Power Conversion System (PCS2Lite) (Remove and Replace)

Raise and support vehicle

Note

Ensure vehicle is not charging

Open all four doors

Lower all four windows

Open hood

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox: (link)

Unlock the vehicle gateway. See Gateway Unlock.

Perform "Start Thermal Fill/Drain (Coolant Only)" through Service UI

Note

Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again

Move LH front seat forward

Move RH front seat forward

Power off vehicle from center display

Note

Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

Remove rear underhood apron

Note

14x clips

Disconnect LV battery and first responder loop

Note

2x connectors, Ensure that one minute has passed after window movement before performing the power-off, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

Release 2nd row seat cushion and disconnect harness connectors

Note

2x clips, 2x connectors, Press tabs backward then pull front edge up

Verify operation of multimeter

Note

Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

Remove all items from pockets and ensure not wearing metal items

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. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

Put on HV insulating gloves and leather over gloves

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

Remove bolts securing ancillary bay probe lid cover from ancillary bay cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover from ancillary bay cover

Verify no high voltage

Note

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

Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover

Note

Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Install new bolts

Remove 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

Remove rear aero shield clips

Note

2x clips, One clip on LH side wheel liner, One clip on RH side wheel liner

Remove rear aero shield

Note

11x bolts, 10mm, 5 Nm

Release clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Release LH side hose clip from rear battery skid plate enclosure

Note

1x fir tree clip

Release RH side hose clips from rear battery skid plate enclosure

Note

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm, Older VINs may be equipped with additional fastener count

Remove upper nut securing HV battery rear skid plate enclosure

Note

1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles

Remove upper bolts securing HV battery rear skid plate enclosure

Note

4x bolts, 13mm, 35 Nm

Remove HV battery rear skid plate enclosure

Position coolant drain container underneath LH rear of HV battery

Disconnect RDU inverter inlet hose from PCS outlet hose coupling

Note

1x spring clip, 2x plugs, Connection is located at the LH rear of the HV Battery, Install plugs once disconnected, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plug

Connect coolant Drain and Fill Adapter to PCS outlet hose coupling

Note

Use adapter with 90 degree angle, Make sure locking clip is fully seated, Make sure valve is open, Valve is inline with the adapter when open, Connection is at LH rear of HV Battery

Connect coolant hose extension to Drain and Fill adapter

Note

Press hose end onto adapter until clicked into place

Connect coolant hose extension to coolant drain hose

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Position coolant drain container underneath RH rear of vehicle

Disconnect rear powertrain supply hose from PCS inlet hose coupling

Note

1x spring clip, Plug hose connections as needed, Connection is located at RH rear of HV Battery, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plugs

Remove coolant drain container from underneath vehicle

Connect coolant Leak Test Adapter to PCS inlet hose coupling

Note

Remove rubber plug from coupler if installed, Make sure the locking clip is fully seated, Connection is at RH rear of HV Battery

Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter

Note

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.

Disconnect coolant Leak Test Adapter with hose from PCS inlet hose coupling

Note

1x spring clip, Leave the Leak Test Fixture hose connected to Leak Test Adapter, Connection is at RH rear of HV Battery

Disconnect coolant Drain and Fill Adapter with extension hose from PCS outlet hose coupling

Note

1x spring clip, leave extension hose attached to drain and fill adapter, Connection is at LH rear of HV battery

Connect coolant Leak Test Adapter with hose to PCS outlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Leave the coolant Leak Test Fixture hose attached to the Leak Test Adapter, Connection is at LH rear of HV Battery

Connect coolant Drain and Fill Adapter with extension hose to PCS inlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Connection is at RH rear of HV battery

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 compressed air from Leak Test Fixture tool

Disconnect coolant hose extension from coolant drain hose

Note

Press grey button to release hose fitting

Disconnect coolant hose extension from coolant Drain and Fill adapter

Note

Press grey button to release hose fitting

Disconnect coolant drain hose adapter from PCS inlet hose coupling

Note

1x spring clip, Install plug to inlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Disconnect coolant Leak Test Fixture outlet hose from Leak Test Adapter

Note

1x hose connection

Disconnect coolant Leak Test Adapter from PCS outlet hose coupling

Note

1x spring clip, Install plug to outlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Lower vehicle until tires are touching ground

Note

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

Disconnect HVC logic connector and install logic cap

Note

1x connector, 1x cap, Release locking tab then push the handle downward to release connector

Remove bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Remove bolts securing ancillary bay cover to HV battery

Note

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

Inspect HV insulating gloves

Note

Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf

Put on HV insulating gloves and leather over gloves

Note

Make sure to wear electrical protective gloves any time Hioki tester is used

Remove ancillary bay cover from HV battery

Note

Raise the front part of the ancillary bay cover and remove the slow ancillary bay cover forward

Install HVC logic cap

Note

1x logic cap

Inspect ancillary bay for any missing insulators

Note

Install service insulator kit before continuing to next step

Remove bolts securing pyro disconnect to ancillary bay

Note

1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal

Remove pyro disconnect from ancillary bay

Note

1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay

Install pyro disconnect dummy

Use rubber bands to secure HVC to vehicle body

Position absorbent sheets below and around PCS2 lite coolant inlet hose to avoid excess coolant dripping

Disconnect PCS2 lite coolant inlet hose from PCS2 lite

Note

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS2 lite and hose, Discard O-ring

Disconnect PCS2 lite coolant outlet hose from PCS2 lite

Note

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS2 lite and hose, Discard O-ring

Disconnect AC filter harness connector from PCS2 Lite

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS2 lite HV DC harness HV connector

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS2 lite logic connector from PCS2 lite

Note

1x connector

Disconnect PCS2 lite LV connector from PCS2 lite

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove bolts securing PCS2 lite to HV battery

Note

5x bolts, 8mm, 15 Nm, Minus 180 degrees, 15 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T20 fasteners, Discard after removal

Secure suction cups to PCS2 lite

Note

Continue pressing plunger until red line is no longer visible

Lift PCS2 lite up and remove it from ancillary bay

Note

2x datums, Slightly tilt rear of PCS2 lite upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Position PCS2 lite into ancillary bay

Note

2x datums, Ensure all busbar insulators beneath PCS2 lite are present, Slightly tilt rear of PCS2 lite upward and lower into position, Align datums into PCS2 lite holes

Remove suction cups from PCS2 lite

Install bolts securing PCS2 lite to HV battery

Note

5x bolts, 8mm, 15 Nm, Minus 180 degrees, 15 Nm, Install new bolts

Connect AC filter harness connector from PCS2 Lite

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 Lite LV connector to PCS2 Lite

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 lite logic connector to PCS2 lite

Note

1x connector

Connect PCS2 lite DC busbar HV connector

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 lite coolant inlet hose to PCS2 lite

Note

2x clips, 1x plug, Remove plug from PCS2 lite, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the O-ring, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Apply light amount of Krytox 203, Install new O-ring

Connect PCS2 lite coolant outlet hose to PCS2 lite

Note

2x clips, 1x plug, Remove plug from PCS2 lite, Place absorbent sheet under hose to catch excess coolant, Caution when installing this hose, it's difficult to align hose to coupling, Use caution not to damage the O-ring, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated, Apply light amount of Krytox 203, Install new O-ring

Position HVC and skylite hinge to PCS2 Lite

Note

Release bungee

Remove pyro disconnect dummy

Clean mating surface of pyro

Note

Allow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, Busbar, And the pyrotechnic battery disconnect

Set multimeter to "LoZ" (low impedance) mode

Measure voltage between busbar and shunt

Note

Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points

Position pyro disconnect to ancillary bay for installation

Note

1x connector, While still measuring the voltage, Have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, And then press the pyrotechnic battery disconnect down onto the busbars, The pyro disconnect can only be installed one way

Install bolts securing pyro disconnect to ancillary bay

Note

2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen

Measure resistance from pyro disconnect to shunt

Note

1x HV joint, 33μΩ or less, Perform zero adjust to Hioki meter prior to testing

Measure resistance from module 2 busbar to pyro disconnect

Note

1x HV joint, 48μΩ or less, Perform zero adjust to Hioki meter prior to testing

Remove service insulator kit

Remove HVC logic cap

Note

1x logic cap

Inspect ancillary bay walls for damage

Note

Any dent or depression in the sealing surface that causes it to not be flat will result in a leak, Any paint that comes off the ancillary bay wall, Whether or not it sticks to the seal, Will require enclosure leak test when reassembled, It can still be reused

Inspect ancillary bay cover seal to confirm it has no visual damage

Note

Image up close for clarity, Delaminated and torn seals cannot be reused

Wipe ancillary bay cover with IPA to clean surface

Note

Allow to 1 minute dry time

Position ancillary bay cover to HV battery for installation

Note

Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered

Remove HV insulating gloves

Install bolts securing ancillary bay cover to HV battery

Note

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, Fasteners are captive, Follow torque sequence per image

Install bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Remove logic cap and connect HVC logic connector

Note

1x connector, 1x cap, Align connector then pull the handle to locking position get connector fully seated

Connect 2nd row seat harness and secure cushion

Note

2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test

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

Connect coolant Leak Test Adapter plug to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove rubber plug from PCS outlet hose coupling if present, Install 90 degree Leak Test Adapter with NPT plug, Make sure the locking clip is fully seated

Connect coolant Leak Test Adapter to PCS inlet hose coupling

Note

Remove rubber plug from coupler if installed, Make sure the locking clip is fully seated, Connection is at RH rear of HV Battery

Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter

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

Close inlet valve on Leak Test Fixture tool

Note

The valve knob should be perpendicular to the air line when closed

Record the PCS coolant loop leak check starting pressure

Note

Record the value shown on the digital gauge

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

Disconnect Leak Test Adapter from PCS inlet hose coupling

Note

1x spring clip

Position coolant drain container underneath RH rear of vehicle

Connect rear PT supply hose to PCS inlet hose coupling

Note

1x spring clip, 1x plug, Remove plug, Perform push-pull-push test to make sure hose is fully seated, Connection is located at RH rear of HV Battery, Vacuum fill required if > 1L lost during repair

Disconnect Leak Test Adapter plug from PCS outlet hose coupling

Note

1x spring clip, Connection located at LH rear of HV Battery

Position coolant drain container underneath LH rear of HV battery

Connect RDU inverter inlet tube to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged, Connection is located at LH rear of HV Battery, Vacuum fill required if > 1L lost during repair

Remove coolant drain container from underneath vehicle

Position HV battery rear skid plate enclosure onto HV battery for installation

Note

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note

4x bolts, 13mm, 35 Nm, Torque at later step

Install upper nut securing HV battery rear skid plate enclosure hand tight

Note

1x nut, 10mm, 13 Nm, Torque at later step

Install lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts

Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note

4x bolts, 13mm, 35 Nm

Torque upper nut securing HV battery rear skid plate enclosure

Note

1x nut, 10mm, 13 Nm

Install RH side hose clips to HV battery rear skid plate enclosure

Note

2x fir tree clips

Install LH side hose clip to HV battery rear skid plate enclosure

Note

1x clip

Install clips securing coolant hoses to LH shear plate

Note

2x fir tree clips

Install rear aero shield

Note

11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts before installing

Install LH and RH clips securing rear aero shield to wheel house liner

Note

2x clips

Lower vehicle fully

Note

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

Remove coolant bottle cap

Note

(*Use this step for Model 3 Heat pump vehicles)

Place empty coolant container into front storage area

Fill container with coolant

Note

Do not draw in air during fill process, For RWD, The entire system requires coolant is 15L, for AWD, The entire system requires coolant is 18L

Place filled coolant container into front storage area

Install coolant reservoir adapter cap onto coolant bottle assembly

Note

(*Use step for Model 3 with Heat Pump & NV35) 1x adapter cap, Adapter found in Vacuum Refill kit, turn clockwise to tighten cap onto coolant bottle

Setup vacuum refill tool

Note

Verify all valves on refill tool are in the closed position, See image for clarity

Connect vacuum refill hose to refill cap on coolant bottle

Note

Perform push-pull-push test to verify hose is fully engaged (*Use this step for Model 3 Heat Pump vehicles)

Position overflow hose into empty container

Place refill hose inside filled coolant container

Note

Make sure hose end is fully submerged into coolant

Connect shop air supply to coolant refill tool

Note

If not already done, Verify refill valve is set to off

Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note

Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant

Note

This purges trapped air from the hose

Monitor gauge for 30 seconds to verify vacuum is maintained in cooling system

Note

If vacuum is not maintained there may be a leak in the cooling system, Verify no loose connections or fittings on vacuum refill tool causing vacuum leak

Continue evacuating cooling system

Note

Open air inlet valve for 3 minutes then close air inlet valve

Slowly open refill valve to allow coolant to be drawn into system

Note

Make sure hose end of refill hose is fully submerged during entire process

Once gauge reads zero, close refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Disconnect vacuum refill hose from refill cap on coolant bottle

Note

(*Use this step for Model 3 Heat Pump procedures)

Remove coolant refill tool from vehicle

Remove both coolant containers from underhood area

Note

(*Use this step for NV35 vehicles)

Connect first responder loop and LV battery

Note

2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

Move RH front seat to original position

Move LH front seat to original position

Reinstall software via UI

Note

Via Controls > Service Mode > Software Reinstall, Select Reinstall button at Software Reinstall dialogue box, Reinstall will begin immediately, Once firmware redeploy is complete, Verify release notes are present via UI