2025-07-03

功率转换系统（结构化电池组）（拆卸和更换）

校正代码 16301012 2.88 注意：除非本程序中另有明确规定，否则上述校正代码和 FRT 反映的是执行本程序（包括关联程序）所需的所有工作。除非明确要求，否则请勿堆叠校正代码。 注意：请参阅平均维修工时，深入了解 FRT 及其创建方式。要提供有关 FRT 值的反馈，请发送电子邮件至 ServiceManualFeedback@tesla.com。。 注意：请参阅人员保护，确保在执行以下程序时穿戴适当的个人防护装备 (PPE)。

2025-05-20: Revised procedure to latest procedure validation.
2023-09-18: Updated torque information.

Remove

Open all doors and lower the windows.
Enable Service Mode. See 维护模式.
通过“维护模式”或 Toolbox 执行以下例行程序（请参阅0005 - 维护模式）：
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT
via Toolbox: (link)via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
Unlock the vehicle gateway. See 网关（解锁）.
Remove the LH 2nd row seat back. See 座椅靠背 - 第二排 - LH（拆卸和更换）.
Remove the RH 2nd row seat back. See 座椅靠背 - 第二排 - RH（拆卸和更换）.
Remove the HEPA filter duct. See 风管 - 高效分子空气 (HEPA)（拆卸和更换）.
Disconnect LV power. See 12V/低压电源（断开和连接）.
Remove the mid aero shield. See 面板 - 流线型护板 - 后部（拆卸和更换）.
Position a coolant drain container under the rear of the vehicle.
Release the PCS supply hose.

注
Plug coolant connections as needed.
Release PCS return hose.

注
Plug coolant connections as needed.
Set up the enclosure leak tester attachments for the PCS coolant flush.

注
Fit onto enclosure leak tester and coolant drain hose.
Connect the enclosure leak tester attachment onto the PCS return hose.
Connect the enclosure leak tester attachment onto the PCS supply hose.
Close both valves on the regulator.
Connect air supply to the regulator.
Turn the RH side regulator valve to the open position.
Set the regulator pressure to 5.0 psi.
Slowly open the LH side regulator valve and allow the coolant to completely drain.

注
Hold the HV battery RH front inlet hose over the fluid catcher. Let the regulator hose hang off the vehicle as needed. Allow about 15 l of coolant to drain from the vehicle.
Close the valves on the regulator once no more coolant is draining from the HV battery RH front inlet port and hose.
Disconnect air supply from the regulator.
Disconnect the enclosure leak tester attachment from the PCS supply hose.

注
Plug coolant connections as needed.
Disconnect the enclosure leak tester attachment from the PCS return hose.

注
Plug coolant connections as needed
Remove the coolant drain container from underneath the vehicle.
Perform the vehicle HV disablement procedure. See 车辆高压禁用程序（结构化电池组）.
Remove the ancillary bay cover. See 盖板 - 高压电池仓（结构化电池组）（拆卸和更换）.
Remove the pyrotechnic battery disconnect. See 烟火电池断接开关（结构化电池组）（拆卸和安装）.
Disconnect the HVC connectors (x7).

注
Lift hinge upwards to release levered connection
Release the ancillary bay harness from the HVC hinge tray.

注
3x clips, 3x guides. Move harness aside as needed.
Remove the HVC hinge tray assembly from the ancillary bay.

注
2x hinge supports. Release tray from supports, and then remove the assembly.
Disconnect the PCS to DC bus HV connector.

注
Release the locking tab by pulling it upward. You may need a plastic trim tool to help lift the connector upward.
Disconnect the PCS logic connector from the PCS.
Disconnect the PCS LV connector from the PCS.

注
Release the locking tab by pulling upward. You may need a plastic trim tool to help lift the connector upward.
Disconnect the AC filter harness.

注
Release the locking tab by pulling upward. You may need a plastic trim tool to help lift the connector upward.
Release the PCS supply hose from the PCS.

注
Carefully release the PCS hose using the special tool. Be cautious and do not damage the hose. No coolant will come out as the system was completely flushed. Use absorbent material if required. Plug the PCS.
Remove the ancillary bay harness clip at the PCS return hose.
Release the PCS return hose from the PCS.

注
Carefully release the PCS hose using the special tool. Be cautious not to damage the hose. No coolant will come out as the system was completely flushed. Use absorbent material if required. Plug PCS.
Remove the bolts (x6) that attach the PCS to the HV battery.

注
Make sure that only the 8mm bolts are removed. Do not remove the T30 fasteners.
Attach suction cups onto the PCS.
Remove the PCS from the vehicle.

注
Assistance recommended. Carefully lift the PCS up and remove it from the vehicle.
Remove the suction cups from the old PCS.

Install

Install suction cups onto the new PCS.
Position PCS into vehicle

注
Assistance recommended. Carefully lift PCS up and position it into vehicle, making sure it is correctly oriented.
Install the bolts (x6) that attach the PCS to the HV battery.
6 Nm (4.4 lbs-ft)
Remove the PCS plugs (x2) from the new PCS.
Install the PCS return hose to the PCS.

注
Perform a push pull push test to make sure that the hose is fully seated.
Install the ancillary bay harness clip of the PCS return hose.
Attach the PCS supply hose to the PCS.

注
Perform a push pull push test to make sure that the hose is fully seated.
Connect the PCS to fastcharge contactor HV harness connector.
Connect the PCS LV connector to the PCS.
Connect the PCS logic connector to the PCS.
Connect the PCS to DC bus HV connector.
Position the HVC hinge tray onto the hinge clips and install it into the vehicle.

注
Take note of the way the harness routes over the hinge.
Connect the HV controller connectors (x7).
Secure the harness clips (x3) onto the HVC hinge tray and route the harness.

注
Attach the harness onto the guides and secure the clips.
测量烟火电池隔离开关安装点间的电压，然后安装烟火电池隔离开关。请参阅烟火电池断接开关（结构化电池组）（拆卸和安装）。
Install the ancillary bay cover. See 盖板 - 高压电池仓（结构化电池组）（拆卸和更换）.
Fully raise the vehicle.
Connect the RDU HV harness onto the HV battery.

注
Make sure that the lever is in the upright and open position. Carefully seat the connector and allow the lever to engage. Fully secure the lever and verify red tab is locked. Take care not to damage any pins.
Install the closed end cap to the RDU inverter inlet hose.

注
Plug hose with cap from the coolant hose plug kit. Plug the hose so it will not leak air. Perform a push-pull-push test.
Attach the coolant leak test adapter to the PT supply hose.

注
This adapter is connected to the regulated air line adapter. Make sure the locking tab is fully seated. Perform push-pull-push test
Attach the pressure test fixture hose to the leak test adapter.
Attach the compressed air line to the pressure test fixture.

注
Make sure that the valves on the pressure regulator are closed.
Open the regulator valve, and then slowly adjust the regulator to 50 psi.

注
Make sure to wear safety glasses and appropriate personal protection equipment.
Slowly open the 2nd valve.
Allow 2 minutes for the pressure to stabilize.
Close the regulator valve.
Record the start pressure value.
Allow 4 minutes to test.
Record the end pressure value.

注
If the pressure did not drop more than 0.35 psi, continue to the next step. If pressure dropped more than 0.35 psi, then inspect for leaks and retest.
Release the compressed air line from the pressure test fixture.
Slowly open the regulator valve to allow air to leave the system.
Release the pressure test fixture hose from the coolant leak test adapter.
Release the coolant leak test adapter from the PT supply hose.
Remove the closed end cap from the RDU inverter inlet hose.
Remove the hose plugs and connect the coolant inlet hose to the rear drive unit.

注
Perform a push-pull-push test to make sure that the hose is fully seated.
Install the PT supply hose at the LH front side of the vehicle.
Install the mid aero shield panel. See 面板 - 流线型护板 - 后部（拆卸和更换）.
Fill coolant to the Max line.
Connect the first responder loop and leave the LV battery disconnected.
Perform a cooling system vacuum refill. See 冷却系统（真空再加注）.
Connect a LV maintainer. See 低压维护设备（连接和断开）.
通过“维护模式”或 Toolbox 执行以下例行程序（请参阅0005 - 维护模式）：
UPDATE_CAN-REDEPLOY
via Toolbox: (link)via Service Mode Plus:
Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
Thermal ➜ HVAC ➜ CAN Redeploy
chassis ➜ DPB Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Post Replacement ➜ CAN Redeploy
chassis ➜ IDB Post Replacement ➜ CAN Redeploy
chassis ➜ RCU Post Replacement ➜ CAN Redeploy
chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
Connect the LV battery connector.
Disconnect the LV maintainer. See 低压维护设备（连接和断开）.
Install the HEPA filter assembly. See e总成 - 过滤器 - HEPA 空调滤清器（拆卸和安装）.
Install the rear underhood apron. See 前备箱挡板 - 后部（拆卸和更换）.
Install the RH 2nd row seat back. See 座椅靠背 - 第二排 - RH（拆卸和更换）.
Install the RH lower c-pillar trim. See 饰板 - C 柱 - 下 - LH（拆卸和更换）.
Install the LH 2nd row seat back. See 座椅靠背 - 第二排 - LH（拆卸和更换）.
Install the LH lower c-pillar trim. See 饰板 - C 柱 - 下 - LH（拆卸和更换）.
Install clips securing rear main cabin carpet to vehicle

注
3x push clips
Install the 2nd row lower seat cushion. See 座椅座垫 - 下部 - 第二排（拆卸和更换）.
Exit Service Mode. See 维护模式.