04/06/2024 18:03:52
Tube - Output - Coolant - Power Conversion System (Structural Pack) (Remove and Replace)
Correction code 16202302 3.12 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.
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 the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
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Remove butyl patches covering LH rocker access holes
Note2x butyl patches, Clean excess butyl from area
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Install lift pad adapters onto LH rocker
Note2x lift pad adapters
- Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove butyl patches covering RH rocker access holes
Note2x butyl patches, Clean excess butyl from area
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Install lift pad adapters onto RH rocker
Note2x lift pad adapters
- Open all four doors
- Lower all four windows
- Move LH front seat forward
- Move RH front seat forward
- Remove the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Remove the LH and RH lower c-pillar trims. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Remove the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
- Remove the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
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Raise and support vehicle
NoteVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
- Open hood
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
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Remove bolt securing frunk to washer fluid reservoir neck
Note1x bolt, 10mm, 5 Nm
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Release washer tank neck from washer tank and set aside
Note1x O-ring, No need to remove hose from neck
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Remove HEPA filter assembly
Note2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
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Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Disconnect LV battery connector and First Responder Loop
Note2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
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Verify operation of multimeter
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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Raise vehicle fully and lower lift onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
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Remove front aero shield
Note12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
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Remove push clips at left and right wheel house liner to mid aero shield
Note2x clips
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Remove mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
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Position coolant drain container underneath LH front of HV battery
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Disconnect PT supply hose at LH front side of vehicle
Note1x spring clip, Plug hose connections as needed
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Install PCS flush adapter onto PT supply hose
NoteRemove plugs as needed, Verify fully seated, Perform push-pull-push test
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Secure coolant cart flush hose to regulator and PCS flush adapter
NoteVerify regulator valve is closed, Pressure regulator is not adjustable
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Position coolant drain container underneath LH RDU area
NotePosition neck to catch all coolant loss
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Disconnect RDU inverter inlet hose from fluid coupling
Note1x spring clip, 2x plugs, Plug drive unit coupling
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Attach compressed air line to coolant pressure tester
NoteMake sure valve is closed on pressure regulator
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Slowly open valve on pressure regulator and allow coolant to drain out of HV battery
NoteAllow system to drain completely
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Close valve on pressure regulator once no coolant is draining from PT return hose
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Disconnect compressed air from coolant pressure tester
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Remove cart flush hose from PCS Flush adapter
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Remove PCS flush adapter from PT supply hose
Note1x spring clip, Plug hose connections as needed
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Remove coolant drain container from underneath vehicle
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Install amp clamp to RDU HV harness
NoteVerify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
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Release RDU HV harness from HV battery
Note1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
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Verify no high voltage at RDU HV header
NoteMake 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
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Lower vehicle until tires are touching the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Disconnect HVC logic connector and install logic cap
Note1x connector, 1x cap, Release locking tab then pivot handle downward to release connector
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Disconnect power connector to HV battery
Note1x connector, Pull locking tab upward then release connection
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Remove bolt securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Remove bolts securing charge port busbar kit to HV header
Note2x bolts, 10mm, 9 Nm
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Disengage LH body harness from rear body and move aside
Note1x clip
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Lift busbar kit connector to remove from HV header
NoteUse inflatable air bag to suspend busbar away from HV header during removal and installation
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Remove NVH insulation from ancillary bay cover
NoteMove insulation aside
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Remove fasteners securing ancillary bay cover to high voltage controller
Note3x bolts, E10, 10 Nm
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Release fasteners securing PCS LVDC header to ancillary bay cover
Note3x bolts, T20, 2.5 Nm
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Release fasteners securing charge port header to ancillary bay cover and remove doubler
Note2x bolts, 10 EPL, 10 Nm, Release charge port header from ancillary bay and remove plastic doubler, Take note of small tabs on shielding
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Release perimeter bolts securing ancillary bay to HV battery
Note22x captured bolts, EPL 10, 5 Nm
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Remove ancillary bay cover from HV battery
NoteRecommend assistance, Lift up on the RH side and pivot the cover, Maneuver away from body casting and charge port components and HV header
- Remove the pyrotechnic battery disconnect. See Pyrotechnic Battery Disconnect (Structural Pack) (Remove and Install).
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Release ancillary bay harness clip by PCS return hose
Note1x clip
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Release PCS return hose from PCS
Note1x hose, Carefully release PCS hose using the special tool, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required, Plug PCS
-
Release PCS return hose from coolant passthrough and remove assembly
Note1x hose, Carefully release PCS hose using the special tool, Rotate hose and lift HVC hinge as required for access, Be cautious and do not damage hose, No coolant will come out as the system was completely flushed, Use absorbent material only if required
-
Position PCS return hose for installation and secure onto coolant passthrough
Note1x hose, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated
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Secure PCS return hose onto PCS
Note1x hose, Carefully secure PCS hose, Perform push pull push test, Verify hose is fully seated
-
Secure ancillary bay harness clip by PCS return hose
Note1x clip
- 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).
-
Inspect ancillary bay phantom seal to verify no damage is present
NoteIf damage is present, Replace ancillary bay phantom seal
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Install ancillary bay cover onto HV battery
NoteRecommend assistance, Guide LH side of cover into position clearing HV header, Maneuver cover past body casting and into position with charge port components
-
Install perimeter bolts securing ancillary bay to HV battery
Note22x captured bolts, EPL 10, 5 Nm, Thread bolts in evenly and torque
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Secure doubler and install fasteners securing charge port header to ancillary bay cover
Note2x bolts, 10 EPL, 10 Nm, Secure doubler onto header and install bolts, Take note of small tabs on shielding
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Install fasteners securing PCS LVDC header to ancillary bay cover
Note3x bolts, T20, 2.5 Nm
-
Install fasteners securing ancillary bay cover to high voltage controller
Note3x bolts, E10, 10 Nm
-
Install NVH insulation onto ancillary bay cover
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Connect power connector to HV battery
Note1x connector, Push red locking tab down to secure connection
-
Connect HVC logic connector
Note1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
-
Clean busbar HV connector contact surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, It is necessary to clean HV connector during re-use of busbar
-
Clean HV connector contact surface of residual Penetrox
NoteAllow 1 minute dry time after removing Penetrox, New busbar comes with Penetrox applied to HV connector
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Apply Penetrox onto HV connector joints
NoteApply 2 drops of Penetrox A-13 about 5mm in diameter to either side of the hole on both leads, Spread evenly to verify the contact surface is fully covered
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Position busbar kit connector and lower onto HV header
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Install bolts securing charge port busbar kit to HV Header
Note2x bolts, 10mm, 9 Nm
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Perform Hioki resistance test at each HV joint from HV busbar lead to bolt head
Note2x HV joints, The acceptable resistance is between 0.050 mΩ (50 μΩ) and 0.195 mΩ (195 μΩ).If the resistance is greater than 0.195 mΩ (195 μΩ), there is too much resistance in the High Voltage joint. Remove the fastener, clean areas with isopropyl alcohol, install fastener back and test again.If the resistance is lower than 0.050 mΩ (50 μΩ), reposition the probes and measure again.If the resistance is repeatedly between 0.00 mΩ and 0.050 mΩ (50 μΩ), hioki test passed, proceed to next step
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Install fastener securing busbar cover access door
Note1x bolt, 10mm, 9 Nm
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Engage LH body harness onto rear body
Note1x clip
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Connect power connector to HV battery
Note1x connector, Push red locking tab down to secure connection
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Connect HVC logic connector
Note1x connector, Pivot handle upward to engage connector and secure locking tab, Remove cap if needed
-
Raise vehicle fully and lower lift onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Secure RDU HV harness onto HV battery
Note1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
- Remove HV insulating gloves
-
Secure closed end cap to RDU inverter inlet hose
Note1x hose, Plug hose with cap from the coolant hose plug kit, Plug hose so it will not leak air, Perform push-pull-push test
-
Secure coolant leak test adapter to PT supply hose
NoteThis adapter is connected to regulated air line adapter, Make sure the locking tab is fully seated, Perform push-pull-push test
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Secure pressure test fixture hose to leak test adapter
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Secure compressed air line to pressure test fixture
NoteMake sure valves are closed on pressure regulator
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Open the regulator valve then slowly adjust regulator to 50 psi
NoteUse caution due to high pressure, Make sure to wear safety glasses and personal protection equipment
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Open the 2nd valve slowly
NoteSlowly allow air to enter system
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Allow 1 minutes and 50 seconds for the pressure to stabilize
NoteAllow 1 minutes and 50 seconds (110 seconds) for pressure to stabilize
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Close the regulator valve
- Record start pressure value
- Allow 4 minutes to test
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Record end pressure value
NoteIf pressure did not drop more than 0.35 psi, continue to next step, If pressure dropped more than 0.35 psi, then inspect for leaks and retest
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Release compressed air line from pressure test fixture
-
Open the regulator valve slowly
NoteSlowly allow air to leave the system
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Release pressure test fixture hose from coolant leak test adapter
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Release coolant leak test adapter to PT supply hose
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Release closed end cap from RDU inverter inlet hose
-
Remove hose plugs and connect coolant inlet hose to rear drive unit
Note1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
-
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
-
Install push clips at left and right wheel house liner to mid aero shield
Note2x clips
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Connect PT supply hose at LH front side of vehicle
Note1x spring clip, Remove plugs as needed
-
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
Note12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
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Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle
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Remove coolant bottle cap
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Fill coolant to the proper level
NoteEnsure that the fluid level filled to the Max line
-
Connect first responder loop and LV battery
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
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Connect to vehicle using Toolbox 3.0
NoteVehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
- Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
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Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
NoteMake sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
- Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
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Inspect coolant level and top off as necessary
NoteEnsure that the fluid level is at the Max line
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Install coolant bottle cap
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Install HEPA filter assembly
Note2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
-
Secure washer tank neck onto washer tank
Note1x O-ring, Ensure washer hose is properly routed
-
Install bolt securing frunk to washer fluid reservoir neck
Note1x bolt, 10mm, 5 Nm
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Install the RH 2nd row seat back. See Seat Back - 2nd Row - RH (Remove and Replace).
- Install the RH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Install the LH 2nd row seat back. See Seat Back - 2nd Row - LH (Remove and Replace).
- Install the LH lower c-pillar trim. See Trim - C-Pillar - Lower - LH (Remove and Replace).
- Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Move LH front seat to original position
- Move RH front seat to original position
- Raise LH front window
- Close LH front door
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Remove lift pad adapters from RH rocker
Note2x lift pad adapters
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Install butyl patches onto RH rocker access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
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Remove lift pad adapters from LH rocker
Note2x lift pad adapters
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Install butyl patches onto LH rocker access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).