Charge Port Door Actuator

Replace the charge port door actuator on a 2024 Model S Plaid. The actuator is the small motor/latch assembly that releases and closes the charge port door on the rear driver-side quarter panel; this job does not require disturbing the high-voltage charge port contacts themselves.

Warnings

Tools required

Parts

• Charge port door actuator assembly (OEM, Model S Plaid 2024) × 1 — Manufacturer-specified charge port actuator for refresh Model S
• Replacement plastic clips/fasteners for trunk/quarter trim (as needed) × 1 — OEM trim retainers

Preparation

1. Park on level ground, place in P, engage parking brake.
2. 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.
3. Disconnect the 12V (or 16V lithium, if equipped under the rear seat on this Plaid) low-voltage battery. The standard 12V is located in the frunk under the nose cowl panel — refer to architecture notes.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. 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.
6. Confirm the vehicle is NOT plugged into a charger and the charge port door is in the closed position (or manually released using the emergency release cable in the trunk if the actuator has failed in the closed position).
7. Open the rear trunk and remove the rear driver-side trunk side trim panel to access the back side of the charge port assembly. Use a plastic trim tool — fasteners are typically push clips and one or two screws.
8. Place painter's tape along the painted edges of the charge port opening to protect the aluminum quarter panel from tool slips.

Procedure

1. 1

   Locate the manual release cable
   With the trunk side trim removed, locate the manufacturer-specified manual charge port release cable behind the charge port housing. Pull it to release the door if the actuator has failed closed. Note its routing for reinstallation.
2. 2

   Identify and disconnect the actuator electrical connector
   Locate the low-voltage harness connector that feeds the charge port door actuator (separate from the larger high-voltage charge inlet connectors). Depress the locking tab and unplug. Do NOT disconnect any orange/HV connectors — those are not part of this job.
   ⚠️If the connector you are about to remove is orange or labeled HV, STOP. The actuator harness is a small low-voltage signal connector only.
3. 3

   Remove the rear cover/access panel of the charge port housing
   Remove the cover screws securing the inner housing/access cover behind the charge port assembly. Set hardware aside in order.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove the actuator mounting bracket bolts
   The charge port door actuator is mounted to a bracket on the inner side of the charge port housing. Remove the bracket bolts that secure the actuator/bracket sub-assembly. Support the actuator with one hand as the last bolt is removed so it does not hang on the harness or the door pivot.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
5. 5

   Disengage the actuator from the door linkage
   Carefully separate the actuator from the charge port door's pivot linkage. Note the orientation of any pivot pin, spring, or clip. Do not force — the linkage is plastic and can break.
   ⚠Do not pry against the painted aluminum quarter panel. Brace against the steel/aluminum charge port housing structure only.
6. 6

   Remove the failed actuator
   Withdraw the actuator from the housing through the inner access opening. Compare the removed unit to the replacement to confirm correct part, connector keying, and linkage geometry before installing the new unit.
7. 7

   Install the new actuator and engage the door linkage
   Position the new actuator, engaging the door pivot/linkage exactly as noted during removal. Verify the door can travel through its full open/close arc by hand before fastening.
8. 8

   Torque the actuator bracket bolts
   Install the bracket bolts and torque to the verified specification.
   Torque spec

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

   Reconnect the actuator harness
   Reseat the low-voltage harness connector until the lock tab clicks. Ensure the harness is routed away from any moving door linkage and not pinched against the aluminum body.
10. 10

    Reinstall the housing cover
    Reinstall the inner access cover and torque the cover screws to the verified specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Re-route and clip the manual release cable to its original location and verify it is accessible from the trunk.
2. Reinstall the rear trunk side trim panel and any clips/fasteners removed for access. Replace any clips that broke during removal.
3. Reconnect the 12V (or 16V) low-voltage battery, observing correct polarity and torque to OEM specification — refer to Tesla Service Manual.
4. Close the trunk and allow the vehicle to wake (touch the door handle or step on the brake from inside).
5. Allow the vehicle 1–2 minutes to complete its low-voltage boot and body controller initialization before testing the charge port.

Verification

• From the touchscreen, tap the charge port icon to command the door open. The door should release and present smoothly with no grinding.
• Press the button on a Tesla charge connector (or the door itself) to confirm the door closes fully and latches flush with the aluminum quarter panel — no proud edge, no gap.
• Plug in a charger (Mobile Connector or Supercharger) and confirm the latch holds the connector and that charging initiates. Unplug and confirm the door auto-closes after the timeout.
• On the touchscreen, check Service > Notifications (or Software > Recent Alerts) for any BCM/charge port DTCs. None should be present.
• Visually inspect that the painted charge port door sits flush and that no harness is pinched.
• Reminder for the owner: although this job is unrelated to scheduled service, the 2024 Model S Plaid still has Tesla-recommended intervals worth tracking — brake fluid every 2 years, cabin (HEPA) filter every 3 years, drive unit fluid inspection per Tesla's revised schedule, and battery coolant inspection at 4 years / 50,000 mi.

More procedures for this vehicle