Power Conversion System (Remove and Replace)
Correction code 1630010081 1630010082 FRT 3.54 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 Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.
- 2024-08-14: Added/rearranged steps according to latest time study.
- 2024-07-08: Added step to install zip tie onto PCS MV connector.
- 2024-05-14: Added install/remove steps for ancillary access bench.
- 2024-04-10: Updated steps to disconnect and connect the PCS MV connector.
Remove
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Remove the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
-
Remove the bolts (x6) that attach the
RH tonneau NVH cover to the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.NoteVehicles built before September 2024 will have a 1-piece NVH cover attached with 5 bolts (8 mm). -
Remove the RH tonneau NVH cover.
NoteRelease rearward, and then slide over the LH side NVH cover before removing upward.NoteIf the vehicle is equipped with a 1-piece NVH cover, maneuver the cover around the bed wall, and then remove it from the vehicle.
-
Remove the bolts (x5) that attach the
LH tonneau NVH cover.NoteSkip to step 8 if the vehicle is equipped with a 1-piece NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the LH tonneau NVH cover.
NoteSlide towards the center. Ensure busbar clearance during removal to avoid damage to the NVH material.
-
Remove the screws (x8) that attach the
tonneau coverbox cross supports.Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
-
Clean all debris from the ancillary
cover.
NoteDuring the removal of the ancillary cover, any debris on top of the cover may be deposited into the ancillary bay.
-
Release the pressurize pack air line
from the ancillary.
Notex1 connectorCAUTIONDo not release air line to the reservoir. Rapid loss of pressure will result if the wrong air line is released.
-
Remove the VOSS fitting from the
Pressurize Pack air line to the ancillary.
Notex1 VOSS fittingNoteSlide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
-
Disconnect the electrical connector,
and then remove the bolt that attaches the pressurize pack valve block to the air
suspension reservoir.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Notex1 clip, x1 zip tieNoteRelease the lock before disengaging the connector.NoteCut the zip tie at the reservoir/ancillary air line bundle.NoteRelease the harness clip at the bracket. -
Release the air suspension valve
block.
Notex3 rubber grommetsNoteRotate clockwise until the top 2 rubber feet have released from the bracket. Pull upwards at a 45 degree angle to release the bottom rubber foot from the bracket.NoteLeave all air lines and connections secured, and then set the assembly aside.
-
Remove the nuts (x2) that attach the
air suspension reservoir to the body.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Notex2 fir tree clips -
Put the air suspension reservoir in
service position, and then install the Ancillary Access Bench (2035746-00-A).
NoteRaise and swing the air suspension reservoir to the side of the bed.
- Open the powered frunk.
- Place the vehicle into Service Mode. See Service Mode.
- Unlock the vehicle Gateway. See Gateway (Unlock).
- On the vehicle touchscreen, navigate to to access the thermal system routines.
-
Touch Coolant System to enter the
coolant circuit screen. Touch Coolant Fill/Drain using the vehicle touchscreen, and then the
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT window will appear. Touch Run.
NoteVerify indicator displays green for Coolant readiness.NoteThermal Fill Drain routine has a 50 minute time limit.
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power.
-
Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
- Raise the vehicle to a comfortable working height.
- Remove the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
-
Disconnect the pressurized pack
lines.
Notex2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
-
Remove the VOSS fitting from
pressurized pack air lines.
Notex2 VOSS fittingNoteSlide the threaded section back, remove the collet, and then slide the threaded section off of air line. Discard after removal.
- Remove all items from pockets and ensure not wearing metal items
-
Inspect the HV insulating
gloves.
NoteCheck gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
-
Put on the HV insulating gloves and
leather over gloves.
-
Verify no HV - Install amp clamp to
RDU HV harness.
NoteVerify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required If current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side. Release locking tab and rotate the release lever up to disengage the connector, Release harness clip, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged 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
-
Secure the RDU header connector to the
ancillary.
Notex1 connectorNoteVerify the lever is in the upright and open position. Carefully seat connector and allow the lever to engage. Fully secure the lever and verify that the red tab is locked.CAUTIONDo not damage any pins.
- Remove the pyro access cover. See High Voltage Battery Assembly - Pyro Access Cover, HVB (Remove and Install).
- Remove the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
- Remove the leather over gloves and HV insulating gloves.
-
Position the coolant drain container
underneath RH rear of the HV battery.
-
Remove the spring clips and disconnect
the rear PT supply and RDU supply hoses, and then immediately plug all the fittings to
prevent excess coolant loss.
NotePlug the coolant connections as needed. If the PCS is being replaced, then allow the coolant to drain.
-
Secure PT Flush adapter to PCS inlet
hose coupling.
NoteRemove plugs as required. Verify fully seated. Perform push-pull-push test.
-
Secure coolant cart flush hose to
regulator and PT Flush adapter.
NoteVerify regulator valve is closed. Pressure regulator is not adjustable (set at 20 psi).
-
Secure PCS Drain adapter to PCS outlet
using male-to-male adapter.
NoteVerify valve is closed. Remove plug as required. Verify fully seated. Perform push-pull-push test.
-
Secure coolant cart drain hose to PCS
drain adapter and coolant drain container.
-
Open valve on PCS Drain adapter.
-
Connect shop air to regulator.
NoteMake sure regulator valve is closed prior to connecting shop air.
-
Slowly open valve on pressure
regulator and allow coolant to drain out of HV battery.
-
Close valve on pressure regulator once
no more coolant is draining
-
Close valve on PCS Drain
adapter.
-
Remove cart drain hose from PCS Drain
adapter.
-
Remove PCS Drain adapter from PCS
outlet.
Note1x spring clip
-
Remove cart flush hose from PT Flush
adapter.
-
Remove PT Flush adapter from PCS inlet
coupling.
Note1x spring clip
- Remove the coolant drain container from underneath the vehicle.
- Lower the vehicle until the tires are touching the ground.
-
Disconnect the ancillary bay MV
electrical connector.
NoteDouble locking. Release the tab, and then pivot the lever. Release the second tab to disengage the electrical connector. Wait 1 second between locking tab release to discharge and prevent arcing.
-
Inspect the HV insulating gloves.
NoteCheck gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting HV gloves.
-
Put on the HV insulating gloves and leather over gloves.
-
Remove the bolt that attaches the
busbar HV connector lid.Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
-
Remove the bolts (x2) that attach the
HV connector to the DC FC header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Release the HV connector
from the DC FC header, and then use an inflatable airbag to suspend the
busbar assembly above the ancillary assembly.
NoteUpon separation, check for grease around the inner perimeter of the DC FC header. If present, additional steps will need to be performed later.
-
Support the HV busbar assembly to
maintain clearance with a bungee cord.
-
Remove the bolts (x2) that attach the
fast charger header doubler.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
-
Remove the bolts (x2) that attach the
low voltage header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the bolts (x22) that attach the
ancillary cover to the HV battery.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
NoteUse E10 5-Lobe socket without magnet.NoteThe bolts are captive and will stay attached to the ancillary cover. Follow fastening order. -
Remove the ancillary cover.
NoteUse a suction cup and maneuver around the busbar and the tonneau cage.
-
While supporting the harness end of the PCS MV connector, press the release, and then
slide the red lock plate away from the black handle.
CAUTIONDo not slide the red lock plate without supporting the PCS MV connector.NoteIf installed, cut and discard the zip ties before releasing the connector.
-
Continue to support the harness end of
the PCS MV connector, raise the black handle to its vertical position to release, and
then pull straight up on the black handle to disconnect the PCS MV connector from the MV
header of the PCS.
CAUTIONThe MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.
-
Remove the bolt that attaches the PCS
MV harness.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Notex1 clip -
Disconnect the HV electrical connector
to the device cluster from PCS.
NoteRelease the locking tab, and then gently pull up.
-
Disconnect the HV electrical harness
connector to the ACJB from PCS.
NoteRelease the locking tab, and then gently pull up.
-
Release the coolant line snap clip zip ties (x4).
NoteCut and discard the small and the large zip ties from PCS coolant line snap clips.
-
Remove PCS coolant line
assembly.
Note2x hoses, 1x hose, Insert the special tool away from the PCS.
-
Remove the PCS captured bolts
(x6).Tip: Use of the following tool(s) is recommended:
- 8 mm socket
-
Remove the PCS from the ancillary
bay.
NoteSecure a suction cup to center of PCS. Remove the PCS with coolant hoses attached and plugs secured at the header.
-
If grease was found around
the inner perimeter of the DC FC header, use a disposable towel to wipe the
grease off the header and the busbar connector.
NoteDo not allow the grease to contact the busbar HV mating surfaces.
Install
-
Install the PCS to the ancillary
bay.
NoteSecure a suction cup to the center of the PCS.NoteInstall the PCS with coolant hoses attached and plugs secured at the header.
-
Install the PCS captured bolts (x6) to
the ancillary.Tip: Use of the following tool(s) is recommended:
- 8 mm socket
-
Lubricate the O-rings on both coolant
hose QC fittings to the PCS.
NoteInspect the O-rings before installation for any damage and replace them, if necessary.
-
Secure the PCS coolant line assembly
to new the PCS.
Notex2 hoses.CAUTIONDo not to damage the O-rings.CAUTIONRest the PCS assembly on edge of flat surface. Do not support the PCS assembly on the coolant line header.NotePerform a push-pull-push test to make sure the coolant hoses are fully latched, and then visually verify the clip is fully seated.
-
Install the coolant line snap clip zip
ties (x4).
NoteMake sure the larger zip tie lands on the metal barn. Tighten the large white zip tie to secure clips from warping. Install the smaller black zip ties to one of the clips very loosely. Trim excess zip tie once secured.
-
Connect the HV electrical harness
connector from the ACJB to the PCS.
NoteSecure the locking tab.
-
Connect the HV electrical connector
from the device cluster to the PCS.
NoteSecure the locking tab.
-
Install the bolt that attaches the PCS
MV harness.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Notex1 clip -
Raise the black handle of the PCS MV connector so that it is at 90 degrees to the
body of the connector.
-
Position the PCS MV connector over the MV header so that the red positive lead of the
connector is closest to the edge of the PCS and over the text "LV+" scribed on the PCS
cover.
NoteThe MV header is symmetrical, and it is possible to connect the PCS MV connector backwards.
-
Holding only the electrical harness
and the black handle, connect the PCS MV connector to the MV header.
-
Use two fingers centered directly over
the pins of the MV header (under the arch of the black handle) to press and hold the PCS
MV connector to the MV header, and then carefully lower the black handle until it is
flat.
CAUTIONThe MV header can break internally if the PCS MV connector is forced or torqued off center of the MV header. Do not press, twist, or pry to the harness end of the PCS MV connector.CAUTIONEnsure the correct orientation and polarity of the connection. Harness color red for LV+ and black for LV-.
-
Install zip ties (x2) onto the PCS MV
connector to secure the black lever to the red connector lock.
NoteFeed the zip ties under the black lever and through the red connector lock opening, and then fasten the zip tie.
-
While supporting the harness end of the PCS MV connector, slide the red lock plate
to the black handle.
CAUTIONDo not slide the red lock plate without supporting the PCS MV connector.
-
Inspect the PCS MV connector that it is not tilted, but is parallel to the top
surface of the PCS.
NoteIf the PCS MV connector is tilted, there may be damage to the MV header inside the PCS. This damage may cause the PCS to go MIA, or deassert the DCDC enable line. Check for respective alerts and faults.
- Remove leather over gloves and HV insulating gloves
- Fully raise the vehicle.
- Position the coolant drain container underneath the RH rear of the HV battery.
-
Remove one PCS coolant header plugs
and connect the leak test adapters from the Coolant Hose Plug Kit (1135762-00-A).
Notex2 spring clipsNoteLeave the coolant plugs in supply and return lines. Secure the NW22 plug to either coolant header port (Item 6 of kit). Combine NW18 Male testing Couple (Item 5 of kit) to Adapter NW18 180° (Item 1 of kit), and then secure to other coolant header port.
-
Attach the coolant pressure tester to
the pressure fitting adapter.
NoteConfirm the hose is screwed securely tight.
-
Attach the coolant pressure tester to
the compressed air line.
NoteMake sure the valves are closed on the pressure regulator.
-
Open the regulator valve, and then
slowly adjust the regulator to 50 psi.
CAUTIONUse caution as coolant may spill.NoteWear safety glasses.
-
Slowly open the second valve.
NoteSlowly open the valve on pressure regulator, and then allow the pressure to reach specification.
-
Close the valve and let pressure
settle.
NoteWait 2 minutes for the pressure to settle, and then record the reading.
-
Set timer for 2 minutes and select
start.
NoteOnce timer is complete, select Stop Reset.
-
Perform the coolant pressure leak
test.
NoteWait for another 4 minutes and record the reading. Max delta 0.35 psi. Check coolant hose to see if it is fully seated or not, if pressure test fails.
-
Close both valves.
-
Remove the coolant pressure tester
from the pressure fitting adapter.
-
Remove the coolant pressure tester
adapter from the PCS coolant header.
-
Secure the rear PT supply and RDU
supply hoses to the PCS coolant header.
Notex2 spring clipsNoteMake sure the locking tabs are fully seated. Perform a push-pull-push test.
- Remove the coolant drain container from underneath vehicle.
-
Inspect the HV insulating
gloves.
NoteCheck gloves for damage prior to use. Refer to service document TN-15-92-003 for information on inspecting the HV gloves.
-
Put on the HV insulating gloves and
leather over gloves.
-
Clean the mating surface of the
pyro.
NoteUse a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.CAUTIONDo not use any other types of cleaner.
- Install the primary and secondary pyro fuses. See Disconnect, Pyro (Remove and Install).
- Remove the leather over gloves and HV insulating gloves.
-
Install new VOSS fittings and nut to
the pyro cover.Tip: Use of the following tool(s) is recommended:
- 12 mm 12-point deep socket
Notex2 VOSS fittingsNoteDo not remove the VOSS plastic plug until the pressurized pack line installation. -
Install the bolts (x4) that attach the
pyro fuse access cover.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
NoteMake sure that the seal is fully seated and undamaged. -
Install the pressurized pack lines
(x2).Tip: Use of the following tool(s) is recommended:
- 12 mm 6 point flare nut wrench
- 12 mm flare nut crowfoot socket
Notex2 VOSS fittingsNoteRemove the plastic caps from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test. - Install the mid aero shield. See Undertray - Mid Aeroshield (Remove and Install).
- Fully lower the vehicle.
-
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.
-
Put on HV insulating gloves and
leather over gloves
-
Install the ancillary cover.
NoteUse a suction cup.NoteManeuver around the busbar and tonneau cage.
-
Install the bolts (x22) that attach
the ancillary cover to the HV battery.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
NoteUse E10 5-Lobe socket without magnet.NoteThe bolts are captive and will stay attached to the ancillary cover. Follow fastening order. -
Install the bolts (x2) that attach the
low voltage header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the bolts (x2) that attach the
fast charger header doubler.Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
-
If grease was found inside
the DC FC header, prepare the grease gun with Mobil XTCE grease, apply a 6
mm diameter continuous bead around the DC FC header inner perimeter, and
then use a gloved finger wetted with alcohol to smear the grease up the
inner wall to a height of 10 mm.
NoteThe grease is part number 1089958-00-A and is available from eProcurement.
-
Clean the HV connector contact surface
of residual Penetrox with IPA wipe.
NoteAllow 1 minute dry time after removing Penetrox.
-
Clean the busbar HV connector contact
surface of residual Penetrox with IPA wipe.
NoteAllow 1 minute dry time after removing Penetrox.NoteIt is necessary to clean the HV connector during re-use of the busbar.
-
Apply Penetrox onto the HV connector
joints.
NoteApply 2 drops of Penetrox A-13 about 5 mm in diameter to either side of the hole on both leads. Spread evenly to verify the contact surface is fully covered.
-
Position the busbar connector, and
then lower it onto the HV header.
NoteRemove the bungee cord.
-
Install the bolts (x2) that attach the
charge port busbar kit to the HV header.Tip: Use of the following tool(s) is recommended:
- 10 mm socket (insulated)
-
Perform a Hioki resistance test at each HV joint from the HV busbar lead to the bolt
head.
Notex2 HV jointsNoteWhen using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.NoteThe acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).
- If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.
- If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.
- If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), the Hioki test passed. proceed to the next step.
-
Install the bolt that attaches the
busbar HV connector lid.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Connect the ancillary bay MV
electrical connector.
NoteDouble locking: Rotate the lever into the second lock. Perform a pull test to ensure the electrical connector is engaged correctly.
- Remove leather over gloves and HV insulating gloves
-
Install the screws (x8) that attach
the tonneau coverbox cross supports.Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
NoteSupports install in the same direction of the fasteners. -
Install the LH tonneau NVH
cover.
NoteMake sure the busbar clearance during installation to avoid damage to the NVH material.
-
Install the bolts (x5) that attach the
LH tonneau NVH cover.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the RH tonneau NVH
cover.
NoteIf the vehicle is equipped with a 1-piece NVH cover, maneuver the cover around the bed wall and into position.
-
Install the bolts (x6) that attach the
RH tonneau NVH cover.Note1-piece NVH covers are attached with 5 bolts (8 mm).Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the Ancillary Access Bench, and
then put the air suspension reservoir into position for installation.
-
Install the nuts (x2) that attach the
air suspension reservoir.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Notex2 fir tree clips -
Secure the air suspension valve
block.
Notex3 rubber grommetsNoteRotate counterclockwise until the top 2 rubber feet are secured onto the bracket. Push downwards at a 45 degree angle to secure the bottom rubber foot into bracket.NotePosition air lines and connections into place for installation.
-
Install a new VOSS air fitting to the
pressurize pack valve block at the ANC circuit.Tip: Use of the following tool(s) is recommended:
- 12 mm socket
Notex1 VOSS fittingNoteDo not remove the VOSS plastic plug until the pressurize pack line install. -
Secure the pressurize pack air line
from the ancillary to the valve block.
Notex1 lineNoteRemove the plastic cap from the VOSS fittings. Press the air lines into the fitting until the mark aligns with the top of the fitting. Verify the line is properly secured by performing a push-pull test.
-
Install the bolt that attaches the
pressurize pack valve block to the air suspension reservoir, and then connect the
electrical connector.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Notex1 clip, x1 zip tieNoteSecure the reservoir and ancillary air lines at the white marked sections. - Install the bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
- Reconnect MV power. See Disconnect MV Power.
-
Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
NoteSkip steps 1 through 5, Perform step 6 and thereafter.
-
Perform the Thermal Performance
through the vehicle touchscreen.
NoteTouch Thermal > Actions > Test Thermal Performance, and then touch Run.
- Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Using Toolbox, click the Actions tab, and then search for "Service-Redeploy".
-
Click SERVICE CAN
REDEPLOY, and then click Run. Allow the routine to
complete.
NoteClick the X at the top right of window to close once complete. Routine will state pass but update will continue to run in the background. UI will show update progress.
- Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
- Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.