Power Conversion System (7-Seat) (Remove and Replace)

Raise and support vehicle

Note

Ensure vehicle is not charging, Remove charging cable if it's plugged in

Open all four doors

Lower all four windows

Move LH front seat forward

Note

Adjust seat back if needed to avoid contacting headliner

Move RH front seat forward

Note

Adjust seatback if needed to avoid contacting headliner

Move 60 seat to easy entry position

Note

Press shoulder switch then push seat forward

Partially remove lower portion of LH rear door seal

Remove LH 7s lower C-pillar trim

Note

8x clips, Rear edge secures onto trunk side trim, Release front clips then rear clips

Move 60 seat to original position

Note

Press shoulder switch then pull seat backward

Fold 2nd row 60 seatback down

Note

Via seat switch or manual tether, Protect seat back upholstery if necessary

Disconnect 2nd row 60 seat connector

Note

1x connector,

Move 60 seat forward using towel bar

Note

With one hand on towel bar pull up and slide the seat forward with your other hand

Remove 60 seat rear outboard track fastener

Note

1x patch bolt, 11mm, 37 Nm, Discard after removal

Remove 60 seat rear inboard track fasteners

Note

2x patch bolts, 11mm, 37 Nm, Discard after removal

Move 60 seat fully rearward using towel bar

Note

pull up bar, slide seat forward

Remove 60 seat outboard track cover

Note

1x clip, Slide covers forward to release from 60 seat tracks

Remove center track cover from 2nd row seats

Note

2x clips, Slide covers forward to release from 2nd row seat tracks

Release cabin carpet from 60 seat

Note

Pull cabin carpet towards front of vehicle

Remove 60 seat front inboard track fasteners

Note

1x bolts, 11mm, 37 Nm, Discard after removal

Remove 2nd row 60 seat frame front outboard track fasteners

Note

1x bolts, 11mm, 37 Nm, Discard after removal

Remove 2nd row 60 seat assembly from vehicle

Note

Recommend assistance, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

Move RH front seat forward

Note

Adjust seatback if needed to avoid contacting headliner

Move 60 seat to easy entry position

Note

Press shoulder switch then push seat forward

Partially remove RH rear door seal

Note

Pillar and sill trim have tabs seated underneath seal

Remove RH C-pillar lower trim

Note

5x clips, Rear edge is mated with groove in trunk side trim, Release clips at front of LH Lower C-Pillar trim working your way back towards rear of sill trim, trim part may slightly differ by vehicle build location, and the number of clips may also varyt, by vehicle build location, Confirm each installation with push-pull test, Clip position should not be adjusted after bracket is removed or will result in bracket not seating properly, if clip position is changed or push-pull action shows bracket not secure, remove clip from tab and seat clip into doghouse on bracket and reinstall

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Fold 2nd row 40 seatback down

Note

Via seat switch or manual tether, Protect seat back upholstery if necessary

Remove 40 seat outboard track cover

Note

1x clip, Slide cover forward to release from 40 seat track

Remove bolts securing 40 seat podium to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

Move 40 seat forward using towel bar

Note

With one hand on towel bar pull up and slide the seat forward with your other hand

Remove bolts securing 40 seat inner and outer tracks to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Discard bolts after removal

Move 40 seat fully rearward using towel bar

Note

pull bar, slide seat forward

Disconnect 2nd row 40 seat connector

Note

1x connector, Newer models may have red locking tab

Remove 40 seat from vehicle

Note

Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium, Note: If seat that is not being replaced does not have ISOFIX flag for child locks, the seat cover will also require replacement

Remove 3rd row seat cushion

Note

2x clips, 1x connector, 2x circular hooks, Press tabs backward then pull front edge up, Press rear seat cushion and lift the front seat cushion

Remove 3rd row LH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster towards front of vehicle to remove

Remove 3rd row RH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster towards front of vehicle to remove

Release LH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

Release RH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Remove bolt then release carpet

Remove 3rd row rear cabin carpet

Open hood

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)

Unlock the vehicle gateway. See Gateway (Unlock).

Access thermal system routines via UI

Note

Select Service mode > Thermal

Perform "Start Thermal Fill/Drain (Coolant Only)" through Service UI

Note

Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again

Power off vehicle from center display

Note

Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

Remove rear apron

Note

16x trim clips, 3x datums, 2x clips

Remove HEPA filter assembly

Note

2x bolts, 10mm, 10 Nm, Pivot rear edge up past brake reservoir then lift up to clear frunk assembly

Disconnect LV battery and first responder loop

Note

2x connectors, Ensure that one minute has passed after window movement before performing the power-off, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge

Verify operation of multimeter

Note

Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery

Remove 3rd row NVH insulator

Note

1x connector, Disconnect connector then remove insulator

Install HVC logic cap

Note

1x logic cap

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

Note

Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

Put on HV insulating gloves and leather over gloves

Note

Use HV cut resistant insulated gloves or HV insulating gloves and leather over gloves, HV Insulating gloves must be worn any time a Hioki Tester or Hi-Pot Tester is used, Refer to service document TN-15-92-003 R5 for PPE requirements depending on vehicle configuration.

Release positive LV output cover from PCS cable

Note

1x cover

Remove PCS cable from LV passthrough output

Note

1x nut, 13mm, 9 Nm, Discard nut after removal

Remove bolts securing ancillary bay probe lid cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

Remove ancillary bay probe lid cover

Verify no high voltage

Note

Make sure to wear PPE (HV gloves, Safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

Wipe ancillary bay cover with IPA to clean surface

Note

Allow to 1 minute dry time

Inspect ancillary bay probe lid cover gasket then position onto ancillary bay cover

Note

Confirm no visual damage present, Wipe ancillary bay with IPA to clean surface, Allow to 1 minute dry time

Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note

2x bolts, EP10 5-Lobe, 6 Nm, Install new bolts

Remove leather over gloves and HV insulating gloves

Raise vehicle fully and lower lift onto locks

Note

Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

Remove LH and RH push clips securing mid aero shield to wheel house liner

Note

2x clips

Remove mid aero shield

Note

11x bolts, 2x tabs, 10mm, 5 Nm

Release LH side hose clip from rear battery skid plate

Note

1x fir tree clip

Release RH side hose clips from rear battery skid plate

Note

2x fir tree clips

Remove lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm

Remove upper bolts securing HV battery rear skid plate enclosure

Note

4x bolts, 13mm, 64 Nm

Remove HV battery rear skid plate enclosure

Position coolant drain container under LH rear of vehicle

Disconnect RDU inverter inlet hose from PCS outlet hose coupling

Note

1x spring clip, 2x plugs, Connection is located at the LH rear of the HV Battery, Install plugs once disconnected, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plug

Connect coolant Drain and Fill Adapter to PCS outlet hose coupling

Note

Use adapter with 90 degree angle, Make sure locking clip is fully seated, Make sure valve is open, Valve is inline with the adaptor when open, Connection is at LH rear of HV Battery

Connect coolant hose extension to Drain and Fill adaptor

Note

Press hose end onto adaptor until clicked into place

Connect coolant hose extension to coolant drain hose

Note

Use caution as coolant may spill, Make sure to wear safety glasses

Position coolant drain container underneath RH rear of HV battery

Disconnect rear powertrain supply hose from PCS inlet hose coupling

Note

1x spring clip, Plug hose connections as needed, Connection is located at RH rear of HV Battery, Coolant loss greater than 1 L will require vacuum fill, If the battery is returned to Reman, Please remove the special tool plugs

Remove coolant drain container from underneath vehicle

Connect coolant Leak Test Adaptor to PCS inlet hose coupling

Note

Remove rubber plug from coupler if installed, Make sure the locking clip is fully seated, Connection is at RH rear of HV Battery

Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter

Note

Hand tighten hose connection, No tool required to tighten

Connect outlet hose to the Leak Test Fixture tool

Note

Hand tighten hose connection, No tool required to tighten

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Connect compressed air to coolant Leak Test Fixture tool

Note

Air supply source should be above 50 psi

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 2 minutes

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Start 2 minute timer

Note

Once timer is complete, select Stop Reset

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Disconnect coolant Leak Test Adaptor with hose from PCS inlet hose coupling

Note

1x spring clip, Leave the Leak Test Fixture hose connected to Leak Test Adaptor, Connection is at RH rear of HV Battery

Disconnect coolant Drain and Fill Adapter with extension hose from PCS outlet hose coupling

Note

1x spring clip, leave extension hose attached to drain and fill adaptor, Connection is at LH rear of HV battery

Connect coolant Leak Test Adaptor with hose to PCS outlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Leave the coolant Leak Test Fixture hose attached to the Leak Test Adaptor, Connection is at LH rear of HV Battery

Connect coolant Drain and Fill Adapter with extension hose to PCS inlet hose coupling

Note

1x spring clip, Make sure the locking tab is fully seated, Connection is at RH rear of HV battery

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Set timer for 2 minutes

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Start 2 minute timer

Note

Once timer is complete, select Stop Reset

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Disconnect compressed air from Leak Test Fixture tool

Disconnect coolant hose extension from coolant drain hose

Note

Press grey button to release hose fitting

Disconnect coolant hose extension from coolant Drain and Fill adaptor

Note

Press grey button to release hose fitting

Disconnect coolant drain hose adapter from PCS inlet hose coupling

Note

1x spring clip, Install plug to inlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Disconnect coolant Leak Test Fixture outlet hose from Leak Test Adapter

Note

1x hose connection

Disconnect coolant Leak Test Adaptor from PCS outlet hose coupling

Note

1x spring clip, Install plug to outlet hose coupling, If the battery is returned to Reman, please remove the special tool plugs

Lower vehicle fully

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Remove bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Remove bolts securing ancillary bay cover to HV battery

Note

18x bolts, E10 5-Lobe, 8 Nm, Use E10 5-Lobe socket without magnet, The fasteners are captive and will stay attached to the ancillary bay cover

Remove HVC logic cap

Note

1x logic cap

Remove ancillary bay cover from HV battery

Install HVC logic cap

Note

1x logic cap

Inspect ancillary bay for any missing insulators

Note

Install service insulator kit before continuing to next step

Remove bolts securing pyro disconnect to ancillary bay

Note

1x insulator, 2x patch bolts, 13mm, 9 Nm, Discard after removal

Remove pyro disconnect from ancillary bay

Note

1x connector, From the bottom, Lift pyro disconnect straight up and out of the ancillary bay

Install pyro disconnect dummy

Disconnect AC harness connector from PCS

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove AC Filter harness

Note

1x connector, 1x clip, 2x bolts, 8mm, 4.5 Nm, Pass harness under PCS hose, Release red locking tab, Discard bolts after removal

Disconnect HV controller connector X483 - BMB daisy B at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X482 - BMB daisy A at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X480 – Shunt at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X481 – Negative contactor sense at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X478 – Positive contactor sense at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X484 – Pyro disconnect at HVC from HV Controller

Note

1x connector

Disconnect HV controller connector X479 –Main HVC connector from HV Controller

Note

1x connector

Remove megaharness clips from HV controller hinge tray

Note

5x harness clips,1x tape, The harness tape needs to be carefully cut with insulating knife

Remove screws securing HVC tray assembly to ancillary bay

Note

2x screws, T25, 2 Nm, 3x wires routed through RH hinge

Remove HV controller and hinge tray from penthouse assembly

Position absorbent sheets below and around PCS coolant inlet hose to avoid excess coolant dripping

Disconnect PCS coolant inlet hose from PCS

Note

2x clips, 2x plugs, Insert the special tool away from the PCS, between the ancillary bay housing and the hose, There is not sufficient room to install the special tool on the PCS side, May cause damage to the tool or the hose retainers, Install plugs to PCS and hose

Disconnect PCS coolant outlet hose from PCS

Note

2x clips, 2x plugs, Use the special tool to release clips, Place absorbent sheet under hose to catch excess coolant, Visually inspect area for any coolant residue, Clean with shop towel if necessary, Install plugs to PCS and hose, Discard O-ring

Disconnect PCS to DC bus HV connector

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect PCS logic connector from PCS

Note

1x connector

Disconnect PCS LV connector from PCS

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Disconnect AC harness connector from PCS

Note

1x connector, Release the locking tab by pulling upward, May need plastic trim tool to help lift the connector upward

Remove bolts securing PCS to HV battery

Note

5x bolts, 8mm, 18 Nm, Ensure only the 8mm fasteners are removed, Do not remove the T30 fasteners

Secure suction cups to PCS

Note

Continue pressing plunger until red line is no longer visible

Lift PCS up and out of ancillary bay area and remove from vehicle

Note

Slightly tilt rear of PCS upward then lift out to remove, Inspect any missing insulators under PCS, Install any missing insulators before continuing to next step, Visually inspect area for any coolant residue, Clean with shop towel if necessary

Install PCS2 AC Filter harness

Note

1x connector, 1x clip, 2x bolts, 8mm, 4.5 Nm, Install new bolts, Engage locking tab

Position PCS2 into ancillary bay

Note

Ensure all busbar insulators beneath PCS are present, Slightly tilt rear of PCS upward and lower into position, Align datums into PCS holes

Remove suction cups from PCS2

Install bolts securing PCS2 to HV battery

Note

5x bolts, 8mm, 18 Nm

Connect PCS2 AC Filter harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 Lite 12V DC harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS logic pigtail on ancillary bay harness to PCS2

Note

1x connector

Secure PCS logic pigtail to HV Pos Contactor with harness edge clip

Note

1x clip, Secure edge band clip onto top of contactor assembly, Secure PCS logic pigtail to edge clip with cable tie, Cut off extra cable tie length

Connect PCS2 Lite HVDC harness connector to PCS2

Note

1x connector, Push connector downward then push the locking tab downward to install connector, Make sure the connector is fully seated

Connect PCS2 Lite coolant inlet hose to PCS2

Note

2x clips, Use caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated

Connect PCS2 Lite coolant outlet hose to PCS2

Note

2x clips, Caution not to damage the o-rings, Perform push-pull-push test to make sure coolant hose is fully latched, Then visually verify clip is fully seated

Position HV controller and hinge tray to penthouse assembly

Note

4x locating pins, 3x wires routed through RH hinge

Secure HVC tray assembly to ancillary bay

Note

2x screws, T25, 2 Nm

Install megharness clips to HV controller hinge tray

Note

5x harness clips, 1x tape, Wrap harness tape around the hinge tray again

Connect HV controller connector X479 –Main HVC connector to HV Controller

Note

1x connector

Connect HV controller connector X484 – Pyro disconnect at HVC to HV Controller

Note

1x connector

Connect HV controller connector X478 – Positive contactor sense at HVC to HV Controller

Note

1x connector

Connect HV controller connector X481 – Negative contactor sense at HVC to HV Controller

Note

1x connector

Connect HV controller connector X480 – Shunt at HVC to HV Controller

Note

1x connector

Connect HV controller connector X482 - BMB daisy A at HVC to HV Controller

Note

1x connector

Connect HV controller connector X483 - BMB daisy B at HVC to HV Controller

Note

1x connector

Remove pyro disconnect dummy

Clean mating surface of pyro

Note

Allow to 1 minute dry time, Use an IPA wipe to clean the HV mating surfaces of the shunt, Busbar, And the pyrotechnic battery disconnect

Set multimeter to "LoZ" (low impedance) mode

Measure voltage between busbar and shunt

Note

Measure the voltage between the busbar (left) and shunt (right) for at least 10 seconds, so as to balance the voltage across the pyrotechnic battery disconnect mount points, Note: The voltage displayed on the multimeter is not as important as balancing the mount points

Position pyro disconnect to ancillary bay for installation

Note

1x connector, While still measuring the voltage, Have an assistant position the pyrotechnic battery disconnect into the HV battery for installation. Make sure to align the pins of the connector with the new pyrotechnic battery disconnect, And then press the pyrotechnic battery disconnect down onto the busbars, The pyro disconnect can only be installed one way

Install bolts securing pyro disconnect to ancillary bay

Note

2x patch bolts, 13mm, 9 Nm, Install new patch bolt, Mark with paint pen

Measure resistance from module 2 busbar to pyro disconnect

Note

1x HV joint, 60μΩ or less, Perform zero adjust to Hioki meter prior to testing

Measure resistance from pyro disconnect to shunt

Note

1x HV joint, 45μΩ or less, Perform zero adjust to Hioki meter prior to testing

Remove service insulator kit

Remove HVC logic cap

Note

1x logic cap

Inspect ancillary bay walls for damage

Note

Any dent or depression in the sealing surface that causes it to not be flat will result in a leak, Any paint that comes off the ancillary bay wall, Whether or not it sticks to the seal, Will require enclosure leak test when reassembled, It can still be reused

Inspect ancillary bay cover seal to confirm it has no visual damage

Note

Image up close for clarity, Delaminated and torn seals cannot be reused

Wipe ancillary bay cover with IPA to clean surface

Note

Allow to 1 minute dry time

Position ancillary bay cover to HV battery for installation

Note

Ensure all accessible insulators are present, Wearing Electrical Protective Gloves is not necessary once all HV components are covered.

Remove leather over gloves and HV insulating gloves

Install bolts securing ancillary bay cover to HV battery

Note

18x bolts, EP10 5-Lobe, 8 Nm, Fasteners are captive, Follow torque sequence per image

Install bolts securing ancillary bay cover to HVC

Note

3x bolts, E10, 5 Nm + 30 degrees

Install positive LV output from PCS cable and torque nut securing it

Note

1x nut, 13mm, 9 Nm, Install new nut, Mark the nut after torque

Install positive LV output cover to PCS cable

Note

1x cover

Remove HVC logic cap

Note

1x logic cap

Install 3rd row NVH insulator

Note

1x connector, Install insulator then connect connector

Position 3rd row rear cabin carpet

Secure RH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

Secure LH side of 3rd row rear carpet

Note

2x clips, 2x location pins, 1x bolt, H11, Lift trim to access bolt, Secure carpet then install bolt

Install 3rd row LH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide LH seat cushion bolster into seat frame complete

Install 3rd row RH seat cushion bolster

Note

1x bolt, 11mm, 37 Nm, 1x location pin, 1x tab, Slide RH seat cushion bolster into seat frame complete

Install 3rd row seat cushion and connect harness

Note

1x connector, Secure 3rd row seat cushion into RH and LH latches

Raise vehicle fully and lower lift onto locks

Note

Set vehicle to comfortable working height, Ensure an audible click of locks on both sides is heard before lowering, Vehicle may tilt to the side if both locks are not engaged

Connect coolant Leak Test Adapter plug to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove rubber plug from PCS outlet hose coupling if present, Install 90 degree Leak Test Adaptor with NPT plug, Make sure the locking clip is fully seated

Connect coolant Leak Test Adaptor to PCS inlet hose coupling

Note

Remove rubber plug from coupler if installed, Make sure the locking clip is fully seated, Connection is at RH rear of HV Battery

Connect coolant Leak Test Fixture inlet hose to Leak Test Adapter

Note

Hand tighten hose connection, No tool required to tighten

Close both valves on the coolant Leak Test Fixture tool

Note

The valve knobs should both be perpendicular to the air lines when closed.

Connect compressed air to coolant Leak Test Fixture tool

Note

Air supply source should be above 50 psi

Open inlet valve on Leak Test Fixture tool then adjust regulator to 50 psi

Note

Turn on digital gauge and set to "psi", Turn inlet valve counter clockwise to open, Turn Regulator knob clockwise to increase pressure and counter clockwise to decrease pressure, Use caution as coolant may spill, Make sure to wear safety glasses

Open outlet valve on Leak Test Fixture tool.

Note

Open valve slowly, Valve knob should be inline with airline when open, Use caution as coolant may spill, Make sure to wear safety glasses

Allow pressure in PCS coolant loop to stabilize at 50 psi

Note

Pressure should settle around 50 psi

Set timer for 4 minutes

Record the PCS coolant loop leak check starting pressure

Note

Record the value shown on the digital gauge

Start 4 minute timer

Note

Once timer is complete, select Stop Reset

Record the PCS coolant loop leak check end pressure

Note

Record the value shown on the digital gauge after 4 minute timer is complete, Max delta between start and end pressures is 0.35 psi, Check coolant hose to see if it is fully seated if pressure test fails

Disconnect compressed air from Leak Test Fixture tool

Open inlet valve on Leak Test Fixture to discharge air from coolant system

Note

1x valve, Turn valve slowly to release air

Disconnect coolant Leak Test Fixture hose from Leak Test Adapter

Disconnect Leak Test Adaptor from PCS inlet hose coupling

Note

1x spring clip

Connect rear PT supply hose to PCS inlet hose coupling

Note

Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.

Disconnect Leak Test Adaptor plug from PCS outlet hose coupling

Note

1x spring clip, Connection located at LH rear of HV Battery

Connect RDU inverter inlet tube to PCS outlet hose coupling

Note

1x spring clip, 1x plug, Remove plugs, Perform push-pull-push test to make sure hose is fully engaged, Connection is located at LH rear of HV Battery, Vacuum fill required if > 1L lost during repair

Position HV battery rear skid plate enclosure

Note

Recommend assistance if needed

Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note

4x bolts, 13mm, 64 Nm

Install lower bolts securing HV battery rear skid plate enclosure

Note

2x bolts, EP10, 13 Nm

Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note

4x bolts, 13mm, 64 Nm

Install RH side hose clips to rear battery skid plate

Note

2x fir tree clips

Install LH side hose clip to rear battery skid plate

Note

1x fir tree clip

lnstall mid aero shield

Note

2x tabs, 11x bolts, 10mm, 5 Nm, Position rear datums first, Apply Loctite 222 onto rear aero shield bolts

Install LH and RH push clips securing mid aero shield to wheel house liner

Note

2x clips

Lower vehicle fully

Note

Raise lift off locks, Then hold lock release lever to keep locks free while vehicle is lowered

Place towel into front storage area

Note

Prevent front storage area pollution

Remove coolant bottle cap

Note

(*Use this step for Model Y vehicles with heat pump)

Place empty coolant container into front storage area

Fill container with coolant

Note

Do not draw in air during fill process, For RWD, The entire system requires coolant is 15L, for AWD, The entire system requires coolant is 18L

Place filled coolant container into front storage area

Install coolant reservoir adaptor cap onto coolant bottle assembly

Note

(*Use step for Model Y & NV36 coolant procedures)1x adaptor cap, Adaptor found in Vacuum Refill kit, turn clockwise to tighten cap onto coolant bottle

Setup vacuum refill tool

Note

Verify all valves on refill tool are in the closed position, See image for clarity

Connect vacuum refill hose to refill cap on coolant bottle

Note

Perform push-pull-push test to verify hose is fully engaged

Position overflow hose into empty container

Place refill hose inside filled coolant container

Note

Make sure hose end is fully submerged into coolant

Connect shop air supply to coolant refill tool

Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note

Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system

Slowly open refill valve to allow coolant to be drawn into system

Note

Make sure hose end of refill hose is fully submerged during entire process

Once gauge reads zero, close refill valve

Disconnect shop air supply from coolant refill tool

Remove coolant refill hose from coolant container

Remove coolant overflow hose from coolant container

Disconnect vacuum refill hose from refill cap on coolant bottle

Remove refill tool cap from coolant bottle assembly

Remove coolant refill tool from vehicle

Remove both coolant containers from inside underhood area

Connect first responder loop and LV battery

Note

2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated

Run ODIN routine UPDATE_CAN-REDEPLOYvia Service Mode Plus:

Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
Thermal ➜ HVAC ➜ CAN Redeploy
chassis ➜ DPB Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Post Replacement ➜ CAN Redeploy
chassis ➜ IDB Post Replacement ➜ CAN Redeploy
chassis ➜ RCU Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
chassis ➜ IBST Replacement Panel ➜ CAN Redeploy

via Toolbox:(link)

Access thermal system routines via UI

Note

Select service mode > Thermal

Run ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:

Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain

via Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain

via Toolbox:(link)

Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:

Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start

via Service Mode Plus:

Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge

via Toolbox:(link)

Coolant air purge run time

Note

Run time: 00:10:00, Subtract overlap time spent on other operations while waiting for coolant purge run

Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)

Inspect coolant level and top off as necessary

Note

Ensure that fluid level is at Max line, Vacuum fill required if greater than 1L lost during repair

Install coolant bottle cap

Install HEPA filter assembly

Note

2x bolts, 10mm, 10 Nm, Pivot forward edge down past frunk assembly, Then carefully move rear edge past brake reservoir and into position, Gently press on RH side of filter to seat seal onto duct, Do not pinch washer hose inbetween HEPA filter assembly and body

Install rear apron

Note

16x trim clips, 3x locator pins, 2x clips, Replace any missing or damaged clips, Ensure pyrotechnic hood actuators are aligned with openings in apron

Close hood

Install 40 seat into vehicle

Note

Recommend assistance, Do not support 40 seat by cushion pan, Support 40 seat by podium

Connect 2nd row 40 seat connector

Note

1x connector,

Install bolts securing 40 seat podium to vehicle hand tight

Note

2x patch bolts, 11mm, 37 Nm, Install new bolts, Torque at later step

Move 40 seat forward using towel bar

Note

pull up bar, slide seat forward

Install bolts securing 40 seat inner and outer tracks to vehicle

Note

2x patch bolts, 11mm, 37 Nm, Install new bolts

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Install cabin carpet to 40 seat

Torque bolts securing 40 seat podium to vehicle

Note

2x patch bolts, 11mm, 37 Nm

Install center track cover to 2nd row seats

Note

2x clip, Slide cover straight on to clip to 2nd row seat tracks

Install 40 seat outboard track cover

Note

1x clip

Position 40 seat into easy entry mode

Note

Press shoulder switch and push 40 seat forward

Install RH rear sill trim

Note

4x tabs, 3x clips, 5x location pins, Install rear edge of RH rear sill trim into trunk side trim and work your way forward securing clips

Reseat RH rear door seal

Note

Seat pillar and sill trim tabs underneath seal

Move 40 seat to original position

Note

Press shoulder switch then pull seat backward

Move RH front seat to original position

Install 2nd row 60 seat assembly

Note

Recommend assistance

Connect 2nd row 60 seat connector

Note

1x connector,

Install fasteners securing 60 seat frame to body

Note

5x patch bolts, 11mm, 37 Nm, Install new patch bolts, bottom seat bolts located in rear

Secure cabin carpet to 60 seat

Note

Strap velcro on

Return 2nd row 60 seatback to vertical position

Note

Via trunk seat switch, Remove seatback protection if necessary

Install 60 seat outboard track cover

Note

1x clip

Position 60 seat into easy entry mode

Note

Press shoulder switch and push 60 seat forward to position into easy entry mode

Install LH 7s lower C-pillar trim

Note

8x clips, Rear edge is secures onto trunk side trim, Secure rear clips then front clips

Reseat LH rear door seal

Note

Seat pillar and sill trim tabs underneath seal

Move 60 seat to original position

Move RH front seat to original position

Move LH front seat to original position

Raise all four windows

Note

Via LH front door switch

Run ODIN routine PROC_ICE_X_ENTER-SERVICE-MODEvia Toolbox:(link)

Unlock the vehicle gateway. See Gateway (Unlock).

Run ODIN routine PROC_VCLEFT_X_2R-SEAT-RECLINE-CALIBRATIONvia Service Mode:Low Voltage ➜ Second Row Seats ➜ Calibratevia Toolbox:(link)

Run ODIN routine PROC_ICE_X_EXIT-SERVICE-MODEvia Toolbox:(link)

Close all four doors

Note

If LV is powered up then unlatch rear doors before closing

Power Conversion System (7-Seat) (Remove and Replace)

Figure 1

Figure 2

Figure 3