2026-08-09

Power Conversion System (Remove and Replace)

Correction code 1630010081 1630010082 FRT 4.14 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

2026-07-20: Updated guidance for when the HV battery pressurize routine fails.
2026-07-07: Updated per latest time study.
2026-06-01: Add note for adding ferrite core installation correction code.
2026-05-12: Added "Vehicle HV Disablement" procedure link and direction for vehicles with Terrestrial Armor installed.
2026-04-15: Added step to run routine at beginning of procedure.
2026-02-26: Add missing step to close the inlet valve during leak test.
2026-01-14: Add steps to inspect for ferrite core on DCA harness, and if necessary, install ferrite core.
2025-11-17: VOSS fittings are reusable. Removed steps that instructed to discard fitting
2025-05-08: Added steps to install/remove pyro access cover to avoid coolant ingress and exposed HV busbars.
2024-12-03: Restructured procedure to not remove PCS coolant hose bundle, only moving hoses aside.
2024-11-22: Added warning to NOT skip steps to remove the tonneau slats.
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.

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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional glove and safety information.

Warning

Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

Warning

DO NOT SKIP the steps to remove the tonneau slats. Work on or around the ancillary bay REQUIRES the removal of the tonneau slats. Failure to remove the tonneau slats while working on or around the ancillary bay will result in conditions that may cause personal injury.

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.

Remove

Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Open the LH front door and lower the LH front window.
Open the powered frunk.
Open the tonneau cover.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
On the vehicle touchscreen, navigate to High Voltage > HV Battery > Pressurize HV Battery, tap Run and allow the routine to complete.

Note
If the HV Pack Pressurize routine fails, refer to Toolbox article 7445600 to determine whether the failure is due to an HV battery enclosure leak and, if confirmed, to diagnose and repair the leak.
Remove the tonneau slats. See Slat System - Tonneau (Remove and Install).
On the vehicle touchscreen, navigate to Service Mode > Thermal > Actions, tap Coolant Fill/Drain, and then tap Run.

Note
Verify indicator displays green for Coolant readiness. Thermal Fill Drain routine has a 50 minute time limit.
Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).
Remove pyro fuse access cover with airlines attached

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Remove cover bolts, Release two airline mounting clips from HV Battery, Do not loosen or remove airline fittings from cover
Reposition pyro cover for access to pyro fuses

Note
1x cover, 2x clips, Move cover to the side and secure to the HV Battery with clamp(*This step is to prevent the need to disconnect airlines from cover)
Remove primary and secondary pyro fuses

Note
4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while removing bolts
Partially install pyro fuse access cover to protect ancillary from contaminates, debris, or coolant ingress during service

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Tighten until snug, Torque not required at this time, only temporary installation
Remove leather over gloves and HV insulating gloves
Position coolant drain container underneath RH rear of 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.

Note
Plug the coolant connections as needed. If the PCS is being replaced, then allow the coolant to drain.
Connect coolant Drain and Fill Adapter to PCS outlet hose coupling

Note
Use adapter 113843-40-A from the Drain & Fill Adaptors kit, Use male to male adaptor from leak test adaptor kit to mate drain and fill adaptor to PCS hose coupler, Remove plugs from battery if present, Make sure spring locking clip is fully seated, Perform push-pull-push test to verify fully seated, Make sure valve on adaptor is open, Valve lever is inline with adaptor when open
Connect waste coolant container to drain and fill adaptor

Note
Connect hose to drain and fill adaptor, Push until audible click, Perform Push-pull-push test to verify fully seated
Connect coolant Leak Test Adaptor to PCS inlet hose coupling

Note
(*Use this step for Cybertruck PCS COOLANT DRAIN process) procedure Remove plug from coupler if installed, Use male to male adaptor from kit to mate leak test adaptor to coupler, Make sure the spring locking clip is fully seated, Perform pull-push-pull test to make sure it is fully seated, Connection is at RH rear of HV Battery
Connect coolant Leak Test Fixture outlet hose to Leak Test Adapter

Note
(*Use this step for Cybertruck PCS COOLANT FLUSH procedure steps) Hand tighten hose connection, No tool required to tighten
Connect outlet hose to the Leak Test Fixture tool

Note
Hand tighten hose connection, No tool required to tighten
Close both valves on the coolant Leak Test Fixture tool

Note
The valve knobs should both be perpendicular to the air lines when closed.
Connect compressed air to coolant Leak Test Fixture tool

Note
Air supply source should be above 50 psi
Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note
Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 2 minutes
Open outlet valve on Leak Test Fixture tool.

Note
Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses
Start 2 minute timer

Note
Once timer is complete, select Stop Reset
Close both valves on the coolant Leak Test Fixture tool

Note
The valve knobs should both be perpendicular to the air lines when closed.
Swap adaptor positions at PCS inlet and outlet couplers

Note
This step is to allow flushing coolant out of PCS in opposite direction, Disconnect each adaptor and connect to the other coupler location, Move leak test adaptor to PCS outlet hose coupler, Move Drain and Fill adaptor to PCS inlet hose coupler, perform push pull test on each connection to make sure fully seated
Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note
Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 2 minutes
Open outlet valve on Leak Test Fixture tool.

Note
Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses
Start 2 minute timer

Note
Once timer is complete, select Stop Reset
Close both valves on the coolant Leak Test Fixture tool

Note
The valve knobs should both be perpendicular to the air lines when closed.
Disconnect coolant Leak Test Fixture outlet hose from Leak Test Adapter

Note
1x hose connection
Disconnect coolant Leak Test Adaptor from PCS outlet hose coupling

Note
1x spring clip, 1x leak adaptor, 1x male to male adaptor
Disconnect Waste Coolant Container from drain and fill adaptor

Note
Disconnect hose from drain and fill adaptor, Press grey button to release hose fitting,
Disconnect coolant Drain and Fill Adapter from PCS inlet hose coupling

Note
1x spring clip, 1x drain and fill adaptor, 1x male to male adaptor
Install plastic coolant plugs into both PCS coolant hose coupler fittings

Note
2x male plugs, 2x spring clips, Make sure metal spring clips are in locked position, Perform push-pull-push test to make sure fully seated, Wipe off any coolant drips or residue at hose ends
Remove coolant drain container from underneath vehicle
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove the bed floor assembly. See Bed Floor Assembly (Remove and Install).
Install Ancillary Access Bench into bed floor opening.

Note
1x bench, place above rear casting ensuring no air lines or harnesses are being pinched(*No image available or access bench in RWD truck bed)
Disconnect harness pigtail from valve and air reservoir

Note
1x connector, 1x clip, release red locking clip on connector to disconnect from valve, Release harness clip from air reservoir
Disconnect ANC air line from valve block

Note
1x VOSS fitting, 12mm, 3.5 Nm, 1x cable tie, Disconnect lower airline and fitting with brown color tape indicator and "ANC" label, Do not release air line to reservoir, Rapid loss of pressure will result if wrong air line is released, Cut cable tie to release airline from bundle
Release air suspension valve block

Note
3x rubber grommets, Rotate clockwise until top 2 rubber feet have released from bracket, Pull upwards at 45 degree angle to release bottom rubber foot from bracket, Leave all air lines and connections secured and set assembly aside
Remove air suspension reservoir fasteners

Note
2x nuts, 13mm, 33 Nm, 2x fir tree clips, Wrench needed on right side nut due to low clearance to bed trim, Disconnect harness fir clips from each end of reservoir assembly
Place air suspension reservoir in service position

Note
Raise and swing air suspension reservoir to the side of the bed, Ancillary access bench may need to be temporarily removed to position air reservoir, Place Ancillary Access Bench back into bed ensuring no air lines or harnesses are being pinched
Remove the tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
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.
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.
Remove mid voltage header bolts

Note
2x bolts, EP10, 6 Nm
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:

External Torx Plus EP10
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 HV Busbar assembly

Note
1X Bungee, Suspend assembly to maintain clearance, wrap bungee around busbar assembly to achieve required cord length, Connect bungee to tie down hook on bed side
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 (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.
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
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.

Note
If 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.

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 the harness end of the PCS MV connector.
Remove the bolt that attaches the PCS MV harness to the vehicle, and then release the harness clips (x2).
6 Nm (4.4 lbs-ft)
TIp
Use of the following tool(s) is recommended:

External Torx E10 5-Lobe
Release the connector lock, and then gently pull the PCS to device cluster HV electrical connector upward to disconnect it.
Release the connector lock, and then gently pull the ACJB to PCS electrical connector upward to disconnect it.
Release coolant hose bundle from PCS.

Note
2x hoses, 2x spring clips. Plug coolant connections as needed.

Note
Vehicles built before December 22, 2023 will have clear collar with zip tie connections. If vehicle has older revision hose then proceed to PCS Coolant Hose Bundle replacement procedure.
Remove bolts securing PCS

Note
6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
Secure vacuum cups to PCS

Note
2x vacuum cups, Continue pressing plunger until red line is no longer visible
Remove PCS from ancillary bay

Note
1x datum, Maneuver PCS around coolant hoses, Remove plugs and vacuum cups as needed
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

Inspect the device cluster harness for the presence of a ferrite core. See image for ferrite core harness location.
- If a ferrite core is installed, skip to the next step.
- If a ferrite core is not installed, refer to Ferrite Core - Device Cluster Assembly (Installation) to install a ferrite core to the device cluster harness before installing the new PCS. Add correction code 16300105726.
Install PCS into ancillary bay

Note
1x datum, Install vacuum cups and coolant plugs to PCS, Maneuver PCS around coolant hoses
Install bolts securing PCS.

Note
6x bolts, E10 5-Lobe, 6 Nm, Use E10 5-Lobe socket without magnet, Bolts are captive and will stay attached, Follow fastening order
Connect coolant hose assembly to PCS

Note
2x hose connections, 2x spring clips, Remove plugs as needed, Vehicles built before December 22, 2023 may have an older revision of hose assembly, If vehicle has older revision then replace the hose assembly with the latest revision, see PCS coolant hose assembly replacement procedure, the older revision hose assembly has a zip tie securing the hose connector, the updated revision has quick connect fittings with metal spring clips.
Connect the HV electrical harness connector from the ACJB to the PCS, and then engage the connector lock.
Connect the HV electrical connector from the device cluster to the PCS, and then engage the connector lock.
Secure PCS MV harness.

Note
1x bolt, EP10, 6 Nm, 2x clips
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.

CAUTION
Ensure 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.

Note
Feed 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.

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 de-assert the DCDC enable line. Check for respective alerts and faults.
Remove leather over gloves and HV insulating gloves
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged
Position coolant drain container underneath RH rear of HV battery
Install male to male adaptors in both PCS hose assembly couplers

Note
2x male to male adaptors, Remove plugs from PCS hose couplers if present,
Connect coolant Leak Test Adaptors to male adaptors at PCS hose assembly

Note
(*Use this step for Cybertruck PCS LEAK TEST process) 2x adaptors, Use 18mm adaptor with flare fitting, Use 18mm adaptor with plug, Make sure the spring locking clips are in locked position, Perform pull-push-pull test to make sure adaptors are fully seated, Connections are at RH rear of HV Battery
Connect coolant Leak Test Fixture outlet hose to Leak Test Adapter

Note
(*Use this step for Cybertruck PCS LEAK TEST process) Hand tighten hose connection, No tool required to tighten
Connect outlet hose to the Leak Test Fixture tool

Note
Hand tighten hose connection, No tool required to tighten
Close both valves on the coolant Leak Test Fixture tool

Note
The valve knobs should both be perpendicular to the air lines when closed.
Connect compressed air to coolant Leak Test Fixture tool

Note
Air supply source should be above 50 psi
Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note
Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses
Open outlet valve on Leak Test Fixture tool.

Note
Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses
Allow pressure in PCS coolant loop to stabilize at 50 psi

Note
Pressure should settle around 50 psi
Set timer for 4 minutes
Record the PCS coolant loop leak check starting pressure

Note
Record the value shown on the digital gauge
Close inlet valve on Leak Test Fixture tool

Note
The valve knob should be perpendicular to the air line when closed
Start 4 minute timer

Note
Once timer is complete, select Stop Reset
Record the PCS coolant loop leak check end pressure

Note
Record the value shown on the digital gauge after 4 minute timer is complete, Max delta between start and end pressures is 0.35 psi, Check coolant hose to see if it is fully seated if pressure test fails
Disconnect compressed air from Leak Test Fixture tool
Open inlet valve on Leak Test Fixture to discharge air from coolant system

Note
1x valve, Turn valve slowly to release air
Disconnect coolant Leak Test Fixture hose from Leak Test Adapter

Note
1x hose, 1x adaptor
Disconnect all test adaptors from PCS coolant hose couplers

Note
4x adaptors
Connect coolant hoses to PCS inlet and outlet hose couplers

Note
2x spring clip, Make sure the locking tabs are fully seated, Perform push-pull-push test, remove any coolant plugs as needed
Remove coolant drain container from underneath vehicle
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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 ancillary cover

Note
Use suction cup and maneuver around busbar and tonneau cage
Remove leather over gloves and HV insulating gloves
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 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)
Note
Early vehicle builds may be equipped with a 10 mm fastener.
TIp
Use of the following tool(s) is recommended:

EP10 socket or

10 mm socket
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
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.
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 tonneau NVH barrier. See Tonneau NVH Barrier Assembly (Remove and Install).
Place air suspension reservoir into position for installation

Note
1x air reservoir, Raise and swing air suspension reservoir to the mounting position, Ensure air lines are not twisted, Ensure no harnesses are caught, Ancillary access bench may need to be temporarily removed to position air reservoir, Place Ancillary Access Bench back into bed ensuring no air lines or harnesses are being pinched
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.
Connect ANC air line to valve block

Note
1x VOSS fitting, 12mm, 3.5 Nm, Inspect O-ring on fitting and metal collet on airline for any damage or missing parts, Replace VOSS fitting if damaged or missing parts are identified, install fitting to valve by hand to avoid cross threading then torque to specification, Install cable tie to secure airlines, Cut off extra cable tie length with side cutters
Connect harness pigtail to valve and air reservoir

Note
1x connector, 1x clip, Connect harness connector to valve and lock red locking clip, Secure harness mounting clip to air reservoir
Remove ancillary access bench from bed floor opening

Note
1x bench
Install the bed floor assembly. See Bed Floor Assembly (Remove and Install).
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged
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
Remove partially installed pyro fuse access cover

Note
4x bolts, E-Torx 5 lobe, 10 Nm
Reposition pyro cover for access to pyro fuses

Note
1x cover, 2x clips, Move cover to the side and secure to the HV Battery with clamp(*This step is to prevent the need to disconnect airlines from cover)
Clean pyro fuse mating surfaces

Note
Using an insulated tool wipe all four busbar mating surfaces within pyro fuse bay, Wipe top and bottom mating surfaces of each pyro fuse, Ensure no debris is present on any mating surface, Process shown with device cluster removed for clarity and safety, HV gloves and associated PPE must be worn at all times when cleaning mating surfaces, Allow 1 minute for IPA to dry
Install primary and secondary pyro fuses

Note
4x bolts, 13mm, 5 Nm + 60 Degrees, Support each pyro fuse while installing bolts, Bolts may be reused
Perform Hioki resistance test at each HV joint from HV busbar lead to pyro fuse busbar

Note
4x HV joints, When using Hioki tester, verify the meter has been properly adjusted and set prior to usage. 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), stop work and escalate the Toolbox session. 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), hioki test passed, proceed to next step
Install pyro fuse access cover with airlines attached

Note
4x bolts, E-Torx 5 lobe, 10 Nm, Ensure seal is fully seated and undamaged, Secure 2 airline mounting clips to HV Battery, If HV pack is being shipped then pyro fuses must be removed
Remove leather over gloves and HV insulating gloves
Install rear skid plate. See Skid Plate - Rear (Remove and Install).
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).

Note
Skip steps 1 through 5, Perform step 6 and thereafter.
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
Perform Thermal Performance Test through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow Toolbox articles 206000
Perform software reinstall

Note
Via UI > Service Mode > Software Reinstall > CAN ECU > Reinstall, Reinstall will begin immediately, Once firmware redeploy is complete, Verify release notes are present via UI
Install the tonneau slats. See Slat System - Tonneau (Remove and Install).
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.

Cybertruck Service Manual

Power Conversion System (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3