2025-04-22

Power Conversion System (Remove and Replace)

Correction code 1630010252 FRT 2.22 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.

Torque Specifications

Table 1. Torque Specifications:PCS Assembly (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x3) securing PCS to HV battery
18 Nm (13.3 lbs-ft)
  • 8 mm socket
  • Class 0 Electrical Protective Gloves
  • Insulated Ratchet/torque wrench
  • Flex head ratchet/flex head torque wrench
 Reuse Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners.

Remove

  1. Open LH front door, and Lower LH front window.
  2. Unlock the gateway. See Gateway (Unlock).
  3. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  4. Remove HV controller and hinge tray from penthouse assembly. See High Voltage System Controller (Remove and Install).
  5. Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping.
  6. Disconnect PCS coolant inlet hose from PCS.
  7. Disconnect PCS coolant outlet hose from PCS.
  8. Disconnect PCS to DC bus HV connector.
  9. Disconnect PCS logic connector from PCS.
  10. Disconnect PCS LV connector from PCS.
  11. Disconnect AC harness connector from PCS.
  12. Remove bolts securing PCS to HV battery.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Class 0 Electrical Protective Gloves
    • Insulated Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
  13. Secure suction cups to PCS.
  14. Lift PCS up and out of ancillary bay area and remove from vehicle.

Install

  1. Position PCS into ancillary bay.
  2. Remove suction cups from PCS.
  3. Install bolts securing PCS to HV battery.
    18 Nm (13.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
    • Class 0 Electrical Protective Gloves
    • Insulated Ratchet/torque wrench
    • Flex head ratchet/flex head torque wrench
  4. Connect AC harness connector to PCS.
  5. Connect PCS LV connector to PCS.
  6. Connect PCS logic connector to PCS.
  7. Connect PCS to DC bus HV connector.
  8. Connect PCS coolant inlet hose to PCS.
  9. Replace O-ring on PCS side outlet hose.
  10. Connect PCS coolant outlet hose to PCS.
  11. Install HV controller and hinge tray to penthouse assembly. See High Voltage System Controller (Remove and Install).
  12. Install the pyrotechnic battery disconnect. See Pyro Disconnect - HV Battery (Remove and Replace).
  13. Use IPA wipes to clean the ancillary bay cover gasket surface, and the mating surface of the HV battery.
  14. Position the ancillary bay cover to the HV battery.
  15. Remove the HV insulating gloves.
  16. Install the bolts (x18) that attach the ancillary bay cover to the HV battery.
    8 Nm (5.9 lbs-ft)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use an External Torx E10 5-Lobe socket that is not magnetized. Sockets with magnets will not fully grip and can possibly strip the bolt head.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • External Torx E10
    • PENTHOUSE SOCKET, 1/4" DR, 5-LOBE, E-TORX MAG
  17. Install the bolts (x3) that attach the ancillary bay cover to the high voltage controller.
    5 Nm (3.7 lbs-ft) + 30 degrees
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • DRIVER KIT, 1/4" HEX, M12
    • External Torx E10
  18. Install PCS cable to 12V pass through output.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Electrical Protective Gloves
    • Cordless Ratchet/Impact Driver
    • 12 mm deep socket
  19. Install positive 12V output cover to PCS cable.
  20. Remove the logic connector cap from the high voltage controller connector.
  21. Install the 2nd row seat assembly. See 2nd Row Seat 5 Seater - LH (Remove and Replace).
  22. Install the 2nd row seat assembly. See 2nd Row Seat 5 Seater - RH (Remove and Replace).
  23. Install the 2nd row lower seat cushion. See 2nd Row Seat Cushion (Remove and Replace).
  24. Perform the penthouse coolant refill. See Penthouse Coolant (Drain And Refill) (Test/Adjust).
  25. Connect the LV power. See LV Power (Disconnect and Connect).
  26. Reinstall the software. See Software Reinstall - Touchscreen.
  27. Select Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  28. Select Coolant Purge Start > Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  29. Install the ancillary bay cover. See Penthouse Cover (Remove and Replace).