2025-05-20

Power Conversion System (Structural Pack) (Remove and Replace)

Correction code 16301012 2.88 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 ServiceManualFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

  • 2025-05-20: Revised procedure to latest procedure validation.
  • 2023-09-18: Updated torque information.

Remove

  1. Open all doors and lower the windows.
  2. Enable Service Mode. See Service Mode.
  3. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANTvia Toolbox: (link)via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
  4. Unlock the vehicle gateway. See Gateway (Unlock).
  5. Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  6. Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  7. Remove the HEPA filter duct. See Duct - HEPA (Remove and Replace).
  8. Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
  9. Remove the mid aero shield. See Panel - Aero Shield - Rear (Remove and Replace).
  10. Position a coolant drain container under the rear of the vehicle.
  11. Release the PCS supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug coolant connections as needed.
  12. Release PCS return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug coolant connections as needed.
  13. Set up the enclosure leak tester attachments for the PCS coolant flush.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fit onto enclosure leak tester and coolant drain hose.
  14. Connect the enclosure leak tester attachment onto the PCS return hose.
  15. Connect the enclosure leak tester attachment onto the PCS supply hose.
  16. Close both valves on the regulator.
  17. Connect air supply to the regulator.
  18. Turn the RH side regulator valve to the open position.
  19. Set the regulator pressure to 5.0 psi.
  20. Slowly open the LH side regulator valve and allow the coolant to completely drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hold the HV battery RH front inlet hose over the fluid catcher. Let the regulator hose hang off the vehicle as needed. Allow about 15 l of coolant to drain from the vehicle.
  21. Close the valves on the regulator once no more coolant is draining from the HV battery RH front inlet port and hose.
  22. Disconnect air supply from the regulator.
  23. Disconnect the enclosure leak tester attachment from the PCS supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug coolant connections as needed.
  24. Disconnect the enclosure leak tester attachment from the PCS return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug coolant connections as needed
  25. Remove the coolant drain container from underneath the vehicle.
  26. Perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure (Structural Pack).
  27. Remove the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  28. Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  29. Disconnect the HVC connectors (x7).
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift hinge upwards to release levered connection
  30. Release the ancillary bay harness from the HVC hinge tray.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 3x guides. Move harness aside as needed.
  31. Remove the HVC hinge tray assembly from the ancillary bay.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x hinge supports. Release tray from supports, and then remove the assembly.
  32. Disconnect the PCS to DC bus HV connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling it upward. You may need a plastic trim tool to help lift the connector upward.
  33. Disconnect the PCS logic connector from the PCS.
  34. Disconnect the PCS LV connector from the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. You may need a plastic trim tool to help lift the connector upward.
  35. Disconnect the AC filter harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the locking tab by pulling upward. You may need a plastic trim tool to help lift the connector upward.
  36. Release the PCS supply hose from the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the PCS hose using the special tool. Be cautious and do not damage the hose. No coolant will come out as the system was completely flushed. Use absorbent material if required. Plug the PCS.
  37. Remove the ancillary bay harness clip at the PCS return hose.
  38. Release the PCS return hose from the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully release the PCS hose using the special tool. Be cautious not to damage the hose. No coolant will come out as the system was completely flushed. Use absorbent material if required. Plug PCS.
  39. Remove the bolts (x6) that attach the PCS to the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that only the 8mm bolts are removed. Do not remove the T30 fasteners.
  40. Attach suction cups onto the PCS.
  41. Remove the PCS from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance recommended. Carefully lift the PCS up and remove it from the vehicle.
  42. Remove the suction cups from the old PCS.

Install

  1. Install suction cups onto the new PCS.
  2. Position PCS into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Assistance recommended. Carefully lift PCS up and position it into vehicle, making sure it is correctly oriented.
  3. Install the bolts (x6) that attach the PCS to the HV battery.
    6 Nm (4.4 lbs-ft)
  4. Remove the PCS plugs (x2) from the new PCS.
  5. Install the PCS return hose to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push pull push test to make sure that the hose is fully seated.
  6. Install the ancillary bay harness clip of the PCS return hose.
  7. Attach the PCS supply hose to the PCS.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push pull push test to make sure that the hose is fully seated.
  8. Connect the PCS to fastcharge contactor HV harness connector.
  9. Connect the PCS LV connector to the PCS.
  10. Connect the PCS logic connector to the PCS.
  11. Connect the PCS to DC bus HV connector.
  12. Position the HVC hinge tray onto the hinge clips and install it into the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the way the harness routes over the hinge.
  13. Connect the HV controller connectors (x7).
  14. Secure the harness clips (x3) onto the HVC hinge tray and route the harness.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the harness onto the guides and secure the clips.
  15. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
  16. Install the ancillary bay cover. See Cover - Ancillary Bay (Structural Pack) (Remove and Replace).
  17. Fully raise the vehicle.
  18. Connect the RDU HV harness onto the HV battery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and verify red tab is locked. Take care not to damage any pins.
  19. Install the closed end cap to the RDU inverter inlet hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Plug hose with cap from the coolant hose plug kit. Plug the hose so it will not leak air. Perform a push-pull-push test.
  20. Attach the coolant leak test adapter to the PT supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    This adapter is connected to the regulated air line adapter. Make sure the locking tab is fully seated. Perform push-pull-push test
  21. Attach the pressure test fixture hose to the leak test adapter.
  22. Attach the compressed air line to the pressure test fixture.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that the valves on the pressure regulator are closed.
  23. Open the regulator valve, and then slowly adjust the regulator to 50 psi.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure to wear safety glasses and appropriate personal protection equipment.
  24. Slowly open the 2nd valve.
  25. Allow 2 minutes for the pressure to stabilize.
  26. Close the regulator valve.
  27. Record the start pressure value.
  28. Allow 4 minutes to test.
  29. Record the end pressure value.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the pressure did not drop more than 0.35 psi, continue to the next step. If pressure dropped more than 0.35 psi, then inspect for leaks and retest.
  30. Release the compressed air line from the pressure test fixture.
  31. Slowly open the regulator valve to allow air to leave the system.
  32. Release the pressure test fixture hose from the coolant leak test adapter.
  33. Release the coolant leak test adapter from the PT supply hose.
  34. Remove the closed end cap from the RDU inverter inlet hose.
  35. Remove the hose plugs and connect the coolant inlet hose to the rear drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  36. Install the PT supply hose at the LH front side of the vehicle.
  37. Install the mid aero shield panel. See Panel - Aero Shield - Rear (Remove and Replace).
  38. Fill coolant to the Max line.
  39. Connect the first responder loop and leave the LV battery disconnected.
  40. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  41. Connect a LV maintainer. See LV Maintainer (Connect and Disconnect).
  42. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): UPDATE_CAN-REDEPLOYvia Toolbox: (link)via 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
  43. Connect the LV battery connector.
  44. Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
  45. Install the HEPA filter assembly. See eAssembly - Filter - HEPA (Remove and Install).
  46. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  47. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  48. Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  49. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  50. Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
  51. Install clips securing rear main cabin carpet to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  52. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  53. Exit Service Mode. See Service Mode.