NEW COSTS 88€
Torx T35, T15, T25
Parts list (available here in manual)
12V LAB Power supply
1- Frist troubleshoot that you got same or similar alerts on MCU screen. You can manualy check if there charge port open and close. First you must prepare car and all safety steps to turn off high voltage and low voltage systems for safety operation on Charge Port. First open trunk liftgate and then proceed with video.
2- Once the HW and LV systems are safely disconnected, proceed by accessing the charge port door. To do this, gently bend the body carpet on the left side of the trunk, revealing the back of the charge port assembly. The first step is to remove the darker orange plastic cover, which will expose three concealed Torx bolts. Take caution with this cover, as it contains a small magnet that is securely glued. Losing this magnet would prevent charging altogether, as it serves as a safety protection for servicing the port in case LV and HV disconnection is accidentally forgotten. After removing the three Torx bolts on the backside of the orange port, proceed to remove the four Torx bolts located at the four corners of the CP Assembly. At this point, you can detach the orange cable connected to the charge port and proceed to remove the BLACK charge port itself.
3- Remove now rear left lamp which holds charge port door. One 8mm nut is visible at the left side of CP and 2 nuts are behind panel which can be removed thru 2 holes. (will add picture later)
4- When you took out lamp disconnect CP door wiring, now remove 3 Torx bolts to take apart charge port door and lamp. You can check resistance between Red and blue wire, if you dont have 10K Ohm then potentiometer is surely damaged. Between Green and Red if there is resistance 3Kohm and Green and Blue 7Kohm that means it is ok, total is 10Kohm. By changing potentiometer rod rotation and position then resistance should change proportionaly with same rules.
5- Once the door mechanism is disassembled, begin by examining the extent of the damage caused by water ingress. Typically, only the potentiometer is affected. You can clean the PCB and small DC motor using ISO Cleaner and then proceed to check the resistance of the component one more time to confirm damage. Then prepare partslist.
6- After you solder Rotary Position Sensors back on PCB, you can assemble pack complete charge port door. You must tightly glue upper cover and leave it until it dries. You can now test charge port door on bench with power supply setup on 12V and 500mA current. Black and White wire by changing polarity will change directiong of door movement (close or open). In same time with your Ohmmeter you can check fluent resistance increase or decrease between green and orange or green and blue.
7- If everyting is working smooth, you can return charge port door to rear lamp, assembly charge port controler and HV wiring. Dont forget to connect CP wiring and HV service cover with magnet. Connect back HV Loop in front first and 12V battery negative terminal. Car will boot in 5 minutes and you can test charge port door. In some cases you will need Toolbox or any other tool to calibrate door because new values could be in offset.