04/06/2024 18:00:36

Power Conversion System (Remove and Install)

Correction code 16301001 2.10 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.

  • 1111868-00-B Connector Removal, Coolant, PCS, M3
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
  • 1114917-00-A Tool, Vacuum Cup, 3" x 6" (Qty 2)
  • 1076927-00-A Resistance meter, micro ohm, Hioki RM 3548
Warning IconA warning icon, calling your attention to a possibly risky situation
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 safety information.

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.

Torque Specifications

Table 1. Torque Specifications: Power Conversion System (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Nuts that attach the positive/negative terminal of the DCDC harness to the positive/negative DCDC passthrough busbar
4.5 Nm (3.3 lbs-ft)
  • 8 mm socket
  • 4 in extension
  • Ratchet/torque wrench
Reuse
Bolts that attach the power conversion system to the HV battery

6 Bolt Power Conversion System:

6 Nm (4.4 lbs-ft)

5 Bolt Power Conversion System:

18 Nm (13.3 lbs-ft)

  • Insulated tools:
    • 8 mm socket
    • 10 in extension
    • Ratchet/torque wrench
 Reuse Upon installation, mark each bolt with a paint pen

Remove

  1. Place the vehicle on the 2-post lift.
    Tip: Ensure the vehicle is not charging.
  2. Open all doors and lower all windows.
  3. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  4. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  5. Remove the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  6. Inspect the ancillary bay for any missing insulators. Install the missing insulators before continuing.
    Informational PurposesAn informational icon, calling your attention
    Note
    The number of bolts on newer vehicles may vary.
  7. Reinstall the logic connector cap onto the high voltage controller (HVC) connector.
  8. Raise the high voltage controller vertically, and then restrain the controller with a bungee strap looped around the rear RH seat headrest.
  9. Remove the HV insulating gloves.
  10. Drain the coolant from the power conversion system. See Ancillary Bay Coolant (Drain and Refill).
  11. Lower the vehicle fully.
  12. Inspect the HV insulating gloves, then put on the HV insulating gloves and leather over gloves.
  13. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  14. Position absorbent sheets below and around the power conversion system (PCS) coolant inlet and outlet hoses to avoid excess coolant dripping.
  15. Use the coolant connector removal tool to release the clips that attach the coolant input tube to the power conversion system, and remove the tube from the power conversion system. See Tube - Input - Coolant - Power Conversion System (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    This video demonstrates how to disconnect the coolant hose from the power conversion system and plug the fittings.
  16. Install plugs into the coolant input port of the power conversion system and the open end of the coolant input tube.
  17. Use the coolant connector removal tool to release the clips that attach the coolant output tube to the power conversion system, and remove the tube from the power conversion system. See Tube - Output - Coolant - Power Conversion System (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to the video in the previous step.
  18. Install plugs into the coolant output port of the power conversion system and the open end of the coolant output tube.
  19. Wipe around the power conversion system coolant ports, wipe the ends of the coolant tubes, and wipe up any spilled coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Spilled coolant can create an electrical path.
  20. If the DCDC passthrough is a cable type, skip to step 23, otherwise, continue to the next step.
  21. Remove the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  22. Remove the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar.
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  23. Raise the locking tab on the DCDC passthrough connector, and then remove the connector from the power conversion system.
    Tip: Use a plastic trim tool to help disconnect the DCDC passthrough connector.
    Figure 1. Busbar Type DCDC Passthrough
    Figure 2. Cable Type DCDC Passthrough
  24. Disconnect the LV connector, the DC bus HV connector, and the HV battery AC inlet harness connector from the power conversion system.
  25. Release the clips that attach the HV battery AC inlet harness to the power conversion system, and move the harness aside.
  26. Remove the hex head bolts that attach the power conversion system to the HV battery.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Only remove the 8 mm hex bolts. DO NOT remove the Torx T30 bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners count may vary depending on production date.
    Informational PurposesAn informational icon, calling your attention
    Note
    Some 5-bolt power conversion system mountings have only 4 bolts. Upon installation of the power conversion system, install the fifth bolt.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 8 mm socket
      • 10 in extension
      • Ratchet/torque wrench
    Figure 3. Vehicles Made Before 9/11/18 - 6-Bolts
    Figure 4. Vehicles Made On 9/11/18 And Thereafter - 5-Bolts
  27. Install 2 suction cups on the power conversion system.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not install the suction cups on top of any labels, as this will reduce suction.
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue pushing the suction button until the red line indicator is no longer visible.
  28. With assistance, use suction cups to lift the power conversion system out of the ancillary bay.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Keep the power conversion system level as you lift it, to prevent spilling coolant.
  29. Inspect the area for coolant residue and wipe with a clean towel.
  30. Remove the plugs from the power conversion system, drain the coolant into a coolant drain, and then replace the plugs.
  31. Remove the absorbent pads from around the power conversion system coolant ports.
  32. Remove the suction cups from the power conversion system.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Wipe the power conversion system dry.
  3. Inspect the area of the ancillary bay where the power conversion system will be installed, and wipe up any spilled coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Spilled coolant can create an electrical path.
  4. Ensure all busbar insulators beneath the PCS are present.
  5. With assistance, use suction cups to lift the power conversion system into the ancillary bay with the datums are aligned into the PCS holes, and then remove the suction cups.
  6. Install the hex head bolts that attach the power conversion system to the HV battery, and then mark the bolts with a paint pen after they are torqued.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fasteners count may vary depending on production date.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the 5-bolt power conversion system mounting had only 4 bolts, install the fifth bolt.
    Tip: Use of the following tool(s) is recommended:
    • Insulated tools:
      • 8 mm socket
      • 10 in extension
      • Ratchet/torque wrench
    • 6 Bolt Power Conversion System - Torque to 6 Nm (4.4 ft-lbs)
    • 5 Bolt Power Conversion System - Torque to 18 Nm (13.3 ft-lbs)
    Figure 5. Vehicles Made Before 9/11/18 - 6-Bolts
    Figure 6. Vehicles Made On 9/11/18 And Thereafter - 5-Bolts
  7. Fasten the clips that attach the HV battery AC inlet harness to the power conversion system.
  8. Connect the logic connector, DC bus HV connector, and HV battery AC inlet harness connector to the power conversion system.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the connectors are fully seated, and then engage the locking tabs.
    Tip: To lock the DC bus HV and HV battery AC inlet connectors, push down on the locking tab.
  9. Firmly connect the DCDC passthrough connector to the power conversion system, and then lower the locking tab.
    Figure 7. Busbar Type DCDC Passthrough
    Figure 8. Cable Type DCDC Passthrough
  10. If the DCDC passthrough is a cable type, skip to step 15, otherwise, continue to the next step.
  11. Install the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    4.5 Nm (3.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  12. Install the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar, and then mark the nut with a paint pen after it is torqued.
    4.5 Nm (3.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 8 mm socket
    • 4 in extension
    • Ratchet/torque wrench
  13. Use the Hioki resistance meter to measure the resistance between the positive joint of the DCDC harness and the positive terminal of the 12V DCDC passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.100 mΩ (100 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
    Figure 9. Generic Measurement - Actual busbars and fasteners might appear different
  14. Use the Hioki resistance meter to measure the resistance between the negative joint of the DCDC harness and the negative terminal of the 12V DCDC passthrough.
    Informational PurposesAn informational icon, calling your attention
    Note
    The maximum acceptable resistance is 0.100 mΩ (100 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
    Figure 10. Generic Measurement - Actual busbars and fasteners might appear different
  15. Cut a slit halfway through 2 absorbent pads and surround each power conversion system coolant tube coupling with a pad.
  16. Remove the plugs from the coolant output tube and coolant output coupling.
  17. Replace the coolant output tube O-rings (2x), and then lubricate the O-rings with Krytox 203.
  18. Connect the coolant output tube to the power conversion system. See Tube - Output - Coolant - Power Conversion System (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the hose is fully aligned with the coupling and that the o-rings are correctly seated before attempting to install the hose.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the coolant output tube is securely connected by firmly pressing down on it, verify that both clips have fully engaged the barb on the power conversion system, and then pull up on the fitting to check retention.
  19. Wipe up any spilled coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Spilled coolant can create an electrical path.
  20. Remove the plugs from the coolant input tube and coolant input coupling.
  21. Replace the coolant input tube O-rings (2x), and then lubricate the O-rings with Krytox 203.
  22. Connect the coolant input tube to the power conversion system. See Tube - Input - Coolant - Power Conversion System (Remove and Replace).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the hose is fully aligned with the coupling and that the o-rings are correctly seated before attempting to install the hose.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the coolant input tube is securely connected by firmly pressing down on it, verify that both clips have fully engaged the barb on the power conversion system, and then pull up on the fitting to check retention.
  23. Wipe up any spilled coolant.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Spilled coolant can create an electrical path.
  24. Remove the leather over gloves and the HV insulating gloves.
  25. On the drive unit pressure test fixture, close P2 (outlet valve), and open P1(inlet valve).
  26. Connect the coolant pressure test adapter to the HV battery.
  27. Connect the drive unit pressure test fixture to the coolant pressure test adapter.
  28. Perform an ancillary bay coolant leak test. See Ancillary Bay Coolant Leak Test.
  29. Connect the 12V auxiliary battery negative terminal only.
    6 Nm (4.4 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    DO NOT reconnect the first responder loop at this time.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not follow the procedure to connect 12V power at this time.
    Figure 11. Model 3/Model Y with lead acid 12V battery
    Figure 12. Model 3 with Li-ion LV battery
  30. Depending on the type of auxiliary battery fitted to the vehicle, choose on of the following:
    • If the vehicle is equipped with a lead-acid 12V auxiliary battery, connect a 12V charger to the 12V auxiliary battery terminals.
    • If the vehicle is equipped with a Li-ion LV auxiliary battery, connect a LV maintainer to the vehicle. See LV Maintainer (Connect and Disconnect).
  31. With an assistant checking the power conversion system for leaks, top off the superbottle.
  32. Connect a laptop with Toolbox to the vehicle.
  33. In Toolbox, type "vcfront" into the search field in the Actions tab. Select the ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start, click RUN, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the vehicle is not in Drive.
    Informational PurposesAn informational icon, calling your attention
    Note
    The test will last for approximately 10 minutes. Monitor and keep the superbottle topped off while the test is running. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. If pump speeds stay above 6900 rpm, there is still air entrapped in the system; run a cooling system vacuum refill.
  34. When the air purge is complete, top off the superbottle, and then install the superbottle cap.
  35. Disconnect the laptop from the vehicle.
  36. Power off the vehicle from the touchscreen.
  37. Remove the 12V charger from the 12V auxiliary battery terminals or disconnect the LV maintainer from the vehicle. See LV Maintainer (Connect and Disconnect).
  38. Depending on the vehicle configuration, choose one of the following:
    • If the vehicle is equipped with a lead-acid 12V auxiliary battery, disconnect the 12V auxiliary battery negative terminal.
    • If the vehicle is equipped with a Li-ion LV auxiliary battery, disconnect the LV battery connector from the LV battery.
  39. Inspect and put on PPE including the HV insulating gloves and leather over gloves.
  40. Release the bungee strap from the high voltage controller and rear RH seat headrest, and then lower the controller into the ancillary bay.
  41. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  42. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  43. Remove the leather over gloves and the HV insulating gloves.
  44. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  45. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  46. Install the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  47. Install the rear apron. See Underhood Apron - Rear (Remove and Replace).
  48. Raise all windows and close all doors.
  49. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.