Replacement of the charge port latch mechanism on the 2024 Tesla Roadster Tri Motor. Note: this vehicle's architecture is not well-documented publicly; proceed with caution and verify all details against an authoritative Tesla service source before commencing.

Warnings

Tools required

Parts

• Charge port latch assembly (manufacturer-specified for this Roadster generation) × 1 — OEM Tesla Roadster charge port latch — verify with parts catalog
• Replacement fasteners (if any are single-use per OEM spec) × 1 — as required by OEM

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with 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/48V on applicable models) low-voltage battery. See architecture notes — Roadster LV battery location varies; consult the service manual.
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. Ensure the charge port door is in the open/unlatched position before removing power, if possible — this simplifies access to the latch fasteners.
7. Have the replacement latch on hand and verify it matches the removed unit before reinstalling trim.
8. Work in a clean, well-lit area; lay out fasteners in order of removal.

Procedure

1. 1

   Verify low-voltage system is de-energized
   Confirm the 12V/LV battery is disconnected and isolated. Use a multimeter at an accessible LV ground reference if needed. Verify the charge port indicator and any latch motor are dead before proceeding.
2. 2

   Access the charge port area
   Open the charge port door manually. Remove any interior trim panel or access cover behind/around the charge port that blocks access to the latch assembly. Use plastic trim tools to release clips — do not pry against painted composite panels.
   ⚠Roadster body panels are composite/aluminum. Excessive prying will crack mounting tabs.
3. 3

   Identify the latch and its harness
   Locate the charge port latch mechanism (typically a small actuator at the top or side of the charge port receptacle housing). Trace its low-voltage connector. Confirm visually that no orange HV cabling needs to be moved or disconnected to reach the latch. If HV cables block access, STOP.
   ⚠️If accessing the latch requires moving, unbolting, or unclipping any orange HV cable or HV connector, abort this procedure.
4. 4

   Disconnect the latch electrical connector
   Release the locking tab on the latch's low-voltage connector and unplug it. Inspect pins for corrosion or damage. Tuck the harness aside so it is not pinched during removal.
5. 5

   Remove the latch retaining fasteners
   Remove the fasteners securing the latch/actuator to the charge port housing or its bracket. Note fastener length and location — they are not always identical. Support the latch as the last fastener is removed.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
6. 6

   Remove the latch assembly
   Withdraw the latch from the housing. If the latch engages a pin or hook on the charge port door, ensure that pin is not bent or damaged. Inspect the housing pocket for debris, corrosion, or moisture intrusion and clean as needed.
7. 7

   Compare old and new latches
   Place the old and new latch side by side. Confirm identical mounting points, connector keying, and actuator geometry. If they differ, do not install — verify part number against VIN before proceeding.
8. 8

   Install the new latch
   Seat the new latch into the housing in the same orientation as removed. Start all fasteners by hand to avoid cross-threading the lightweight housing. Then torque to specification.
   ⚠Do not over-torque — the charge port housing mount points are easily stripped.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
9. 9

   Reconnect the latch harness
   Plug the LV connector back into the new latch until the lock tab clicks. Confirm the harness routing is original and not pinched between the latch and housing.
10. 10

    Reinstall trim and access panels
    Reinstall any interior trim or access cover that was removed. Seat all clips fully. If any cover screws were removed, torque to OEM specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification — do not leave any 'hand tight' for later.
2. Confirm the charge port door pivots freely and the new latch engages/releases the door pin without binding.
3. Reconnect the 12V/LV battery in the reverse order of disconnection (positive first, then negative ground last — verify against service manual for this model).
4. Allow vehicle systems to wake and complete self-checks (typically 1-2 minutes) before testing the charge port.

Verification

• From the touchscreen (or key fob, depending on Roadster UI), command the charge port door to open. Confirm the latch releases and the door opens fully.
• Insert the charging connector (or the appropriate test plug) and confirm the latch engages and locks the connector in place.
• Initiate a low-power AC charge session and confirm the vehicle reports a normal charging state with no charge port faults on the display.
• Stop charging and confirm the latch releases the connector on command without manual override.
• Cycle the charge port door open/close several times to verify consistent operation.
• Check for any stored body-control or charge port fault codes using a compatible scan tool. Clear any codes set during service and confirm they do not return.
• Note: this job does not affect Tesla's published service intervals (brake fluid 2 yr, cabin filter 2 yr, drive unit fluid ~12,500 mi initial then 25k-50k mi, coolant 4 yr / 50k mi inspection, tire rotation every 6,250 mi). Reference these separately when planning the next service.

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