Tesla Model 3: Power Conversion System- Remove

SPECIAL TOOLS

Connector Removal, Coolant, PCS, M3 (1111868-00-B)

Kit, Svc Plug, Cooling Hose, Model 3 (1135762-00-A)

Tool, Vacuum Cup, 3" x 6" (Qty 2) (1114917-00-A)

Resistance meter, microohm, Hioki RM 3548 (1076927-00-A)

Warning:

Only technicians who have been trained in High Voltage Awareness 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.

Remove

1. Drain the coolant from the power conversion system. See Penthouse Coolant (Drain and Refill).
2. Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).
3. Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).

4. Release the clips (x5) that attach the electrical harness to the hinge tray.

5. Raise the hinge tray vertically, pull up on the tray at each hinge, and then remove the tray from the vehicle.

7. Use the coolant connector removal tool to release the clips that attach the coolant input tube to the power conversion system, and remove the tube from the power conversion system. See Tube - Input - Coolant - Power Conversion System (Remove and Replace).
8. Install plugs into the coolant input port of the power conversion system and the open end of the coolant input tube.

9. Use the coolant connector removal tool to release the clips that attach the coolant output tube to the power conversion system, and remove the tube from the power conversion system. See Tube - Output - Coolant - Power Conversion System (Remove and Replace).
10. Install plugs into the coolant output port of the power conversion system and the open end of the coolant output tube.
11. Wipe around the power conversion system coolant ports, wipe the ends of the coolant tubes, and wipe up any spilled coolant.

Caution:

Spilled coolant can create an electrical path.

12. Remove the nut that attaches the positive terminal of the DCDC harness to the positive DCDC passthrough busbar.

13. Remove the nut that attaches the negative terminal of the DCDC harness to the negative DCDC passthrough busbar.

14. Release the clip and disconnect the DCDC harness from the power conversion system.

15. Disconnect the LV connector, the DC bus HV connector, and the HV battery AC inlet harness connector from the power conversion system.

16. Release the clips that attach the HV battery AC inlet harness to the power conversion system, and move the harness aside.

Vehicles Made Before 9/11/18 - 6-Bolts

Vehicles Made On 9/11/18 And Thereafter - 4-Bolts

18. With assistance, use suction cups to lift the power conversion system out of the penthouse.

Caution: Keep the power conversion system level as you lift it, to prevent spilling coolant.

19. Visually inspect the area from which the power conversion system was removed.

• If any of the insulators (x3) are missing from the busbar bolt heads, install the insulators now.
• If all of the insulators are installed, continue to the next step.

20. Remove the plugs from the power conversion system, drain the coolant into a coolant drain, and then replace the plugs.
21. Remove the absorbent pads from around the power conversion system coolant ports.

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