2025-11-12

PCS Assembly (Remove and Replace)

Correction code 1630010252 FRT 2.22 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-07-02: Clarified steps to drain the ancillary bay.
  • 2025-04-22: Added a note to clarify previous 6 PCS fixed bolts must be upgraded to 5 bolts with part number 1115833-00-B.

Torque Specifications

Table 1. Torque Specifications:PCS Assembly (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (X5) securing PCS to HV battery
18 Nm (13.3 lbs-ft)
  • Electrical Protective Gloves
  • RATCHET, 0.25IN SQ DR, HV INSULATED
  • SKT, 1/4" SQ DR, 8MM, HV INSULATED
 Reuse Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners.

Remove

  1. Raise and support vehicle.
  2. Open all four doors and lower all four windows.
  3. Move LH front seat forward.
  4. Enter Service Mode. See Service Mode.
  5. Select Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant + Refrigerant), click Runto let routine complete.
  6. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
  7. Remove the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  8. Vacuum drain the coolant from the ancillary bay. See Ancillary Bay Coolant (Drain and Refill) (Test/Adjust).
  9. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  10. Install the pyrotechnic disconnect dummy.
  11. Use a bungee cord to secure HVC in an upwards position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wrap bungee around RH headrest.
  12. Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping.
  13. Disconnect the PCS coolant inlet hose from the PCS.
  14. Position absorbent sheets below and around the PCS coolant outlet hose to avoid excess coolant dripping.
  15. Disconnect the PCS coolant outlet hose from the PCS and install plugs.
  16. Disconnect the PCS logic connector from the PCS.
  17. Disconnect the PCS LV connector from the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward, may need plastic trim tool to help lift the connector upward.
  18. Disconnect the PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward, may need plastic trim tool to help lift the connector upward.
  19. Disconnect the PCS to fastcharge contactor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward, may need plastic trim tool to help lift the connector upward.
  20. For vehicles that have a 1-Phase charging system: release the clips (x2) that attach the PCS to fastcharge contactor HV harness to the PCS and set the harness aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    There are differences in different regions, depending on having a 1-Phase or 3-Phase charging system: 1-Phase has a wiring harness fixing bracket, 3-Phase comes without this bracket.
  21. Remove the bolts (x5) that attach the PCS to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • RATCHET, 0.25IN SQ DR, HV INSULATED
    • SKT, 1/4" SQ DR, 8MM, HV INSULATED
  22. Secure suction cups to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue pressing plunger until red line is no longer visible.
  23. Lift the PCS up and out of the ancillary bay area and remove the PCS from vehicle.
  24. Remove the suction cups from the old PCS.

Install

  1. Remove the PCS plugs from the new PCS.
  2. Drain water from the new PCS.
  3. Reinstall plugs on the new PCS prior to installing it into vehicle.
  4. Attach suction cups to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue pressing plunger until red line is no longer visible.
  5. Position the PCS into the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure all busbar insulators beneath PCS are present, slightly tilt rear of PCS upward and lower into position, align datum into PCS holes, inspect for any coolant residue inside the ancillary bay and clean with absorbent sheets if necessary.
  6. Remove the suction cups from PCS.
  7. Install the bolts securing PCS to the HV battery.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • RATCHET, 0.25IN SQ DR, HV INSULATED
    • SKT, 1/4" SQ DR, 8MM, HV INSULATED
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners count may vary depending on production date, Follow torque specification for number of fasteners equipped.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the PCS came with 6 bolts then install new bolt and change it to 5 bolts (1115833-00-B).
  8. For vehicles that have a 1-Phase charging system: release the clips (x2) that attach the PCS to fastcharge contactor HV harness to the PCS and set the harness aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    There are differences in different regions, depending on having a 1-Phase or 3-Phase charging system: 1-Phase has a wiring harness fixing bracket, 3-Phase comes without this bracket.
  9. Connect the PCS to fastcharge contactor HV harness connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push connector downward then push the locking tab downward to install connector, make sure the connector is fully seated.
  10. Connect the PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push connector downward then push the locking tab downward to install connector, make sure the connector is fully seated.
  11. Connect the PCS LV connector to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push connector downward then push the locking tab downward to install connector, make sure the connector is fully seated.
  12. Connect the PCS logic connector to the PCS.
  13. Remove the plug from the PCS inlet hose.
  14. Replace the o-rings on the PCS inlet hose.
  15. Secure the inlet hose to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    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-rings, perform push-pull-push test to make sure coolant hose is fully latched, then visually verify clip is fully seated.
  16. Remove the plug from the PCS outlet hose.
  17. Replace the o-rings on the PCS outlet hose.
  18. Secure the PCS outlet hose to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Place absorbent sheet under hose to catch excess coolant, caution not to damage the o-rings, perform push-pull-push test to make sure coolant hose is fully latched, then visually verify clip is fully seated, visually inspect area for any coolant residue, clean with shop towel if necessary
  19. Move the HVC back to its original position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release bungee from back of headrest.
  20. Perform the ancillary bay coolant leak test. See Ancillary Bay Coolant Leak Test (Inspection).
  21. Install the rear skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  22. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  23. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Before installing the ancillary bay cover, inspect the ancillary bay cover seal and confirm there is no visual damage. If the seal is torn and/or delaminated, replace the ancillary bay cover.
  24. Perform ancillary bay coolant refill. See Ancillary Bay Coolant (Drain and Refill) (Test/Adjust).
  25. Connect first responder loop and leave LV battery disconnected.
  26. Connect low-voltage battery maintenance charger. See LV Maintainer (Connect and Disconnect) (Maintenance).
  27. Select Stop Thermal Fill Drain, click Runto let routine complete.
  28. Reinstall software. See Software Reinstall - Touchscreen.
  29. Disconnect low-voltage battery maintenance charger. See LV Maintainer (Connect and Disconnect) (Maintenance).
  30. Select Coolant Purge Start, click Runto let routine complete.
  31. Inspect coolant level and top off as necessary.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that fluid level is at Max line.
  32. Select Thermal > Refrigerant System > Run Heat Pump Commissioning, clickRunto let routine complete.
  33. Select Thermal > Actions > Test Thermal Performance, clickRunto let routine complete.
  34. Install the 2nd row seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  35. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).