SB-13-44-010

R4

Tesla Motors, Inc.

May 25, 2016

Service Bulletin

2nd Charger Upgrade, 2nd Generation
Classification

Parts and
Accessories
Bulletin

Section/Group

44 - High
Voltage System

Country/Region

All

Year

2013-2016

Model

Model S

Version

2nd Generation
Charger

Bulletin Classification: This bulletin provides instructions and guidelines for a vehicle procedure that is not the result of a
defect. This bulletin might not be VIN-specific. These instructions assume knowledge of motor vehicle and high voltage
electrical component repairs, and should only be executed by trained professionals. Tesla Motors assumes no liability for
injury or property damage due to a failure to properly follow these instructions or repairs attempted by unqualified
individuals.
This Service Bulletin supersedes SB-13-44-010 R3, dated 1-Sep-15. Each content change is marked by a vertical line in
the left margin. Discard the previous version and replace it with this one.
This bulletin describes how to install a second (slave) charger in a vehicle that is currently configured with only one
(master) charger.
NOTE: This bulletin is valid for the following Model S vehicles:
•
•
•
•

European vehicles built before approximately April 11, 2016
Asian Pacific vehicles built before approximately April 11, 2016
North American vehicles built between October 16, 2013 and October 31, 2013
North American vehicles built between December 3, 2013 and approximately April 11, 2016

Correction Description

Correction

Time

Install 2nd Generation Slave Charger

S011344010

2.4

(Obsolete code; do not use)

S021344010

—

SB-13-44-010 Not Applicable

S031344010

0.0

Required Part(s): Part Number

Description

Quantity

Choose one of the following kits, as appropriate:

1047977-20-A

Vehicles in China:
GEN 2 DUAL CHARG UPGRADE KIT, CN

1

1047977-00-B

Vehicles in all other locations:
GEN 2 DUAL CHARG UPGRADE KIT, NA/EU

1

These part numbers were current at the time of publication. Use the revisions listed or later,
unless otherwise specified in the Parts Manual.

SB-13-44-010

Page 1 of 11

Configure the New Slave 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 minimum rating of class 00
(500V) must be worn any time a high voltage cable is handled. Refer to TN-15-92-003, “High Voltage Awareness Care
Points” for additional safety information.
1. Disconnect the First Responder Loop.
NOTE: Do not disconnect 12V power.
2. Connect an external charger to the 12V battery.
NOTE: It is necessary to support the 12V battery with the external charger while configuring the slave charger.
3. Remove the 2nd row seat frame:
•
•

For vehicles with standard 2nd row seats, refer to Service Manual procedure 13023002
For vehicles with executive 2nd row seats, refer to Service Manual procedure 13021002

4. Confirm that the vehicle has a 2nd generation charger (Figure 1).
NOTE: If the vehicle has a 1st generation charger, do not perform this procedure; refer to SB-12-44-005 instead.
NOTE: If the vehicle has a 3rd generation charger, do not perform this procedure; refer to Toolbox article 28740 to perform
the “High Amperage Charger Upgrade”.
5. Disconnect the front 12-pin harness from the master charger, then disconnect the rear 10-pin harness from the master
charger (Figure 1).
CAUTION: Do not disconnect the rear harness first. Disconnecting harnesses in the wrong order triggers multiple
high-priority alerts.

Unplug rear 10-pin
harness second
Unplug front 12-pin
harness first

Figure 1
6. Temporarily place the new slave charger on top of the master charger.
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7. Connect the rear 10-pin harness to the new slave charger, then connect the front 12-pin harness to the new slave
charger.
CAUTION: Do not connect the front harness first. Connecting harnesses in the wrong order triggers multiple highpriority alerts.
8. Connect a laptop with Toolbox to the vehicle.
9. In Toolbox, open the Charger Config panel.
10. Switch the charger configuration from “Master Charger” to “Slave Charger” (Figure 2):
CAUTION: Failure to reconfigure the slave charger can result in alerts later in this procedure.
a. Click the “Slave Charger” radio button.
b. Ensure that the “Routine” is set to “Switch Charger Configurations”.
c.

Click the Start/Play button.

Figure 2
11. Disconnect the front 12-pin harness from the new slave charger, then disconnect the rear 10-pin harness from the
new slave charger.
CAUTION: Do not disconnect the rear harness first. Disconnecting harnesses in the wrong order triggers multiple
high-priority alerts.
12. Temporarily remove the slave charger.
13. Connect the rear 10-pin harness to the master charger, then connect the front 12-pin harness to the master charger.
CAUTION: Do not connect the front harness first. Connecting harnesses in the wrong order triggers multiple highpriority alerts.
NOTE: Leave the laptop connected to the vehicle.

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Page 3 of 11

Install the New Slave Charger
1. Disconnect the slave charger harness connector from the HVIL termination connector (Figure 3).

HVIL termination
connector

Slave charger
harness connector

Figure 3
2. Use the cable tie to secure the HVIL termination connector to the coolant hose (Figure 4).
NOTE: Ensure that the HVIL termination connector is tightly secured so that it does not move or rattle.

Figure 4
3. Move the slave charger harness connector out of the way so that it is not damaged if coolant is spilled in later steps.
NOTE: This connector is secured to the new slave charger in a later step.
4. Disconnect the 12V external charger.
5. Disconnect 12V power:
•
•

Rear wheel drive (RWD) vehicles: refer to Service Manual procedure 17010100
Dual Motor vehicles: refer to Service Manual procedure 17010200

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Page 4 of 11

6. Dual Motor vehicles only: Release the bolt and 2 nuts that secure the mounting bracket (torque 9 Nm)
(Figure 5).

Figure 5 (Bracket highlighted in blue)
WARNING: Do not continue this procedure without wearing proper HV gloves.
7. Remove the High Voltage Junction Box (HVJB) cover (refer to Service Manual procedure 44301102).
WARNING: Perform all of the voltage checks listed in the HVJB cover procedure. If any voltage reading is more than
10V, the high voltage contactors are not fully opened. Due to the risk of electrocution, contact Service Engineering before
performing any further work.
8. Europe only: If equipped, remove the relay box from the vehicle.
9. Remove and discard the 2 harnesses between the connections inside the HVJB that lead to the master charger
(Figure 6).

Master charger

Figure 6
10. Release the 3 or 4 bolts that secure the HVJB to the body (torque 5 Nm). Gently lift up the front of the HVJB and
support it.
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Page 5 of 11

11. Cover the rear LH floor of the vehicle with shop towels or other absorbent material to catch any coolant that is spilled
in later steps.
12. Clamp the main coolant hose at both ends of the temporary coolant hose. Ensure that the clamps are placed outboard
of the locking rings (Figure 7).
CAUTION: It might be necessary to gently pull the main coolant hose out from underneath the HVJB in order to
clamp it. Do not damage the main coolant hose.

Clamp here
Clamp here

Restrictor
Restrictor

Locking ring

Locking ring
Figure 7
13. Remove the cap from the inboard pipe on the new slave charger (Figure 8) and have it ready for the next step.

Figure 8
14. Use a pair of pliers to release the locking ring that secures the inboard side of the main coolant hose (Figure 7).
Release the inboard restrictor from the main coolant hose, and immediately tilt the open edge of the temporary
coolant hose upwards to reduce spilling. Place the cap from the new charger over the restrictor on the main coolant
hose.
15. Repeat the 2 previous steps for the outboard side of the temporary coolant hose. Remove the temporary coolant hose
from the vehicle.
16. Clean up any spilled coolant.
17. Set the new slave charger into position over the 4 mounting studs.
CAUTION: Do not damage the mounting studs.
18. Install the 4 nuts that secure the slave charger to the studs on the body (torque 7 Nm).
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Page 6 of 11

19. Attach both ends of the main coolant hose to the new slave charger.
20. Remove both clamps from the main coolant hose.
21. Secure the new ground strap to the small bolt hole at the inboard rear of the new slave charger (torque 7 Nm)
(Figure 9).

Attach ground
strap here

Inboard side
of vehicle

Outboard side
of vehicle

.
Figure 9
22. Set the HVJB back into position and reinstall the 3 or 4 bolts that secure it to the body (torque 5 Nm).
23. Remove the lockout cover from the LH side of the HVJB (Figure 10).

Lockout cover

Figure 10

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Page 7 of 11

24. Install the 4 new harnesses that connect the HVJB to the chargers (Figure 11).

Harness to rear port
of master charger

Harness to rear port
of slave charger

Harness to front port
of master charger
Harness to front port
of slave charger

Figure 11
CAUTION: The harnesses for the different chargers are visually similar and have similar part numbers. Ensure that
the correct harnesses are installed in the correct location. Note that the harnesses to the master charger are slightly
longer than the harnesses to the slave charger.
CAUTION: During installation, ensure that the harnesses are arranged neatly and are not twisted, and that they do
not put unnecessary stress on the ports inside the HVJB or the charger (Figures 12‒14).
Wires twisted
together

Wires
stacked on
top of each
other

Wires lay
flat and next
to each
other

Correct
Figure 12

Incorrect
Figure 13

Incorrect
Figure 14

25. Secure the HVJB cover. Refer to Service Manual procedure 44301102 for the proper bolt torque sequence.

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Page 8 of 11

26. Release the nut at the rear of the vehicle that secures the ground strap from the HVJB, and lift the ground strap off of
the stud (Figure 15).

Figure 15
27. Attach the ground strap from the new slave charger to the ground stud, then secure the ground strap from the HVJB
to the ground stud. Ensure that the ground strap for the slave charger points down (Figure 16). Secure the ground
stud nut (torque 7 Nm).

Ground strap from
HVJB
Ground strap from
new slave charger

Figure 16

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28. Connect the slave charger HVIL loopback connector to the front of the new slave charger, and connect the 12-pin
harness to the rear of the new slave charger (Figure 17).

HVIL loopback
connector

12-pin harness

Figure 17
29. Dual Motor Vehicles only: Install the screw that secures the fuse bracket to the slave charger (torque 9 Nm)
(Figure 18).

Figure 18

Change Vehicle Configuration for Dual Chargers
1. Reconnect the First Responder Loop.
2. Reconnect the 12V battery.
3. Reconnect the 12V external charger.
NOTE: Even though the 12V battery should draw power from the HV system, it is necessary to connect a 12V power
supply in case there is a problem that prevents the contactors from closing.

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Page 10 of 11

4. Use Toolbox to change the “Charger Type” configuration variable to Dual (10kW) (Figure 19).

Figure 19
5. Perform a full firmware update.
NOTE: Leave the laptop connected to the vehicle.

Reinstallation and Coolant Purge
1. Perform the coolant purge procedure (refer to Service Manual procedure 18300000).
2. Reinstall all components that were removed for access.
3. Test drive the vehicle and verify that there are no alerts.
4. If possible, charge the vehicle at above 40A for several minutes and verify that there are no alerts.

Affected VIN(s)

All Model S vehicles built with a single 2nd generation charger, except North American vehicles
built before October 16, 2013, or between October 31, 2013 and December 3, 2013.

For feedback on the accuracy of this document, email ServiceBulletinFeedback@tesla.com.

SB-13-44-010

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