25/03/2024 17:27:30

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

Correction code 16301002 2.58 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.

  • 2023-06-08: Corrected the step at the end of the Installation procedure to disconnect charger/LV maintainer rather than disconnecting 12V/LV battery.
  • 2024-02-20: Replace the steps of high voltage controller removal with steps of pivoting the controller upwards and securing it with a bungee strap.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning

Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

Install

  1. Perform a zero adjust of the Hioki resistance meter in preparation to measure resistances later in this procedure. See Resistance Meter (Zero Adjust).
  2. Remove the shipping plugs from the replacement power conversion system.
  3. Tilt the power conversion system and drain the shipping water into a coolant drain.
  4. Refit the shipping plugs.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the plugs again until instructed.
  5. Install the power conversion system. See Power Conversion System (Non-Structural Pack) (Remove and Install).
    Informational PurposesAn informational icon, calling your attention
    Note
    Back to the current procedure after connecting the 12V charger/LV maintainer.
  6. With an assistant checking the power conversion system for leaks, top off the superbottle.
  7. Connect a laptop with Toolbox to the vehicle.
  8. In Toolbox, type "vcfront" into the search field.
  9. Select the ODIN routine TEST-RESET_VCFRONTvia Toolbox: (link)via Service Mode Plus:
    • Low Voltage ➜ Power Distribution ➜ Reset VCFRONT
    • Mid Voltage ➜ Power Distribution ➜ Reset VCFRONT
    , and then click RUN.
  10. Select the ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via 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
    , and then click RUN.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the vehicle is not in Drive.
    Informational PurposesAn informational icon, calling your attention
    Note
    The test will last for approximately 10 minutes. Monitor and keep the superbottle topped off while the test is running. Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. If pump speeds stay above 6900 rpm, there is still air entrapped in the system; run a cooling system vacuum refill.
  11. When the air purge is complete, top off the superbottle, and then install the superbottle cap.
  12. Disconnect the laptop from the vehicle.
  13. Power off the vehicle from the touchscreen.
  14. Remove the 12V charger from the 12V auxiliary battery terminals or disconnect the LV maintainer from the vehicle. See LV Maintainer (Connect and Disconnect).
  15. Depending on the vehicle configuration, choose one of the following:
    • If the vehicle is equipped with a lead-acid 12V auxiliary battery, disconnect the 12V auxiliary battery negative terminal.
    • If the vehicle is equipped with a Li-ion LV auxiliary battery, disconnect the LV battery connector from the LV battery.
  16. Inspect and put on PPE including the HV insulating gloves and leather over gloves.
  17. Release the bungee strap from the high voltage controller and rear RH seat headrest, and then lower the controller into the ancillary bay.
  18. Measure the voltage across the pyrotechnic battery disconnect mount points, and then install the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Remove and Replace).
  19. Install the ancillary bay cover. See Cover - Ancillary Bay (Remove and Replace).
  20. Remove the leather over gloves and the HV insulating gloves.
  21. Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
  22. Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
  23. Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  24. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  25. Perform a software CAN redeploy. See Software Reinstall - Toolbox.
  26. After the software CAN redeploy is complete, remove the 12V charger from the 12V auxiliary battery terminals or disconnect the LV maintainer from the vehicle. See LV Maintainer (Connect and Disconnect).
  27. Install the rear apron. See Underhood Apron - Rear (Remove and Replace).
  28. Raise all windows and close all doors.
  29. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.