Tesla Model S: DCDC Converter (Dual Motor) (Remove and Replace)
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 00 (500V) must be worn any
time a high voltage cable is handled. Refer to Tech Note
TN-15-92-003, "High Voltage Awareness Care Points" for additional
safety information.
Removal
- Disconnect 12V and HV power (refer to procedure).
- Remove the wiper motor (refer to procedure).
- Remove the LH and RH shock tower to bulkhead struts (refer to
procedure).
- Release the bolts (x2) that secure each fuse box to the front
crossmember (torque 5 Nm).
- If the vehicle is equipped with air suspension, release the
bolts (x2) that secure the air reservoir (torque 2.5 Nm). Carefully
set the reservoir in the RH side of the underhood area.
Note: It is not necessary to disconnect the air
lines.
- Remove the battery coolant heater (refer to procedure).
Caution: Do not allow coolant to spill onto the High
Voltage Battery, forward junction box, DCDC Converter,
battery coolant heater, or any harnesses.
Tip: After removing the heater, plug the upper coolant hose on
the DCDC converter and remove the clamp. This provides additional
clearance in the working area to remove the DCDC converter.
- Release the harnesses (x2) on the RH side of the DCDC converter.
Note: Before continuing, place a coolant catcher
underneath the vehicle and place suitable absorbent material around
the affected area.
- Clamp and release the lower hose on the DCDC converter.
- Release the bolts (x2) that secure the DCDC converter bracket to
the bulkhead (torque 22 Nm).
- Release the nut that secures the bracket on the lower LH side of
the DCDC converter (torque 22 Nm).
Caution: This nut is very difficult to retrieve if
dropped. It might be helpful to use a magnet to hold the nut
while it is being removed.
- Release the nut that secures the ground strap to the stud on the
bulkhead (torque 9 Nm).
- Release the ground bolt from the DCDC converter (torque 25 Nm).
- Release the 12V positive bolt from the DCDC converter (torque 13
Nm).
- Remove the DCDC converter from the vehicle.
Installation
Installation procedure is the reverse of removal, except for the
following:
- Transfer the top coolant hose to the new DCDC converter.
- Refill and bleed the cooling system (refer to procedure).
- If necessary, adjust the wipers (refer to procedure).
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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
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
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
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Tire performance is reduced in low ambient
temperatures, resulting in reduced grip and an increased
susceptibility to damage from impacts. Performance
tires (summer applications) have reduced traction in
ambient temperatures below 40º F (5º C), and are not
recommended in snow/ice conditions.
Check
Close panoramic roof glass using touch screen.
Connect a laptop with Toolbox to the vehicle.
In Toolbox, select Views > Body/Security >
Panoramic Sunroof, then select "Calibrate". The sunroof opens and
closes.
When calibration is complete