Tesla Model S: Master Charger - RH - 2nd Generation (Remove and Replace) - Removal
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 are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
minimum rating of class 00 (500V) 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.
Removal
- Disconnect HV power, but leave 12V power connected. Perform the
electrical isolation procedure (refer to procedure), except for the
disconnection of the 12V battery ground.
- Connect an external charger to the 12V battery.
- Remove the 2nd row seat frame:
- Standard seats: Refer to procedure.
- Executive seats: Refer to procedure.
- Disconnect the connectors (x2) from the side of the master
charger in the following order:
Caution: Disconnecting harnesses in the wrong order triggers
multiple high-priority alerts.
- Disconnect the 12-pin harness from the front port.
- Disconnect the 10-pin harness from the rear port.
- Remove the HVJB cover (refer to procedure).
Warning: The previous step contains instructions to check
for high voltage inside the HVJB. Do not proceed unless no high
voltage is present.
- Release the 2 harnesses that connect the HVJB to the master
charger. If equipped, release the 2 harnesses that connect the HVJB
to the slave charger.
- Release all fasteners inside the High Voltage Junction Box (HVJB)
so that it can lifted up in order to replace the charger in a later
step:
Note: Vehicles equipped with 3-phase charging have
4 charge port cables instead of 2.
- Dual motor vehicles only: Mark the rear HV
cable that leads to the front drive unit as B-, and the forward
HV cable that leads to the front drive unit as B+.
Table 1: HV Cable fasteners inside HVJB
1 |
B+ Front
Drive Unit (if equipped) |
2 |
B- Front
Drive Unit (if equipped) |
3 |
B+
battery/drive inverter |
4 |
B-
battery/drive inverter |
5 |
B+ forward
junction box |
6 |
B- forward
junction box |
7 |
B- charge
port |
8 |
B+ charge
port |
- Release the 2 nuts that secure the HV cables that lead to
the front drive unit (torque 9 Nm).
Note: Refer to Table 1.
Note: It is not necessary to replace the
fastener(s) after it is removed. The threaded area
has a reusable dry sealant, which looks similar to
adhesive patch material.
- Mark the rear HV cables that lead to the battery and drive
inverter as B‒, and the forward HV cables that lead to the
battery and drive inverter as B+.
Note: Refer to Table 1.
- Release the 2 nuts that secure the HV cables that lead to
the battery and drive inverter (torque 9 Nm).
Note: Refer to Table 1.
Note: It is not necessary to replace the
fastener(s) after it is removed. The threaded area
has a reusable dry sealant, which looks similar to
adhesive patch material.
- Mark the rear HV cable that leads to the forward junction
box as B+ and the forward HV cable that leads to the forward
junction box as B‒.
Note: Refer to Table 1.
- Release the 2 bolts that secure the HV cables that lead to
the forward junction box (torque 4 Nm).
Note: It is not necessary to replace the
fastener(s) after it is removed. The threaded area
has a reusable dry sealant, which looks similar to
adhesive patch material.
- Mark the HV cables that lead to the charge port:
- Single-phase charging: : Mark
the forward cable as B- and the rear cable as B+.
- 3-phase charging: : Starting
from the front and working toward the rear of the
vehicle, mark the 4 HV cables that lead to the
charge port from front to rear as L2, L3, L1, and N.
Note: Refer to Table 2.
Table 2: 3-Phase charge port cables
1 |
B+ N charge
port |
2 |
B- L1 charge
port |
3 |
B+ L3 charge
port |
4 |
B- L2 charge
port |
- Release the bolts that secure the HV cables that lead to the
charge port.
- North America, Japan: 2 bolts
(torque 9 Nm).
- Europe, APAC: 4 bolts (torque 4
Nm).
Note: Refer to Table 1.
Note: It is not necessary to replace the
fastener(s) after it is removed. The threaded area has a
reusable dry sealant, which looks similar to adhesive
patch material.
- Release the 4 bolts that secure the HVJB to the body (torque 5
Nm).
Note: Do not remove the HVJB from the vehicle. It
is only necessary to release the bolts so that the HVJB can
be lifted up in a later step.
HVJB shown removed from vehicle, for clarity.
- Release the ground strap from the rear of the charger (torque 7
Nm).
Note: Leave the ground strap secured to the
vehicle.
- Release the 4 bolts that secure the charger to the body (torque
7 Nm).
Note: It is necessary to lift the front of the HVJB out of
the way in order to access the inboard coolant hose. Have an
assistant hold up the front of the HVJB 20-30 mm.
- Clamp the coolant hoses on both the inboard and outboard sides
of the charger, approximately 150 mm from the edge of the charger.
- Ensure that all harnesses and cables are protected from any
coolant that might be spilled in a later step.
- Lift up the inboard side of the charger. Cover the floor of the
vehicle with towels or shop rags to catch any coolant that might be
spilled in a later step.
- Remove the coolant plug from the inboard side of the new charger
and have it ready before performing the next step.
- Tilt the inboard edge of the charger upwards. Use pliers or a
similar tool to release the locking ring from the inboard coolant
hose. Remove the coolant hose from the new charger and immediately
install the coolant plug onto the old charger to stop coolant from
spilling out.
- Repeat steps 13-15 for the outboard coolant hose.
- Lift the charger out of the vehicle.
- If the charger is being shipped or stored, allow the coolant to
drain from the charger, then use compressed air lightly to blow out
any remaining coolant.
Caution: Do not exceed 25 PSI when using compressed
air to blow out any remaining coolant.
READ NEXT:
Fully clean the area before installing the new charger.
Note: Have an assistant hold up the front of the HVJB
20-30 mm until the coolant hoses have been secured to the
charger.
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
Warning: Only technicians who have been trained in High
Voltage Awareness are permitted to perform this procedure. Proper
personal protective equipment (PPE) and insulating HV gloves with a
SEE MORE:
Removal
Remove Door Motor (refer to procedure)
Remove Door Grip (refer to procedure)
Remove press sensor screw.
Release door press sensor wiring connector.
Remove pivot pin connecting control link to PVT cartrid
Special tools required for this procedure:
Caution: Use the specified coolant only. In this manual, refer
to General Information > Capacities, Fluids, and
Lubricants > Fluids.
Supplier
Part Number
Descr