04/06/2024 18:02:21

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.

2024-05-14: Added install/remove steps for ancillary access bench.
2024-04-10: Updated steps to disconnect and connect the PCS MV connector.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

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.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
2-peice NVH assembly order of operations requires RH side to be released first to allow busbar clearance for LH side removal.
Remove the RH tonneau NVH cover.

Note
Release rearward, and then slide over the LH side NVH cover before removing upward.
Remove the bolts (x5) that attach the LH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the LH tonneau NVH cover.

Note
Slide 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.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
Clean all debris from the ancillary cover.

Note
During 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.

Note
x1 connector

CAUTION
Do 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.

Note
x1 VOSS fitting

Note
Slide 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.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
x1 clip, x1 zip tie

Note
Release the lock before disengaging the connector.

Note
Cut the zip tie at the reservoir/ancillary air line bundle.

Note
Release the harness clip at the bracket.
Release the air suspension valve block.

Note
x3 rubber grommets

Note
Rotate 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.

Note
Leave 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.
33 Nm (24.3 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Note
x2 fir tree clips
Put the air suspension reservoir in service position, and then install the Ancillary Access Bench (2035746-00-A).

Note
Raise and swing the air suspension reservoir to the side of the bed.
Open the powered frunk.
Put the vehicle in Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
Access the thermal system routines using the vehicle touchscreen.

Note
Touch quick controls > Service mode > Thermal > Actions
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.

Note
Verify indicator displays green for Coolant readiness.

Note
Thermal 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

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing MV battery, Touch lightly and do not damage terminals
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Disconnect the pressurized pack lines.

Note
x2 VOSS fittings, 12 mm, 8 Nm. Discard and replace the VOSS fittings.
Remove the VOSS fitting from pressurized pack air lines.

Note
x2 VOSS fitting

Note
Slide 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.

Note
Check 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

Note
Verify 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 requiredIf 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 damagedMake 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.

Note
x1 connector

Note
Verify 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.

CAUTION
Do 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.
Disconnect the rear PT supply and RDU supply hoses.

Note
x2 spring clip

Note
Plug the hoses immediately to prevent excess coolant loss.

Note
Allow PCS coolant to drain as much as possible before plugging.
Remove the bolts (x2) that attach the PCS coolant header to the ancillary floor.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
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.

Note
Double 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.

Note
Check 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.
9 Nm (6.6 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Remove the bolts (x2) that attach the HV connector to the DC FC header.
9 Nm (6.6 lbs-ft)
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.

Note
Upon 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.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Remove the bolts (x2) that attach the low voltage header.
6 Nm (4.4 lbs-ft)
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.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
Use E10 5-Lobe socket without magnet.

Note
The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
Remove the ancillary cover.

Note
Use 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.

CAUTION
Do not slide the red lock plate without supporting the PCS MV 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.

CAUTION
The 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.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
x1 clip
Disconnect the HV electrical connector to the device cluster from PCS.

Note
Release the locking tab, and then gently pull up.
Disconnect the HV electrical harness connector to the ACJB from PCS.

Note
Release the locking tab, and then gently pull up.
Remove the PCS captured bolts (x6).
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 8 mm socket
Remove the PCS from the ancillary bay.

Note
Secure a suction cup to center of PCS. Remove the PCS with coolant hoses attached and plugs secured at the header.
Release the coolant line snap clip zip ties (x4).

Note
Cut and discard the small and the large zip ties from PCS coolant line snap clips.
Remove the PCS coolant line assembly.

Note
Insert the special tool away from the PCS.
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.

Note
Do not allow the grease to contact the busbar HV mating surfaces.

Install

Lubricate the O-rings on both coolant hose QC fittings to the PCS.

Note
Inspect the O-rings before installation for any damage and replace them, if necessary.
Secure the PCS coolant line assembly to new the PCS.

Note
x2 hoses.

CAUTION
Do not to damage the O-rings.

CAUTION
Rest the PCS assembly on edge of flat surface. Do not support the PCS assembly on the coolant line header.

Note
Perform 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).

Note
Make 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.
Install the PCS to the ancillary bay.

Note
Secure a suction cup to the center of the PCS.

Note
Install the PCS with coolant hoses attached and plugs secured at the header.
Install the PCS captured bolts (x6) to the ancillary.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 8 mm socket
Connect the HV electrical harness connector from the ACJB to the PCS.

Note
Secure the locking tab.
Connect the HV electrical connector from the device cluster to the PCS.

Note
Secure the locking tab.
Install the bolt that attaches the PCS MV harness.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
x1 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.

Note
The 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.

CAUTION
The 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.
While supporting the harness end of the PCS MV connector, slide the red lock plate to the black handle.

CAUTION
Do 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.

Note
If 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.
Install the bolts (x2) that attach the PCS coolant header to the ancillary floor.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
Put 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).

Note
x2 spring clips

Note
Leave 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.

Note
Confirm the hose is screwed securely tight.
Attach the coolant pressure tester to the compressed air line.

Note
Make sure the valves are closed on the pressure regulator.
Open the regulator valve, and then slowly adjust the regulator to 50 psi.

CAUTION
Use caution as coolant may spill.

Note
Wear safety glasses.
Slowly open the second valve.

Note
Slowly open the valve on pressure regulator, and then allow the pressure to reach specification.
Close the valve and let pressure settle.

Note
Wait 2 minutes for the pressure to settle, and then record the reading.
Set timer for 2 minutes and select start.

Note
Once timer is complete, select Stop Reset.
Perform the coolant pressure leak test.

Note
Wait 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.

Note
x2 spring clips

Note
Make 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.

Note
Check 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.

Note
Use a non-conductive plastic tool to clean the busbar side. Allow 1 minute for the Isopropyl Alcohol (IPA) to fully dry.

CAUTION
Do 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.
8 Nm (5.9 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 12 mm 12-point deep socket
Note
x2 VOSS fittings

Note
Do not remove the VOSS plastic plug until the pressurized pack line installation.
Install the bolts (x4) that attach the pyro fuse access cover.
10 Nm (7.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
Make sure that the seal is fully seated and undamaged.
Install the pressurized pack lines (x2).
8 Nm (5.9 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 12 mm 6 point flare nut wrench
- 12 mm flare nut crowfoot socket
Note
x2 VOSS fittings

Note
Remove 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.

Note
x6 clips; x3 bolts, 15 mm, 42 Nm; x5 bolts, 13 mm, 28 Nm; x2 bolts, 10 mm, 6 Nm

Note
Apply Loctite 222 onto mid aero shield bolts and install the fasteners.
Fully lower the vehicle.
Inspect HV insulating gloves

Note
Check 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.

Note
Use a suction cup.

Note
Maneuver around the busbar and tonneau cage.
Install the bolts (x22) that attach the ancillary cover to the HV battery.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- External Torx E10 5-Lobe
Note
Use E10 5-Lobe socket without magnet.

Note
The bolts are captive and will stay attached to the ancillary cover. Follow fastening order.
Install the bolts (x2) that attach the low voltage header.
6 Nm (4.4 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Install the bolts (x2) that attach the fast charger header doubler.
10 Nm (7.4 lbs-ft)
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.

Note
The grease is part number 1089958-00-A and is available from eProcurement.
Clean the HV connector contact surface of residual Penetrox with IPA wipe.

Note
Allow 1 minute dry time after removing Penetrox.
Clean the busbar HV connector contact surface of residual Penetrox with IPA wipe.

Note
Allow 1 minute dry time after removing Penetrox.

Note
It is necessary to clean the HV connector during re-use of the busbar.
Apply Penetrox onto the HV connector joints.

Note
Apply 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.

Note
Remove the bungee cord.
Install the bolts (x2) that attach the charge port busbar kit to the HV header.
9 Nm (6.6 lbs-ft)
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.
Note
x2 HV joints

Note
When using a Hioki tester, verify the meter has been properly adjusted and set prior to usage.
Note
The 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.
9 Nm (6.6 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Connect the ancillary bay MV electrical connector.

Note
Double 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.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
Note
Supports install in the same direction of the fasteners.
Install the LH tonneau NVH cover.

Note
Make sure the busbar clearance during installation to avoid damage to the NVH material.
Install the bolts (x5) that attach the LH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Install the RH tonneau NVH cover.
Install the bolts (x6) that attach the RH tonneau NVH cover.
5 Nm (3.7 lbs-ft)
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.
33 Nm (24.3 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Note
x2 fir tree clips
Secure the air suspension valve block.

Note
x3 rubber grommets

Note
Rotate 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.

Note
Position air lines and connections into place for installation.
Install a new VOSS air fitting to the pressurize pack valve block at the ANC circuit.
8 Nm (5.9 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 12 mm socket
Note
x1 VOSS fitting

Note
Do 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.

Note
x1 line

Note
Remove 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.
5 Nm (3.7 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
x1 clip, x1 zip tie

Note
Secure 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).
Connect MV power. See Disconnect MV Power.
Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).

Note
Skip steps 1 through 5, Perform step 6 and thereafter.
Perform the Thermal Performance through the vehicle touchscreen.

Note
Touch 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.

Note
Click 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.