14/12/2022 05:40:21

Master Charger - RH - 2nd Generation (Remove and Replace)

Correction Code 44102202

Note

This procedure describes how to remove and install the 2nd generation master charger. If the vehicle is equipped with a 1st generation master charger, refer to procedure 44100202 (refer to procedure).

Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Warning

To avoid personal injury, eye protection must be worn while using compressed air.

Procedure

Open all four doors
Lower all four windows
Move both front seats fully forward
Open hood

Note
Using MCU touchscreen > Controls > Frunk Trunk
Remove rear underhood apron

Note
8x clips
Remove LH underhood apron

Note
9x clips
Remove RH underhood apron

Note
9x clips
Remove rear bolts securing underhood storage unit to body

Note
2x bolts, 13mm, 4 Nm, Peel back carpet for access
Remove front nuts securing underhood storage unit to body

Note
2x nuts, 8mm, 8 Nm, Peel back carpet for access
Disconnect emergency hood release and front light harness

Note
2x connectors, Push wiring harness grommet through underhood storage unit
Remove underhood storage unit from vehicle
Remove the cabin filter and cover then lift up the RH side of cowl screen panel to access cabin filter housing

Note
2x push clips, Place shop rag under trim to support if needed
Remove bolts securing front HVAC filter housing

Note
2x bolts, 10mm, 1.5 Nm
Remove front HVAC filter housing

Note
2x tabs
Power down vehicle using MCU

Note
Controls > Safety&Security > Power Off > ''POWER OFF''
Disconnect the 12V battery negative terminal

Note
1x nut, 10mm, 5 Nm
Disconnect the first responder loop

Note
Wait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
Remove 2nd row seat bottom cushion

Note
2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
Remove NVH padding from underneath 2nd row seat cushion

Note
If equipped
Remove bolts securing seat bottom frame

Note
8x bolts, 11mm, 26 Nm
Release harness clips from frame

Note
5x clips, 3x edge clips
Disconnect seat frame harness connector

Note
1x connector
Lift up and support seat bottom frame

Note
Release harness clips if necessary
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves, https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
Remove the HVIL bolt from the HV junction box

Note
1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
Remove bolts securing HVJB cover to HVJB box

Note
7x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
Lift carefully the HVJB lid up and remove
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Remove HV insulating gloves
Disconnect and remove all 4 HV harnesses from both chargers to HVJB

Note
8x connectors
Remove the charge port HV cables

Note
4x bolts, 8mm, 4 Nm, bolts are captured
Remove the DCDC HV cables

Note
2x bolts, 8mm, 4 Nm, Bolts are captured
Remove the front drive unit HV cables

Note
2x nuts, 13mm, 9 Nm, 1x bracket, Nuts are captured
Remove the drive inverter and HV battery cables

Note
2x nuts, 13mm, 9 Nm, Nuts are captured
Remove bolt securing ground tot HVJB

Note
1x bolt, T30, 6 Nm
Release coolant hose

Note
2x barrel clips, Move hose from covering HV junction box bolts
Remove the bolts that secure the HV junction box

Note
4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
Disconnect the HVJB connector

Note
1x electrical connector, Lift HV junction box assembly slightly for access
Remove HV junction box from vehicle
Disconnect connectors gen 2 master charger

Note
2x connectors
Remove bolt that secures ground strap to master charger case

Note
1x bolt, 10mm, 6.5 Nm
Remove nuts that secure master charger

Note
4x nuts, 10mm, 6.5 Nm
Lift master charger slightly and place absorbent material under each coolant hose
Clamp both master charger coolant hoses

Note
2x hoses
Disconnect coolant hoses from master charger and remove from vehicle

Note
2x hose clamps, Note orientation of clamps
Remove absorbent rags and clean residual coolant
Position master charger and install coolant hoses

Note
Inspect charger after removing from packaging, Confirm installation of EMI gasket on housing, If not installed, Install EMI gasket when installing charger fasteners
Remove hose clamps from master charger coolant hoses

Note
2x hoses
Install nuts that secure master charger

Note
4x nuts, 10mm, 6.5 Nm
Install bolt that secures ground strap to master charger case

Note
1x bolt, 10mm, 6.5 Nm
Connect gen 2 master charger

Note
2x connectors
Place HV junction box into vehicle
Connect HV junction box fan harness

Note
1x electrical connector, Lift HV junction box assembly slightly for access
Place the HVJB into place

Note
Be careful not to damage wiring harness while putting the HVJB into place
Install the bolts that secure the HV junction box

Note
4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
Secure coolant hose

Note
2x barrel clips
Install bolt securing ground tot HVJB

Note
1x bolt, T30, 6 Nm
Install drive inverter and HV battery cables

Note
4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
Install the front drive unit HV cables

Note
4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
Install the DCDC HV cables

Note
2x bolts, 8mm, 4 Nm, Clean HV cables and HVJB connecting points with IPA wipes
Install the charge port HV cables

Note
4x bolts, 8 mm, 4.4 Nm, Clean HV cables and HVJB connecting points with IPA wipes
Install the HV cables from the junction box to both chargers

Note
8x connectors
Carefully put the HVJB lid onto the HVJB box
Install the HV junction box cover

Note
7x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
Install the HVIL bolt into the HV junction box cover

Note
1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
Lower seat frame into position and secure harness clips to frame

Note
8x clips
Connect seat frame harness connector

Note
1x connector
Install and torque bolts securing seat frame to vehicle

Note
8x bolts, 11mm, 26 Nm
Place NVH padding onto seat frame
Reinstall seat bottom cushion

Note
2x clips, 7x connectors if equipped, Replace clips if necessary
Connect first responder loop

Note
1x connector, Engage red locking tab
Connect 12V battery negative terminal

Note
1x nut, 10mm, 5 Nm
Connect 12V charger

Note
The vehicle 12V system must remain supported until vehicle firmware is completed
Remove coolant bottle cap

Note
1x cap
Top off coolant bottle
Bleed air from the colling system. See Cooling System - Partial Refill and Bleed.
Connect vehicle to WiFi connection

Note
Connect vehicle to WiFi or Tesla WiFi if available. Maintain WiFi connection for profile functions and firmware download
Place vehicle in service mode with touchscreen

Note
Pre-FW 2020.48.25 hold Tesla "T" icon at top of center display for four seconds and then type "service" into Access Code box, Post-FW 2020.48.25 The Tesla T has been removed from the top bar of the UI, Press and hold the vehicle's badge icon for 2 seconds in Controls > Software for Access Code box.
Select "Service Mode" on the Control Panel menu, then select "Software Reinstall"
Select "Request" to initiate software installation

Note
Vehicle will send a request to Tesla server for the re-installation of the current firmware, yellow clock installation icon should appear within 5 minutes
Select the clock on the center display, then select "Install Now" to start firmware update

Note
Tap center display next to software update window until clock runs down to 0,After displayed installation time, Check the center display and ensure the firmware package was successfully installed
Exit Service Mode

Note
Select "Service Mode" on the Control Panel menu, then select "Exit Service Mode"
Disconnect 12V charger from vehicle

Note
After FW update has completed the vehicle should no longer need auxiliary 12V support
Install front HVAC filter housing

Note
2x tabs
Install bolts securing front HVAC filter housing

Note
2x bolts, 10mm, 1.5 Nm
Install cabin filter and cover then secure cowl screen panel

Note
2x push clips
Top off coolant bottle
Install coolant bottle cap

Note
1x cap
Position underhood storage unit into vehicle

Note
Push wiring harness grommet back through underhood storage unit
Connect emergency hood release and front light harness

Note
2x connectors
Install front nuts securing underhood storage unit to body

Note
2x nuts, 8mm, 8 Nm, Seat seal around carpet
Install rear bolts securing underhood storage unit to body

Note
2x bolts, 13mm, 4 Nm, Seat seal around carpet
Install RH underhood apron

Note
9x clips
Install LH underhood apron

Note
9 x clips
Install rear underhood apron

Note
8x clips
Close hood

Note
Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
Move both front seats to their original positions
Raise all 4 windows
Close all four doors
Verify charging system operation

Note
Charge vehicle using known good UMC and verify vehicle charges without issue

Model S Service Manual

Master Charger - RH - 2nd Generation (Remove and Replace)

Procedure

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