2026-09-24

Inlet Hose - PCS2 Lite - Ancillary Bay (Remove and Replace)

Correction code 16300500902 FRT 2.16 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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. 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.

Warning
Remove all jewelry (watches, bracelets, rings, necklaces, earrings, ID tags, piercings, etc.) from your person, and all objects (keys, coins, pens, pencils, tools, fasteners, etc.) from your pockets before performing any procedure that exposes you to high voltage.
Warning
If corrective eyewear is necessary to safely perform any procedure, make sure that the eyewear is securely restrained to the head and cannot fall off.
Warning

Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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 safety information.

Remove

  1. Place the vehicle on the 2-post lift.
    Note
    Ensure the vehicle is not charging.
  2. Open all four doors and lower all four windows.
  3. Enter Service Mode. See Service Mode.
  4. Run PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox:(link)
    Note
    This routine has a 5-hour limit. After 5 hours, this routine must be performed again.
  5. Perform the Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure (Test/Adjust).
    Note
    Return to the current procedure once the rear drive unit HV cable bracket is installed to the HV battery.
  6. Drain the coolant from the power conversion system. See Ancillary Bay Coolant (Drain and Refill) (Test/Adjust).
  7. Disconnect the coolant drain hose adapters from the power conversion system inlet and outlet hoses and plug the power conversion inlet and outlet hoses.
  8. Remove the coolant collection tools, and then remove the coolant pressure tester from underneath the vehicle.
  9. Lower the vehicle fully.
  10. Remove the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  11. Remove the ancillary bay cover. See Ancillary Bay Cover (Remove and Replace).
    Warning
    HV insulating gloves and leather glove protectors must be worn throughout the remainder of this procedure. Do not remove gloves or protectors until otherwise noted.
  12. Install the logic connector cap to the high voltage controller connector.
  13. Inspect the ancillary bay for missing insulators.
    Note
    Install the service insulator kit before proceeding with the following steps.
  14. Remove the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  15. Disconnect high voltage controller (HVC) connectors (x7).
  16. Release the clips (x8) that attach the megaharness to the high voltage controller skylite hinge.
  17. Remove the HVC and skylite hinge from the skylite hinge post.
    Note
    2x tabs, 2x location holes
    Note
    Press to release the two tabs, and then pull outward to remove.
  18. Remove the screw that attaches the RH skylite hinge post to the ancillary bay.
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  19. Move the harnesses (x3) outward, and then remove the RH Skylite hinge post from the ancillary bay.
    Note
    3x harness, 2x locating pins
    Note
    Inspect the wire insulation layer. If it is damaged, replace the harness.
  20. Place an absorbent sheet under and around the PCS2 lite coolant inlet hose to catch excess coolant.
  21. Disconnect the PCS2 Lite coolant inlet hose from the PCS2 Lite by releasing the clips (x2) with the PCS coolant connector removal tool (1111868-00-B).
    Note
    Place an absorbent sheet under the hose to catch excess coolant.
    Note
    Visually inspect for coolant residue and clean with a shop towel if needed.
    Note
    Install 2 plugs on the PCS2 Lite and hose, and discard the O-ring.
  22. Disconnect the PCS2 Lite coolant inlet hose from the ancillary bay by releasing the clips (x2) with the coolant connector removal tool (2029761-00-A), and then remove the hose from the vehicle.
    Note
    Place an absorbent sheet under the hose to catch excess coolant.
    Note
    Visually inspect for coolant residue and clean with a shop towel if needed.
    Note
    Install 2 plugs on the PCS2 Lite and hose, and discard the O-ring.

Install

  1. Connect the PCS2 Lite coolant inlet hose to the ancillary bay as follows:
    1. Remove 2 plugs from the ancillary bay and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1091895-00-A).
    4. Align the hose to the ancillary bay and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  2. Connect the PCS2 Lite coolant inlet hose to the PCS2 Lite as follows:
    1. Remove 2 plugs from the coupling and hose.
    2. Place an absorbent sheet under the hose to catch excess coolant.
    3. Apply a light amount of Krytox 203 to install a new O-ring (1803223-00-A).
    4. Align the hose to the coupling and secure the clips (x2); use caution not to damage the O-ring.
    5. Perform a push-pull-push test to ensure the coolant hose is fully latched, then visually verify the clips are fully seated.
  3. Install the RH skylite hinge post to the ancillary bay, and then insert the harnesses (x3) into the slot.
    Note
    2x locating pins
  4. Install the screw that attaches the RH skylite hinge post to the ancillary bay.
    2 Nm (1.5 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  5. Install the HVC and skylite hinge to the skylite hinge post.
    Note
    2x tabs, 2x location holes
  6. Install the clips (x8) that attach the megaharness to the HVC skylite hinge.
  7. Connect the HVC connectors (x7).
  8. Measure the voltage across the pyrotechninc battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  9. Remove the service insulator kit.
  10. Remove the logic connector cap from the high voltage controller connector.
  11. Install the ancillary bay cover. See Ancillary Bay Cover (Remove and Install).
    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.
  12. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  13. Perform an ancillary bay coolant leak test. See Ancillary Bay Coolant Leak Test (Inspection).
  14. Install the rear HV battery skid plate. See Skid Plate - HV Battery - Rear (Remove and Replace).
  15. Install the rear aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  16. Refill the coolant. See Ancillary Bay Coolant (Drain and Refill) (Test/Adjust).