10/02/2017 09:09:31

Power Electronics Module (PEM) - Roadster 2.x

Correction code 39010802

Remove

  1. Isolate electrical system (refer to procedure).
  2. Disconnect APS 12V connector from PEM.
  3. Remove security screws (x4) securing access panel to PEM (torque - 3.5 Nm).
  4. Remove panel.
  5. Read safety information label.
  6. Lift safety label and open tags to retain in open position.
  7. Locate position of main power cables note these pass through a Toriod choke. (European vehicles only).
  8. Check for residual voltage using multimeter across terminals arrowed.
  9. If voltage is present STOP do not continue until multimeter reads low or zero voltage.
  10. Disconnect EV inlet pilot connector on rear side wall of PEM and position aside.
  11. Remove nut securing battery B+ power cable (torque 9 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Exercise caution to prevent metallic objects from falling into the Power Electronics Module (PEM) high-voltage access chamber.
  12. Remove nut securing battery B- power cable (torque 5 Nm).
  13. Remove Belleville washers noting fitted position for installation (convex side up).
  14. Disconnect cables from terminals (x2).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The plastic insulator can be easily damaged. Do not allow the bolts to press into the plastic. During reinstallation, hold the cables in place while tightening the nuts.
  15. Remove nuts from B+ and B- ground cables (torque 5 Nm).
  16. Collect Belleville washers (x2) and disconnect cables.
  17. Loosen cable gland nut and release waterproof grommet (torque 10 Nm).
  18. Wrap power cables with electrical tape, then withdraw power cables from PEM and collect Toroid choke.
  19. Fit insulators to high voltage cables immediately after removal.
  20. Inspect Toroid choke for damage (Replace if ceramic coating is chipped or cracked).
  21. Remove nuts (x3) securing charging cables to PEM (torque 5 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    To prevent damage, make sure that cables are aligned correctly with no excessive twist or bends.
  22. Collect Belleville washers (x3).
  23. Disconnect charging cables.
  24. Loosen cable gland nuts (x2) and release waterproof grommet (torque 10 Nm).
  25. Release cables from PEM.
  26. Disconnect ground strap from body (torque 5 Nm).
  27. Remove screws (x4) securing trunk access panel to PEM.
  28. Remove access panel.
  29. Remove screws (x4) securing warning notice panel.
  30. Remove notice panel.
  31. Remove nuts (x2) securing cable clamp (torque - 3.5 Nm).
  32. Remove cable clamp.
  33. Remove cable terminal screws (x3) (torque 9 Nm).
  34. Collect Belleville washers (x3).
  35. Disconnect cables from PEM and position aside.
  36. Remove bolt securing coolant tank to battery assembly and position aside (torque 5 Nm).
  37. Remove bolts (x3) securing RH side of PEM to body (torque - 3.5 Nm).
  38. Remove bolts (x3) securing LH side of PEM to body (torque - 3.5 Nm).
  39. Position a suitable material between PEM and rear bulkhead to prevent paint damage.
  40. Remove bolt securing RH side of PEM to body (torque 15 Nm).
  41. Remove bolt securing LH side of PEM to body (torque 15 Nm).
  42. Lift RH side of PEM and support on wooden block.
  43. Working through trunk aperture disconnect PEM logic and motor encoder connectors.
  44. Working from RH side of PEM release vertical latches then disconnect battery heater and blower fan connectors.
  45. Carefully raise LH side of PEM and support on wooden block.
  46. Release clip, slide PEM cooling duct intake inboard to release connecting tabs (x6) and pins (x5).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure not to damage components.

  47. Check cooling duct has fully released from underside of PEM.
  48. With assistance, remove PEM from vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure not to damage components.

Install

Installation procedure is the reverse of removal, except for the following:

  1. Spade terminal connections must be cleaned before connection.
  2. Follow the removal procedure as components are removed sequentially.
  3. Ferrite chokes must be installed to original positions if removed from cables.