Reinstall the trunk side trim panel and any clips that were removed. Replace any broken push-pin retainers with new ones.
2. Reseat the trunk carpet/felt liner.
3. Remove painter's tape from around the charge port opening.
4. Reconnect the 12V battery (negative terminal last) in the frunk and reinstall the nose cowl panel.
5. Close the frunk by lowering it gently and pressing down on both sides until latched — do not slam (aluminum hood).

Verification

• Power the vehicle on and wake the touchscreen. Allow 30-60 seconds for systems to fully boot.
• From the touchscreen: Controls > Charging > Open Charge Port. Confirm the door opens smoothly with no grinding, hesitation, or partial travel.
• Press the charge port button on the door itself (or close from the screen) and confirm the door closes fully and latches flush with the quarter panel.
• Cycle the door open/close at least 3 times to confirm consistent operation.
• Plug in a charge cable (Mobile Connector or Wall Connector) and confirm the door holds open and the latch engages on the connector. Then unplug and confirm the door closes automatically.
• Check the touchscreen for any charge-port-related alerts (e.g. 'Unable to close charge port'). Clear any stale alerts.
• Inspect the door fitment with the body — gap should be even, and the painted door should sit flush with the quarter panel with no proud edges.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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