2026-03-23

Power Conversion System (Remove and Replace)

Correction code 16301002 4.62 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. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

Remove

  1. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  2. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  3. Remove the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  4. Use a plastic trim to tool to raise the connector lock up, press the tab in, and then disconnect the electrical harness from the power conversion system HV DC connector.
  5. Press the tab in, and then disconnect the electrical harness from the power conversion system logic connector.
  6. Press the tab in, and then use a plastic trim tool to disconnect the electrical harness from the power conversion system LV DC connector.
  7. Use a plastic trim to tool to raise the connector lock up, press the tab in, and then disconnect the AC filter electrical harness from the power conversion system HV AC connector.
  8. Release the clips (x3) that attach the AC filter electrical harness to the mounting tray, and then move the AC filter electrical harness to the side.
  9. Remove the 8 mm bolts (x6) that attach the power conversion system to the mounting tray.
  10. Lift the power conversion system slightly up, shift to the LH side to clear the battery enclosure lip, and then straight up and out of the HV battery.
  11. Remove PCS coolant inlet and outlet hose plugs.
  12. Drain remaining coolant from PCS. And reinstall coolant plugs after drain.
  13. Disconnect coolant inlet hose from PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the special tool to release the 2x clips on the hose , Then install the shipping plugs from new PCS.
  14. Disconnect coolant outlet hose from PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use the special tool to release the 2x clips on the hose , Then install the shipping plugs from new PCS.

Install

  1. Connect coolant outlet hose to PCS.
  2. Connect coolant inlet hose to PCS.
  3. If installing a replacement power conversion system and the HV battery is a Rev F or earlier, continue to the next step. Otherwise, skip to step 11.
  4. Place the replacement power conversion system upside down on a suitable workbench.
  5. Position the mica armor onto the power conversion system as shown, and align the holes in the mica armor with those in the power conversion system.
  6. Apply Kapton tape along the mica armor edge to fully secure the armor to the power conversion system.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the holes are still in alignment with each other.
  7. Carefully place the power conversion system right side up.
  8. Carefully fold the mica armor over the tabs (x3) of the power conversion system, so that the holes in the armor align with the holes in the power conversion system.
  9. Apply Kapton tape along the mica armor edge to fully secure the armor to the power conversion system.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the holes are still in alignment with each other.
  10. Verify that the mica armor is fully secured to the power conversion system. Apply additional Kapton tape as necessary.
  11. Lower the power conversion system into the HV battery, shift to the RH side so that it is under the battery enclosure lip, and aligns with the mounting holes.
  12. Install the bolts (x6) that attach the power conversion system to the mounting tray.
    6 Nm (4.4 lbs-ft)
  13. Move the AC filter electrical harness to along the power conversion system, and then fasten the clips (x3) that attach the electrical harness to the mounting tray.
  14. Connect the AC filter electrical harness to the power conversion system HV AC connector, and then press the connector lock down.
  15. Connect the electrical harness to the power conversion system LV DC connector.
  16. Connect the electrical harness to the power conversion system logic connector.
  17. Connect the electrical harness from the power conversion system HV DC connector, and then press the connector lock down.
  18. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  19. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  20. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  21. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  22. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  23. Reinstall software. See Firmware Reinstall - Touchscreen.