14/12/2022 05:40:21

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

Correction Code 44102202

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

Procedure

  1. Open all four doors
  2. Lower all four windows
  3. Move both front seats fully forward
  4. Open hood
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    Note
    Using MCU touchscreen > Controls > Frunk Trunk
  5. Remove rear underhood apron
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    Note
    8x clips
  6. Remove LH underhood apron
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    Note
    9x clips
  7. Remove RH underhood apron
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    Note
    9x clips
  8. Remove rear bolts securing underhood storage unit to body
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    Note
    2x bolts, 13mm, 4 Nm, Peel back carpet for access
  9. Remove front nuts securing underhood storage unit to body
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    Note
    2x nuts, 8mm, 8 Nm, Peel back carpet for access
  10. Disconnect emergency hood release and front light harness
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    Note
    2x connectors, Push wiring harness grommet through underhood storage unit
  11. Remove underhood storage unit from vehicle
  12. Remove the cabin filter and cover then lift up the RH side of cowl screen panel to access cabin filter housing
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    Note
    2x push clips, Place shop rag under trim to support if needed
  13. Remove bolts securing front HVAC filter housing
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    Note
    2x bolts, 10mm, 1.5 Nm
  14. Remove front HVAC filter housing
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    Note
    2x tabs
  15. Power down vehicle using MCU
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    Note
    Controls > Safety&Security > Power Off > ''POWER OFF''
  16. Disconnect the 12V battery negative terminal
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    Note
    1x nut, 10mm, 5 Nm
  17. Disconnect the first responder loop
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    Note
    Wait at least 2 minutes for all electrical circuits to fully discharge, Release red locking tab then disconnect.
  18. Remove 2nd row seat bottom cushion
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    Note
    2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
  19. Remove NVH padding from underneath 2nd row seat cushion
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    Note
    If equipped
  20. Remove bolts securing seat bottom frame
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    Note
    8x bolts, 11mm, 26 Nm
  21. Release harness clips from frame
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    Note
    5x clips, 3x edge clips
  22. Disconnect seat frame harness connector
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    Note
    1x connector
  23. Lift up and support seat bottom frame
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    Note
    Release harness clips if necessary
  24. Remove all items from pockets and ensure not wearing metal items
  25. Inspect HV insulating gloves
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    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
  26. Put on HV insulating gloves and leather over gloves
  27. Remove the HVIL bolt from the HV junction box
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    Note
    1x bolt, 8mm, 4 Nm (NA, JP, Discard after removal), 5 Nm (EU, APAC, fastener is reusable)
  28. Remove bolts securing HVJB cover to HVJB box
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    Note
    7x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
  29. Lift carefully the HVJB lid up and remove
  30. Verify no high voltage
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    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
  31. Remove HV insulating gloves
  32. Disconnect and remove all 4 HV harnesses from both chargers to HVJB
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    Note
    8x connectors
  33. Remove the charge port HV cables
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    Note
    4x bolts, 8mm, 4 Nm, bolts are captured
  34. Remove the DCDC HV cables
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    Note
    2x bolts, 8mm, 4 Nm, Bolts are captured
  35. Remove the front drive unit HV cables
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    Note
    2x nuts, 13mm, 9 Nm, 1x bracket, Nuts are captured
  36. Remove the drive inverter and HV battery cables
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    Note
    2x nuts, 13mm, 9 Nm, Nuts are captured
  37. Remove bolt securing ground tot HVJB
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    Note
    1x bolt, T30, 6 Nm
  38. Release coolant hose
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    Note
    2x barrel clips, Move hose from covering HV junction box bolts
  39. Remove the bolts that secure the HV junction box
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    Note
    4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
  40. Disconnect the HVJB connector
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    Note
    1x electrical connector, Lift HV junction box assembly slightly for access
  41. Remove HV junction box from vehicle
  42. Disconnect connectors gen 2 master charger
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    Note
    2x connectors
  43. Remove bolt that secures ground strap to master charger case
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    Note
    1x bolt, 10mm, 6.5 Nm
  44. Remove nuts that secure master charger
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    Note
    4x nuts, 10mm, 6.5 Nm
  45. Lift master charger slightly and place absorbent material under each coolant hose
  46. Clamp both master charger coolant hoses
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    Note
    2x hoses
  47. Disconnect coolant hoses from master charger and remove from vehicle
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    Note
    2x hose clamps, Note orientation of clamps
  48. Remove absorbent rags and clean residual coolant
  49. Position master charger and install coolant hoses
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    Note
    Inspect charger after removing from packaging, Confirm installation of EMI gasket on housing, If not installed, Install EMI gasket when installing charger fasteners
  50. Remove hose clamps from master charger coolant hoses
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    Note
    2x hoses
  51. Install nuts that secure master charger
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    Note
    4x nuts, 10mm, 6.5 Nm
  52. Install bolt that secures ground strap to master charger case
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    Note
    1x bolt, 10mm, 6.5 Nm
  53. Connect gen 2 master charger
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    Note
    2x connectors
  54. Place HV junction box into vehicle
  55. Connect HV junction box fan harness
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    Note
    1x electrical connector, Lift HV junction box assembly slightly for access
  56. Place the HVJB into place
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    Note
    Be careful not to damage wiring harness while putting the HVJB into place
  57. Install the bolts that secure the HV junction box
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    Note
    4x bolts, 10mm, 5 Nm, Fastener count may vary based on configuration from 2,3 and 4 bolts
  58. Secure coolant hose
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    Note
    2x barrel clips
  59. Install bolt securing ground tot HVJB
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    Note
    1x bolt, T30, 6 Nm
  60. Install drive inverter and HV battery cables
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    Note
    4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
  61. Install the front drive unit HV cables
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 13mm, 9 Nm, Clean HV cables and HVJB connecting points with IPA wipes
  62. Install the DCDC HV cables
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    Note
    2x bolts, 8mm, 4 Nm, Clean HV cables and HVJB connecting points with IPA wipes
  63. Install the charge port HV cables
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    Note
    4x bolts, 8 mm, 4.4 Nm, Clean HV cables and HVJB connecting points with IPA wipes
  64. Install the HV cables from the junction box to both chargers
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    Note
    8x connectors
  65. Carefully put the HVJB lid onto the HVJB box
  66. Install the HV junction box cover
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    Note
    7x nuts, 10mm, 8 Nm, 1x bolt, 10mm, 8 Nm, Fastener count may vary based on configuration
  67. Install the HVIL bolt into the HV junction box cover
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    Note
    1x bolt, 8mm, 4 Nm (NA, JP, Install new fastener), 5 Nm (EU, APAC, fastener is reusable)
  68. Lower seat frame into position and secure harness clips to frame
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    Note
    8x clips
  69. Connect seat frame harness connector
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    Note
    1x connector
  70. Install and torque bolts securing seat frame to vehicle
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    Note
    8x bolts, 11mm, 26 Nm
  71. Place NVH padding onto seat frame
  72. Reinstall seat bottom cushion
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    Note
    2x clips, 7x connectors if equipped, Replace clips if necessary
  73. Connect first responder loop
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    Note
    1x connector, Engage red locking tab
  74. Connect 12V battery negative terminal
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    Note
    1x nut, 10mm, 5 Nm
  75. Connect 12V charger
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    Note
    The vehicle 12V system must remain supported until vehicle firmware is completed
  76. Remove coolant bottle cap
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    Note
    1x cap
  77. Top off coolant bottle
  78. Bleed air from the colling system. See Cooling System - Partial Refill and Bleed.
  79. Connect vehicle to WiFi connection
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    Note
    Connect vehicle to WiFi or Tesla WiFi if available. Maintain WiFi connection for profile functions and firmware download
  80. Place vehicle in service mode with touchscreen
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    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.
  81. Select "Service Mode" on the Control Panel menu, then select "Software Reinstall"
  82. Select "Request" to initiate software installation
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    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
  83. Select the clock on the center display, then select "Install Now" to start firmware update
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    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
  84. Exit Service Mode
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    Note
    Select "Service Mode" on the Control Panel menu, then select "Exit Service Mode"
  85. Disconnect 12V charger from vehicle
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    Note
    After FW update has completed the vehicle should no longer need auxiliary 12V support
  86. Install front HVAC filter housing
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    Note
    2x tabs
  87. Install bolts securing front HVAC filter housing
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    Note
    2x bolts, 10mm, 1.5 Nm
  88. Install cabin filter and cover then secure cowl screen panel
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    Note
    2x push clips
  89. Top off coolant bottle
  90. Install coolant bottle cap
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    Note
    1x cap
  91. Position underhood storage unit into vehicle
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    Note
    Push wiring harness grommet back through underhood storage unit
  92. Connect emergency hood release and front light harness
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    Note
    2x connectors
  93. Install front nuts securing underhood storage unit to body
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    Note
    2x nuts, 8mm, 8 Nm, Seat seal around carpet
  94. Install rear bolts securing underhood storage unit to body
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    Note
    2x bolts, 13mm, 4 Nm, Seat seal around carpet
  95. Install RH underhood apron
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    Note
    9x clips
  96. Install LH underhood apron
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    Note
    9 x clips
  97. Install rear underhood apron
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    Note
    8x clips
  98. Close hood
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    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  99. Move both front seats to their original positions
  100. Raise all 4 windows
  101. Close all four doors
  102. Verify charging system operation
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    Note
    Charge vehicle using known good UMC and verify vehicle charges without issue