2025-09-25
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.
- 2025-09-25: The step for removing the HV gloves has been relocated to occur after the HV components have been enclosed.
Procedure
- Open all four doors
- Lower all four windows
- Move both front seats fully forward
-
Open hood
NoteUsing MCU touchscreen > Controls > Frunk Trunk
-
Remove rear underhood apron
Note8x clips
-
Remove LH underhood apron
Note9x clips
-
Remove RH underhood apron
Note9x clips
-
Remove rear bolts securing underhood storage unit to body
Note2x bolts, 13mm, 4 Nm, Peel back carpet for access
-
Remove front nuts securing underhood storage unit to body
Note2x nuts, 8mm, 8 Nm, Peel back carpet for access
-
Disconnect emergency hood release and front light harness
Note2x 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
Note2x push clips, Place shop rag under trim to support if needed
-
Remove bolts securing front HVAC filter housing
Note2x bolts, 10mm, 1.5 Nm
-
Remove front HVAC filter housing
Note2x tabs
-
Power down vehicle using MCU
NoteControls > Safety&Security > Power Off > ''POWER OFF''
-
Disconnect the 12V battery negative terminal
Note1x nut, 10mm, 5 Nm
-
Disconnect the first responder loop
NoteWait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
-
Remove 2nd row seat bottom cushion
Note2x 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
NoteIf equipped
-
Remove bolts securing seat bottom frame
Note8x bolts, 11mm, 26 Nm
-
Release harness clips from frame
Note5x clips, 3x edge clips
-
Disconnect seat frame harness connector
Note1x connector
-
Lift up and support seat bottom frame
NoteRelease harness clips if necessary
-
Remove all items from pockets and ensure not wearing metal items
-
Inspect HV insulating gloves
NoteCheck 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
Note1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
-
Remove bolts securing HVJB cover to HVJB box
Note7x 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
NoteMake 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
-
Disconnect and remove all 4 HV harnesses from both chargers to HVJB
Note8x connectors
-
Remove the charge port HV cables
Note4x bolts, 8mm, 4 Nm, bolts are captured
-
Remove the DCDC HV cables
Note2x bolts, 8mm, 4 Nm, Bolts are captured
-
Remove the front drive unit HV cables
Note2x nuts, 13mm, 9 Nm, 1x bracket, Nuts are captured
-
Remove the drive inverter and HV battery cables
Note2x nuts, 13mm, 9 Nm, Nuts are captured
-
Remove bolt securing ground tot HVJB
Note1x bolt, T30, 6 Nm
-
Release coolant hose
Note2x barrel clips, Move hose from covering HV junction box bolts
-
Remove the bolts that secure the HV junction box
Note4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
-
Disconnect the HVJB connector
Note1x electrical connector, Lift HV junction box assembly slightly for access
-
Remove HV junction box from vehicle
-
Disconnect connectors gen 2 master charger
Note2x connectors
-
Remove bolt that secures ground strap to master charger case
Note1x bolt, 10mm, 6.5 Nm
-
Remove nuts that secure master charger
Note4x nuts, 10mm, 6.5 Nm
-
Lift master charger slightly and place absorbent material under each coolant hose
-
Clamp both master charger coolant hoses
Note2x hoses
-
Disconnect coolant hoses from master charger and remove from vehicle
Note2x hose clamps, Note orientation of clamps
-
Remove absorbent rags and clean residual coolant
-
Position master charger and install coolant hoses
NoteInspect 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
Note2x hoses
-
Install nuts that secure master charger
Note4x nuts, 10mm, 6.5 Nm
-
Install bolt that secures ground strap to master charger case
Note1x bolt, 10mm, 6.5 Nm
-
Connect gen 2 master charger
Note2x connectors
-
Place HV junction box into vehicle
-
Connect HV junction box fan harness
Note1x electrical connector, Lift HV junction box assembly slightly for access
-
Place the HVJB into place
NoteBe careful not to damage wiring harness while putting the HVJB into place
-
Install the bolts that secure the HV junction box
Note4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
-
Secure coolant hose
Note2x barrel clips
-
Install bolt securing ground tot HVJB
Note1x bolt, T30, 6 Nm
-
Install drive inverter and HV battery cables
Note4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
-
Install the front drive unit HV cables
Note4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
-
Install the DCDC HV cables
Note2x bolts, 8mm, 4 Nm, Clean HV cables and HVJB connecting points with IPA wipes
-
Install the charge port HV cables
Note4x 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
Note8x connectors
-
Carefully put the HVJB lid onto the HVJB box
-
Install the HV junction box cover
Note7x 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
Note1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
-
Remove HV insulating gloves
-
Lower seat frame into position and secure harness clips to frame
Note8x clips
-
Connect seat frame harness connector
Note1x connector
-
Install and torque bolts securing seat frame to vehicle
Note8x bolts, 11mm, 26 Nm
-
Place NVH padding onto seat frame
-
Reinstall seat bottom cushion
Note2x clips, 7x connectors if equipped, Replace clips if necessary
-
Connect first responder loop
Note1x connector, Engage red locking tab
-
Connect 12V battery negative terminal
Note1x nut, 10mm, 5 Nm
-
Connect 12V charger
NoteThe vehicle 12V system must remain supported until vehicle firmware is completed
-
Remove coolant bottle cap
Note1x cap
-
Top off coolant bottle
- Bleed air from the colling system. See Cooling System - Partial Refill and Bleed.
-
Connect vehicle to WiFi connection
NoteConnect vehicle to WiFi or Tesla WiFi if available. Maintain WiFi connection for profile functions and firmware download
-
Place vehicle in service mode with touchscreen
NotePre-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
NoteVehicle 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
NoteTap 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
NoteSelect "Service Mode" on the Control Panel menu, then select "Exit Service Mode"
-
Disconnect 12V charger from vehicle
NoteAfter FW update has completed the vehicle should no longer need auxiliary 12V support
-
Install front HVAC filter housing
Note2x tabs
-
Install bolts securing front HVAC filter housing
Note2x bolts, 10mm, 1.5 Nm
-
Install cabin filter and cover then secure cowl screen panel
Note2x push clips
-
Top off coolant bottle
-
Install coolant bottle cap
Note1x cap
-
Position underhood storage unit into vehicle
NotePush wiring harness grommet back through underhood storage unit
-
Connect emergency hood release and front light harness
Note2x connectors
-
Install front nuts securing underhood storage unit to body
Note2x nuts, 8mm, 8 Nm, Seat seal around carpet
-
Install rear bolts securing underhood storage unit to body
Note2x bolts, 13mm, 4 Nm, Seat seal around carpet
-
Install RH underhood apron
Note9x clips
-
Install LH underhood apron
Note9 x clips
-
Install rear underhood apron
Note8x clips
-
Close hood
NotePress 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
NoteCharge vehicle using known good UMC and verify vehicle charges without issue