Tesla Model 3: Tube - Output - Coolant - Power Conversion System (Remove and Replace)

Tube - Input - Coolant - Power Conversion System- Remove

SPECIAL TOOLS

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

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

Drain the coolant from the power conversion system. See Penthouse Coolant (Drain and Refill).

Remove the pyrotechnic battery disconnect from the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).

Remove the high voltage controller. See Controller - High Voltage (Remove and Replace).

Release the clips that attach the harness to the hinge tray and hinges.

Raise the hinge tray and remove the hinge tray from the hinges.

Cut a slit halfway through 2 absorbent pads and surround each coolant input tube fitting with a pad.

Example of Coolant Connector Removal Tool Use

7. Use the coolant connector removal tool to spread the tube fitting clips wider than the barb on the power conversion system.
8. Pull up on the tool and the tube fitting together to disconnect the fitting from the power conversion system.
9. Repeat step 7 and step 8 for the other tube fitting at the battery flange.

10. Remove the tube from the vehicle.
11. Install a plugs into the power conversion system and the battery flange.
12. Wipe up any spilled coolant.

Caution:  Spilled coolant can create an electrical path

Tube - Input - Coolant - Power Conversion System- Install

Install

1. Wipe up any spilled coolant.

Caution:  Spilled coolant can create an electrical path.

O-rings in good condition

2. Make sure that the o-rings are not damaged and that they are properly seated in the connector groove prior to inserting the tube into the power conversion system. Replace components as necessary.

O-ring in poor condition

3. Lubricate the coolant input tube o-rings with Silaramic lubricant.
4. Remove the plugs from the power conversion system and the battery flange.

5. Install the coolant input tube into the power conversion system and the battery flange

Example of a Secure Connection

6. Firmly press down on the tube fittings, to make sure that the fittings are securely connected.

Caution:

Verify that both clips have fully engaged the barb on the power conversion system and battery flange, and then pull up on the fittings to check retention

7. Remove the absorbent pads from around the coolant input tube fittings, and wipe up any spilled coolant.

Caution:

Spilled coolant can create an electrical path.

8. Perform a penthouse coolant leak test. See Penthouse Coolant Leak Test.
9. Connect the 12V auxiliary battery negative terminal only. Torque 6 Nm

Caution:

Do not follow the procedure to connect 12V power at this time

10. Connect a 12V charger to the 12V auxiliary battery terminals
11. Refill the coolant. See Penthouse Coolant (Drain and Refill).
12. On the touchscreen, touch Controls > Safety & Security > Vehicle Power > Power Off.
13. Disconnect the 12V charger from the 12V auxiliary battery terminals.
14. Disconnect the 12V auxiliary battery negative terminal.
15. Install the hinge tray into the hinges, and then lower the hinge tray.
16. Fasten the clips that attach the harness to the hinge tray and hinges.
17. Install the high voltage controller. See Controller - High Voltage (Remove and Replace).
18. Install the pyrotechnic battery disconnect into the penthouse. See Pyrotechnic Battery Disconnect (Remove and Replace).