26/01/2024 05:51:03

PCS Assembly (Remove and Replace)

Correction code 1630010252 FRT 2.16 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.

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 vehicle

Note
Ensure vehicle is not charging
Open all four doors
Lower all four windows
Move LH front seat forward
Place vehicle in service mode

Note
Via UI > Controls > Software, Touch and hold "Model 3" for 4 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
Run Thermal Fill Drain (Coolant + Refrigerant) through the UI

Note
Select Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant + Refrigerant), Click Run, Close once routine is completed
Move RH front seat forward
Open hood
Remove rear underhood apron

Note
14x clips
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect LV battery and First Responder Loop

Note
2x connectors, 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

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

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove the ancillary bay probe lid cover from the ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect the ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present,Wipe the ancillary bay with IPA to clean surface,Allow to 1 minute dry time
Install bolts securing the ancillary bay probe lid cover to the ancillary bay cover

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects
Remove LH and RH clips securing rear aero shield to wheel house liner

Note
2x clips
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 tube from LH rear of HV battery

Note
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
Attach coolant drain hose adapter to PCS outlet hose coupling

Note
Use adapter with 90 degree angle, Make sure locking tab is fully seated
Attach coolant drain hose adapter to coolant hose extension
Attach 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 PT supply hose from rear of HV battery

Note
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill
Attach coolant pressure tester to PCS inlet hose coupling

Note
This adapter connected to regulated air line adapter, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Attach compressed air line to coolant pressure tester

Note
Verify valve is in closed position
Open regulator valve then slowly adjust regulator to 50 psi

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Open 2nd valve slowly

Note
Use caution as coolant may spill, Make sure to wear safety glasses
Set timer for 2 minutes and select start

Note
Once timer is complete, select Stop Reset
Close both valves
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS inlet hose coupling
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
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 the ancillary bay cover to HVC

Note
3x bolts, E10, 5 Nm + 30 degrees
Remove bolts securing the 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 the ancillary bay cover from HV battery
Inspect the ancillary bay for any missing insulators

Note
Install service insulator kit before continuing to next step, The number of bolts on newer vehicles may vary
Remove bolts securing pyro disconnect to the ancillary bay

Note
1x insulator, patch bolts, 13mm, 9 Nm, Discard after removal
Remove pyro disconnect from the ancillary bay

Note
1x connector from the bottom, Lift pyro disconnect straight up and out of the ancillary bay
Install pyro disconnect dummy
Use bungee to secure HVC in an upwards position

Note
Wrap bungee around RH headrest
Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping
Disconnect PCS coolant inlet hose from PCS

Note
2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose
Position absorbent sheets below and around the PCS coolant outlet hose to avoid excess coolant dripping
Disconnect PCS coolant outlet hose from PCS and install plugs

Note
1x hose, Use the special tool to release the 2x clips
Disconnect PCS logic connector from PCS

Note
1x connector
Disconnect PCS LV connector from PCS

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upwardLift the HVC up from the front
Disconnect PCS to DC bus HV connector

Note
1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward
Disconnect PCS to fastcharge contactor HV harness connector

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

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.
Remove bolts securing PCS to HV battery

Note
5x bolts, 8mm, 18 Nm, Ensure onlythe 8mm fasteners are removed, Do not remove the T30 fasteners
Secure suction cups to PCS

Note
Continue pressing plunger until red line is no longer visible
Lift PCS up and out of the ancillary bay area and remove from vehicle

Note
Slightly tilt rear of PCS 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
Remove suction cups from the old PCS

Install

Remove PCS plugs from new PCS

Note
2x plugs
Drain water from new PCS
Reinstall plugs on new PCS prior installing into vehicle

Note
Clean any water/coolant with absorbent sheets if necessary
Attach suction cups to PCS

Note
Continue pressing plunger until red line is no longer visible
Position the PCS into ancillary bay

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
Remove suction cups from PCS
Install bolts securing PCS to HV battery

Note
5x bolts, 8mm, 18 Nm
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.

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.
Connect PCS to fastcharge contactor HV harness connector

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated
Connect PCS to DC bus 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 PCS LV connector to PCS

Note
1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seatedLift the HVC up from the front
Connect PCS logic connector to PCS

Note
1x connector
Remove plug from PCS inlet hose
Replace o-rings on PCS inlet hose

Note
2x o-rings, Apply light amount of Krytox 203
Secure inlet hose to PCS

Note
1x hose, 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
Remove plug from PCS outlet hose
Replace o-rings on PCS outlet hose

Note
2x o-rings, Apply light amount of Krytox 203
Secure PCS outlet hose to PCS

Note
1x hose, 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
Lay HVC in original position

Note
Release bungee from back of headrest
Remove HV insulating gloves
Raise vehicle fully and lower lift onto locks

Note
Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side
Position coolant drain container underneath LH rear of HV battery
Install coolant pressure test plug adapter to PCS outlet hose coupling

Note
Remove plug from coupling, Make sure the locking tab is fully seated
Position coolant drain container underneath RH rear of vehicle
Install coolant pressure adapter to PCS inlet hose coupling

Note
Remove plug from coupling, Make sure the locking tab is fully seated
Attach coolant pressure tester to pressure fitting adapter
Attach coolant pressure tester to compressed air line

Note
Make sure valves are closed on pressure regulator
Set pressure regulator to specified pressure value

Note
Set pressure to 50 psi
Slowly open valve on pressure regulator and allow pressure to reach specification
Close the valve and let pressure settle

Note
Wait 2 minutes for pressure to settle, Record the reading
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
Disconnect compressed air from coolant pressure tester
Remove pressure fitting adapter from coolant pressure tester
Remove coolant pressure tester from PCS inlet hose coupling
Connect rear PT supply hose to rear of HV battery

Note
1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated
Remove coolant pressure test plug adapter from PCS outlet hose coupling
Connect RDU inverter inlet hose to rear of HV battery

Note
1x spring clip, Remove plug from rear PT supply hose, Make sure the locking tab is fully seated
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
lnstall rear aero shield

Note
11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts
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
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 pyro disconnect dummy
Clean mating surfaces

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
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
Position pyro disconnect to the ancillary bay for installation

Note
1x connector, Make sure to align the 2 pins with pyro disconnect, The pyro disconnect can only be installed one way
Install bolts securing pyro disconnect to the ancillary bay

Note
2x patch bolts, 13mm, 9 Nm
Measure resistance from module 2 busbar to pyro disconnect

Note
1x HV joint, 48_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Measure resistance from pyro disconnect to shunt

Note
1x HV joint, 33_xD835__xDF07_Ω or less, Perform zero adjust to Hioki meter prior to testing
Remove service insulator kit
Wipe the ancillary bay with IPA to clean surface

Note
Allow to 1 minute dry time
Inspect the ancillary bay walls for damage

Note
Any dent or depression in the seal that causes it to not be flat will result in a leak, and cannot be reused, 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 the ancillary bay cover seal to confirm it has no visual damage

Note
Image up close for clarity, Delaminated and torn seals cannot be reused
Position the 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 the 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 the 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
Remove coolant bottle cap
Place empty coolant container into front storage area
Fill container with at least 15L of coolant
Place filled coolant container into front storage area
Install refill tool cap onto coolant bottle assembly
Setup vacuum refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully engaged
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 a vacuum is maintained in cooling system
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close 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
Remove vacuum refill hose from refill cap on coolant bottle
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect first responder loop and leave LV battery disconnected

Note
1x connector, Engage locking tab, Connect FRL but leave LV battery disconnected
Connecting low-voltage battery maintenancer-Charger

Note
Release positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time
Select "Stop Thermal Fill Drain" through UI

Note
Allow routine to complete, ensure routine is successful
Reinstall Firmware via service UI

Note
Controls > Service Mode > Software Reinstall, Installation will begin immediately
Disconnect low-voltage battery maintenancer-Charger and connect LV battery
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Select "Start Coolant Air Purge" using the UI

Note
Wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time, it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Install coolant bottle cap
Perform Heat Pump Commissioning through UI

Note
Select Thermal > Sensors and Valves > Run Heat Pump Commissioning, click Run, close once routine is passed
Perform Thermal Performance through the UI

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
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
Install rear underhood apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Move RH front seat to original position
Move LH front seat to original position
Raise all windows
Close all four doors

PCS Assembly (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3