23/05/2024 08:49:26

Power Conversion System (Remove and Replace)

Correction code 16301002 6.25 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 proper PPE is worn when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
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

  1. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. Perform a cooling system thermal fill drain. See Thermal Fluid - Cooling System (Fill/Drain).
  3. Remove the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  4. Position the 2 post lift pads for HV battery removal.
  5. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  7. Remove the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  8. Remove the 2nd row mid floor panel. See:
  9. Remove the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  10. Remove the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  11. Remove the 2nd row rear floor panel. See:
  12. Remove the bolts (x2) that attach the busbar duct to the body, and then remove the busbar duct from the vehicle.
  13. Remove the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  14. Remove the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  15. Remove the trunk side trim bracket. See:
  16. Disconnect LV power. See LV Power (Disconnect and Connect).
  17. Remove the 3rd row seat cushion, if installed. See Cushion - Seat - 3rd Row (Remove and Replace).
  18. Remove the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  19. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace). .
  20. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  21. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  22. Remove the HV Battery. See HV Battery (AWD) (Remove and Install).
  23. Perform a power conversion system coolant drain. See Power Conversion System Coolant (Drain).
  24. Remove the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  25. 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.
  26. Press the tab in, and then disconnect the electrical harness from the power conversion system logic connector.
  27. Press the tab in, and then use a plastic trim tool to disconnect the electrical harness from the power conversion system LV DC connector.
  28. 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.
  29. 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.
  30. Remove the 8 mm bolts (x6) that attach the power conversion system to the mounting tray.
  31. 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.

Install

  1. 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 9.
  2. Place the replacement power conversion system upside down on a suitable workbench.
  3. 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.
  4. 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.
  5. Carefully place the power conversion system right side up.
  6. 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.
  7. 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.
  8. Verify that the mica armor is fully secured to the power conversion system. Apply additional Kapton tape as necessary.
  9. 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.
  10. Install the 8 mm bolts (x6) that attach the power conversion system to the mounting tray.
    6 Nm (4.4 lbs-ft)
  11. 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.
  12. Connect the AC filter electrical harness to the power conversion system HV AC connector, and then press the connector lock down.
  13. Connect the electrical harness to the power conversion system LV DC connector.
  14. Connect the electrical harness to the power conversion system logic connector..
  15. Connect the electrical harness from the power conversion system HV DC connector, and then press the connector lock down.
  16. Install the HV battery front access cover. See Cover - Front Access - HV Battery (Remove and Install).
  17. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  18. Perform a power conversion system coolant leak test. See Power Conversion System Coolant Leak Test (On Table).
  19. Perform an HV battery air leak test. See HV Battery Air Leak Test (On Table).
  20. Install the HV Battery. See HV Battery (AWD) (Remove and Install).
  21. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  22. Install the LH inner reinforcement. See Reinforcement - Inner - LH (Remove and Replace).
  23. Install the 3rd row seat cushion, if previously removed. See Cushion - Seat - 3rd Row (Remove and Replace).
  24. Connect LV power. See LV Power (Disconnect and Connect).
  25. Install the trunk side trim bracket. See:
  26. Install the trunk sill trim. See Trim - Sill - Trunk (Remove and Replace).
  27. Install the LH upper C-pillar trim. See Trim - C-Pillar - Upper - LH (Remove and Replace).
  28. Install the busbar duct to the body, and then install the bolts (x2) that attach the busbar duct to the body.
    2.5 Nm (1.8 lbs-ft)
  29. Install the 2nd row rear floor panel. See:
  30. Install the LH and RH lower C-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  31. Install the LH and RH mid C-pillar trim. See Trim - C-Pillar - Mid - LH (Remove and Replace).
  32. Install the 2nd row mid floor panel. See:
  33. Install the LH and RH sill panel trims. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  34. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  35. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  36. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  37. In Toolbox 3, click the Action/Autodiag tab, type "redeploy" into the search field, click on Service Redeploy, click RUN, and allow the routine to complete.
  38. Disconnect the laptop with Toolbox 3 from the vehicle. See Toolbox 3 (Connect and Disconnect).
  39. Install the LH and RH rocker panel moldings. See Molding - Rocker Panel - LH (Remove and Replace).
  40. Hold the LH and RH upper B-pillar buttons in the "Close" position to manually calibrate the LH and RH rear doors.
  41. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.