2024-05-31

Master Charger - RH - 2nd Generation - Dual to Single Charger (Modify)

Correction code 44102207 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See to learn more about FRTs and how they are created. To provide feedback on FRT values, email ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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Note
This procedure describes how to convert the 2nd generation dual charging system to a single charging system by removing the slave charger and retrofitting required parts. This can be cost efficient for customers that have a defective slave charger but accept a decrease in AC 3-phase charging performance by not replacing the defective part.
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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.
Parts required for this procedure:
Part number Name
1026860-00-B BLOCK OFF PLATE, 3P HVJB
1024956-00-C HIGH VOLTAGE JUNCTION BOX TO CHARGER LOGIC HARNESS ASSEMBLY - 2 WHEEL DRIVE - SINGLE CHARGER
1007991-00-D CHARGER BYPASS HOSE ASSEMBLY

Procedure

  1. Open all doors and lower the windows.
  2. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  3. Using Toolbox 3, change the charger configuration.
    Informational PurposesAn informational icon, calling your attention
    Note
    In Toolbox, navigate to Tools > Vehicle Configuration > Chargertype, and then change the configuration to "TeslaSingle". Click Apply Changes and wait for the MCU to reboot.
  4. Disconnect 12V power. See Disconnect 12V Power.
  5. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure
  6. Remove the slave charger to junction box HV cable connectors (x4).
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    Note
    Discard the cables after removal.
  7. Disconnect the master charger to junction box HV cable connectors (x2).
  8. Release the barrel clips (x2) that attach the coolant hose.
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    Note
    Move the hose to expose the HV junction box bolts.
  9. Remove the bolts that attach the HV junction box.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of bolts may vary depending on configuration between 2, 3 or 4 bolts
  10. Disconnect the HVJB connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift HV junction box assembly slightly for access.
  11. Disconnect the 10 pin logic connector from the master charger.
  12. Disconnect the slave charger connector.
  13. Remove the clips (x4) that attach the slave charger LV harness, remove the LV harness and discard it.
  14. Remove the bolt that attaches the slave charger ground strap and discard the ground strap after removal.
  15. Release the barrel clips (x2) that attach the coolant hose to the body to gain access to the slave charger fasteners.
  16. Remove the nuts (x4) that attach the slave charger assembly.
  17. Lift the slave charger slightly, and then put absorbent material under each coolant hose.
  18. Clamp both coolant hoses of the slave charger assembly.
  19. Disconnect the coolant hoses from the slave charger assembly, and then and remove the slave charger assembly from the vehicle.
  20. Remove absorbent rags and clean any residual coolant.
  21. Install the charger bypass coolant hose.
  22. Install the clips that attach the LV slave charger bypass harness.
  23. Connect the 10 pin logic connector to the master charger.
  24. Connect the HV junction box fan harness connector.
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    Note
    Lift the HV junction box assembly slightly for access.
  25. Connect the HVIL termination connector.
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    Note
    Secure the connector with zip ties so it doesn't rattle.
  26. Install the HV junction box bolts (x4) (torque 5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of bolts may vary depending on the configuration between 2, 3 and 4 bolts.
  27. Attach the barrel clips (x2) that attach the coolant hose.
  28. Connect the master charger to junction box HV cable connectors to the master charger.
  29. Install the junction box block off plate cover.
  30. Install the nuts (x6) that attach the HV junction box cover (torque 8 Nm), and then install the bolt that attaches the ground cable (torque 8 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the ground cable between the bolt and the HVJB cover. Fastener count may vary depending on configuration.
  31. Install the HVIL bolt into the HV junction box cover.
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    Note
    NA and JP: install a new bolt, torque 4 Nm. EU and APAC: the bolt is reusable, torque 5 Nm.
  32. Connect 12V power. See Disconnect 12V Power.
  33. Perform a coolant air purge. See Cooling System - Partial Refill and Bleed.
  34. Install the 2nd row seat frame and cushion. See Frame - Seat Base - 2nd Row Cushion (Remove and Replace).
  35. Install the front HVAC filter housing, and then install the bolts (x2) that attach the filter housing (torque 1.5 Nm).
  36. Attach the clips that attach the RH side of the cowl screen panel and the cabin filter cover to the strut.
  37. Install the RH underhood apron.
  38. Inspect the coolant level and top off as necessary, and then reinstall the coolant reservoir cap.
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    Note
    Fill the reservoir to the "NOM" line with G-48 coolant.
  39. Install the rear underhood apron.
  40. Verify correct charging system operation.
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    Note
    Charge the vehicle using a known good UMC and verify that the vehicle charges without any issue.