23/07/2024 17:33:18

Rear Drive Unit Assembly - Tri Motor - Drive Inverter Assembly - LH (Remove and Replace)

Correction code 4020092032 FRT 2.16 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

2024-05-01: Updated the "Resolver Error Lean" procedure, and added a 'Note" to the leak test adapter to make sure the surfaces are clean and free to debris, and the adapter is fully seated to prevent false test failure.

Remove

Open the LH front door and lower the LH front window.
Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
Unlock the vehicle gateway. See Gateway (Unlock).
On the vehicle touchscreen, navigate to Service Mode Plus > High Voltage.
Tap Procedures.
Tap Rear Left Drive Inverter Replacement.

Note
If replacing the right rear inverter, then tap Rear Right Drive Inverter Replacement instead.
Tap Store Boot + App Data and Start Fluid Fill/Drain, tap Run, and allow the routine to complete.
Open the tonneau cover.
Open the tailgate.
Open the powered frunk.
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Remove the bed cargo tub struts. See Tonneau - Bed Cargo Tub Strut (Remove and Install).
Remove the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
Remove the truck bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
Remove the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
Remove the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
Remove the LH bed side wall. Repeat this step for RH side.

Note
Recommend assistance.

Note
x1 bolt, 15 mm, 46 Nm; x2 bolts, T45, 36 Nm; x4 bolts, 10 mm, 11 Nm; x2 nuts, 10 mm, 7 Nm; x4 clips, x1 fastener cover, x1 electrical connector.

Note
Release the locking tabs.

Note
Disconnect the bed outlet electrical connectors from the bed side wall and ground strap; x1 bolt, 10 mm, 10 Nm

Note
x2 electrical connectors. Release the locking tabs. Slide lock to release
Remove the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
Lower the vehicle until the tires are touching the ground.
Position the coolant catcher below the rear drive unit.
Release the LH RDU inverter to the heat exchange hose from the inverter.

Note
x1 clip, x1 hose.

Note
Plug both ends. Use a flathead screwdriver to release the clip on the hose, and then release hose. Move aside as needed.

Note
Use a shop towel to clean and remove remaining coolant residue from the inverter.
Release the RDU supply hose from the rear drive unit.

Note
x2 clip, x2 hose

Note
Plug both ends. Use a flathead screwdriver to release the clip on the hose, and then release the hose. Move aside as needed. Use a shop towel to clean and remove remaining coolant residue from the inverter.
Remove the bolts (x2) that attach the LH RDU HV harness onto the rear drive unit.
11 Nm (8.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Disconnect the LH RDU HV cable from the rear drive unit.

Note
Disengage the locking tab, and then release the connector body. Move aside as needed.
Disconnect the LH RDU logic electrical connector.

Note
x1 harness clip\

Note
Release the locking tab.

CAUTION
Do not get coolant ingress into this connector.

Note
Move aside as needed.
Remove the label from the phase cover.

Note
Discard the label after removal.
Remove the bolts (x2) that attach the phase out cover to the front drive unit.
Note
torque: 5 Nm +20 deg
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
Remove the phase out cover.

Note
Use a plastic trim tool to aid in removal.

CAUTION
If the phase out cover or O-rings are damaged, then replace it with a new one.
Remove the bolts (x3) that attach the inverter to the 3 phase busbars.
Note
torque: 5 Nm +40 deg
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
CAUTION
Do not drop fasteners.
Put on ESD wrist strap and secure it to inverter housing
Remove and discard the bolts (x9) that attach the LH inverter to the rear drive unit.
Note
torque: 6 Nm +20 deg
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
Note
Discard the bolts after removal.
Remove the LH inverter from the rear drive unit, and then drain the coolant from the inverter.

Note
Gasket is one time use.

CAUTION
Avoid damage to the PCBA.
Put the inverter on the ESD mat.
Remove the ESD wrist strap from the old inverter.

Install

Prepare the new inverter.

Note
Save packaging to MRB the old inverter.

Note
Remove any red protective covers.
Secure the ESD strap onto the new inverter housing.
Wipe the HV cable lugs to ensure contact surfaces are free of debris with an Isopropyl Alcohol (IPA) wipe.

Note
Allow 1 minute dry time.
Thread in and flush the new bolts (x9) that attach the inverter to the rear drive unit.
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
Note
Thread in the bolts fasteners until they are flush.

Note
Follow the run down sequence.

CAUTION
Do not overtighten the bolts.

Note
Tightening of the bolts will be performed in the next step.
Tighten the bolts (x9) that attach the inverter to the rear drive unit.
Note
torque: 6 Nm + 20deg
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
CAUTION
Follow the tightening sequence as shown.
Install new bolts (x3) that attach the inverter to the 3 phase lugs.
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Note
Torque to 12.5 Nm, then reverse 180 degrees, and then torque to 5 Nm + 40 degrees.

Note
Install new bolts.

CAUTION
Bolts must be pre-conditioned to the sequence shown.
Install the phase out cover.

Note
If phase out cover or O-rings is damaged, then replace it with a new one.
Install the bolts (x2) that attach the phase out cover to the rear drive unit.
Note
torque: 5 Nm + 20deg
Tip: Use of the following tool(s) is recommended:
- External Torx Plus EP10
Install a new label to the LH phase out cover.
Remove the ESD wrist strap from the inverter.
Take the old inverter and prepare for MRB. Label properly for return or disposal.

Note
Use ESD wrist strap. Label inverter for MRB and return to packaging. Secure any protective red caps. Return or dispose of packaging through proper channels. Label the part as MRB.
Install the leak test adapter plug (1450875-00-A) to the electrical connector at the drive inverter.

Note
Make sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
Install the leak test adapter to the RDU HV electrical connector.

Note
Make sure the surfaces are clean, free debris, and the adapter is fully seated otherwise a false test failure may occur.
Connect regulator to adapter at the HV connector.
Close both valves on the regulator test tool.
Connect regulator to air supply.
Turn on regulator and open valve closest to regulator.
Set regulator to 1 psi.
Open the 2nd valve to inject air.

Note
Close valve when pressure reaches 1 psi and stable
Wait 45 seconds for the pressure to settle.
Record start pressure valve.
Wait 60 seconds for test.
Record end pressure valve.

Note
If pressure did not drop more than 0.04 psi, continue to next step. If pressure dropped more than 0.04 psi, then inspect for leaks.
Disconnect air supply from regulator tool
Disconnect regulator from leak test adapter at the HV connector.
Remove leak test adapter from the HV connector.
Remove leak test adapter plug from 12V connector at inverter - placeholder
Connect the LH RDU logic connection.

Note
x1 harness clip

Note
Verify the lever is fully engaged.
Connect the LH RDU HV connector.

Note
Engage the locking tab.
Install the bolts (x2) that attach the LH RDU HV harness onto the rear drive unit.
11 Nm (8.1 lbs-ft)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Secure the RDU supply hose onto the inverters.

Note
x2 clip, x2 hose

Note
Re secure the clip if it is detached from the hose. Engage the hose and verify the hose is fully and properly secured. Perform a push-pull-push test.
Secure the LH inverter to heat exchange hose from the drive inverter.

Note
x1 clip, x1 hose.

Note
Re secure the clip if it is detached from hose. Engage the hose and verify the hose is fully and properly secured. Perform a push-pull-push test.
Remove coolant catcher from below vehicle
Remove coolant bottle cap
Install vacuum refill cap onto coolant bottle assembly
Place empty coolant container into front storage area

Note
If frunk is not installed take caution, CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
Fill container with at least 15L of coolant
Place filled coolant container onto coolant drain & fill cart

Note
Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle
Setup coolant refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose to refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Position overflow hose into empty container
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
Slowly open the refill valve to allow coolant to be drawn into the system

Note
Make sure hose end of refill hose is fully submerged during entire process
Once the gauge reads zero, close the coolant refill valve
Remove shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove vacuum refill cap from coolant bottle assembly
Remove coolant refill tool from vehicle

Note
Move coolant drain & fill cart away from vehicle
Remove coolant container from inside underhood area
Reconnect MV power. See Disconnect MV Power.
Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete

Note
Select 'Close' once complete
Select "Restore Bootloader Data after Perform CAN Redeploy", click "Run", and allow routine to complete

Note
Select 'Close' once complete
Select "Restore Application Data", click "Run", and allow routine to complete

Note
Select 'Close' once complete
Select ‘Coolant Air Purge’, click ‘Run’, and allow routine to complete
Select ‘Thermal System Performance Test ’, click ‘Run’, and allow routine to complete

Note
Select 'Close' once complete
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Close the powered frunk.
Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn.

Note
Use safety stanchions to section off vehicle before driving vehicle on a lift.
Partially raise the vehicle.
Touch Resolver Error Learn, and then touch Run. Allow the routine to complete.

Warning
Read the instructions thoroughly. Follow the appropriate safety precautions. Vehicle needs to be driven on a lift. Verify the wheels are clear of contacting the ground.

Note
Vehicle software must be 2022.16.2 or later for the routine to operate.
1. Shift into Drive within 10 seconds of starting this routine.
2. Gently and gradually press the accelerator pedal (feathered) until the required speed has been reached.
  
  CAUTION
  Pressing the accelerator pedal too firmly may result in failure of the routine which requires running the routine again.
  
  Note
  The required speed varies depending on the conditions and is top-limited by the routine procedure.
3. Keep the accelerator pedal pressed until the motor starts to slow down on its own.
4. After the speedometer reaches 0 MPH, press the brake pedal and shift into Park.
  
  CAUTION
  Do NOT press the brake pedal during coast down. Brake softly if canceling the routine.
Lower the vehicle until the tires are touching the ground.
Remove the safety stanchions from around vehicle after resolver learn is completed.

Note
Remove all stanchions after vehicle is finished with the resolver error learn.
Install the bed cargo smugglers bay. See Bed Cargo Tub - Bed Cargo Smugglers Bay (Remove and Install).
Install the RH bed side wall. Repeat this step for the LH bed side wall.

Note
Recommend assistance.

Note
x1 bolt, 15 mm, 46 Nm; x2 bolts, T45, 36 Nm; x4 bolts, 10 mm, 11 Nm; x2 nuts, 10 mm, 7 Nm; x4 clips, x1 fastener cover, x1 electrical connector.
Install the LH and RH rear bed closeouts. See Truck Bed - Rear Bed Closeout - LH (Remove and Install).
Install the LH and RH upper bed side wall assemblies. See Truck Bed Exterior Trim - Upper Bed Side Wall Assembly - LH (Remove and Install).
Install the truck bed floor assembly. See Truck Bed - Bed Floor Assembly (Remove and Install).
Install the bed cargo tub lid. See Bed Cargo Tub - Bed Cargo Tub Lid (Remove and Replace).
Install the bed cargo tub struts. See Tonneau - Bed Cargo Tub Strut (Remove and Install).
Close the tonneau cover.
Close the tailgate.
Raise the LH front window and close the LH front door.
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.