22/05/2024 14:16:10

Front Drive Inverter - Drive Inverter (Remove and Replace)

Correction code 3920048022 FRT 2.52 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 IconA warning icon, calling your attention to a possibly risky situation
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.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Put the vehicle in Service Mode. See Service Mode.
  3. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  4. Unlock the vehicle gateway. See Gateway (Unlock).
  5. On the vehicle touchscreen, navigate to Service Mode Plus > High Voltage > Procedures > Front Drive Inverter Replacement.
  6. Touch Store Boot + App Data and Start Fluid Fill/Drain, and then touch Run. Allow routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Close once completed.
  7. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  8. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  9. Disconnect MV power. See Disconnect MV Power.
  10. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  11. Remove the push clips (x4) and bolts (x8) that attach the undertray skid plate to the vehicle, and then pivot the rear of the skid plate downwards and then forward to release the tabs (x8) and remove it from the vehicle.
    4 Nm (2.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  12. Remove the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
  13. Remove the bolt that attaches the FDU HV harness, and then disconnect the electrical connector.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the harness clear of the front subframe.
  14. Disconnect the FDU logic electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the latch and pivot locking arm down to remove.
  15. Put a coolant catcher below the RH front of the vehicle.
  16. Lower the vehicle until the tires are touching the ground.
  17. Remove the front center applique. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
  18. Remove the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
  19. Remove the cooling fan module. See Fan and Radiator - Cooling Fan Module (Remove and Install).
  20. Support the front drive unit.
  21. Release the spring clip, disconnect the inverter coolant return hose, and then plug the fittings.
  22. Remove the bolt that attaches the RH FDU mount bolt.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
  23. Release the clips that attach the NVH pad to the vehicle, and then remove the pad from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Revisions may be secured by velcro.
  24. Remove the bolts (x2) that attach the RH mount.
    35 Nm (25.8 lbs-ft) +55 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx E14
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the 2 foremost bolts. Final bolt will be removed at a later step.
    Informational PurposesAn informational icon, calling your attention
    Note
    Image shown with the front drive unit removed from the vehicle for clarity.
  25. Remove the bolt that attaches the LH FDU mount bolt.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Access bolt through hole in the HCU bracket.
  26. Lower and remove the underhoist stand.
    Informational PurposesAn informational icon, calling your attention
    Note
    The front drive unit will rest on the front subframe.
  27. Remove the label from the phase cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the label after removal.
  28. Remove the bolts (x2) that attach the phase out cover to the front drive unit.
    5 Nm (3.7 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  29. Remove the phase out cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a plastic trim tool to aid in removal.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the phase out cover or O-rings are damaged, then replace it with a new one.
  30. Remove the bolts (x3) that attach the inverter to the 3 phase lugs.
    5 Nm (3.7 lbs-ft) +43 deg
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop fasteners.
  31. Remove the upper bolts (x3) that attach the inverter to the front drive unit.
    6 Nm (4.4 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Informational PurposesAn informational icon, calling your attention
    Note
    The remaining bolts will be removed at a later step.
  32. Release the spring clip, disconnect the inverter coolant inlet hose, and then plug the fittings.
  33. Remove the bolts (x2) that attach the motor case gear bushing to the front subframe.
    110 Nm (81.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  34. Relieve the tension from the front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Using a pry bar or pole hoist to relieve the tension.
  35. Remove the bolt that attaches the RH mount.
    35 Nm (25.8 lbs-ft) +55 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx E14
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove one remaining bolt. Shift the front drive unit towards the LH side to gain clearance. Negotiate the RH mount out of the vehicle.
  36. Put on the ESD wrist strap and secure it to the inverter housing.
  37. Remove the bolts (x6) that attach the inverter to the front drive unit.
    6 Nm (4.4 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Once the remaining bolts are removed, pull the inverter straight away from the front drive unit to ensure that the busbars are not damaged.
  38. Place the drive inverter onto the ESD mat.
  39. Remove the ESD wrist strap from the old inverter.

Install

  1. Prepare the new inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Save packaging to MRB the old inverter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove any red protective covers.
  2. Secure the ESD strap onto the new inverter housing.
  3. Wipe the HV cable lugs to ensure contact surfaces are free of debris with an Isopropyl Alcohol (IPA) wipe.
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow 1 minute dry time.
  4. Install the lower bolts (x6) that attach the inverter to the front drive unit.
    6 Nm (4.4 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the inverter straight inwards. Make sure busbars are not damaged.
  5. Install the upper bolts (x3) that attach the inverter to the front drive unit.
    6 Nm (4.4 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  6. Position the RH mount.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 bolt, E14
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the RH mount into position. Shift the front drive unit towards the LH side for clearance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Loosely install lower bolt. Torque at a later step.
  7. Remove hose plugs, connect the inverter coolant inlet hose, and then secure the spring clip.
  8. Install the bolts (x3) that attach the inverter to the 3 phase lugs.
    5 Nm (3.7 lbs-ft) +43 deg
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not drop fasteners.
  9. Install the phase out cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the phase out cover or O-rings are damaged, then replace it with a new one.
  10. Install the bolts (x2) that attach the phase out cover to the front drive unit.
    5 Nm (3.7 lbs-ft) +20 deg
    Tip: Use of the following tool(s) is recommended:
    • External Torx Plus EP10
  11. Install a new label to the phase cover.
  12. Remove the ESD wrist strap from the inverter.
  13. Take the old inverter and prepare for MRB. Label properly for return or disposal.
    Informational PurposesAn informational icon, calling your attention
    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.
  14. Install the leak test adapter plug to 12V connector at inverter - placeholder
  15. Install the leak test adapter to the HV connector - placeholder
  16. Connect regulator to adapter at the HV connector.
  17. Close both valves on the regulator test tool.
  18. Connect regulator to air supply.
  19. Turn on regulator and open valve closest to regulator.
  20. Set regulator to 1 psi.
  21. Open the 2nd valve to inject air.
    Informational PurposesAn informational icon, calling your attention
    Note
    Close valve when pressure reaches 1 psi and stable.
  22. Wait 45 seconds for pressure to settle.
  23. Record start pressure valve.
  24. Wait 60 seconds for test.
  25. Record end pressure valve.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the 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.
  26. Disconnect air supply from the regulator tool.
  27. Disconnect regulator from leak test adapter at the HV connector.
  28. Remove leak test adapter from the HV connector.
  29. Remove the leak test adapter plug from 12V connector at inverter - placeholder
  30. Secure the NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    x6 ball and socket clips
  31. Connect the FDU logic electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pivot the locking arm up to secure.
  32. Secure the FDU HV harness.
    10 Nm (7.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 electrical connector
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the locking tab is engaged.
  33. Support the front drive unit.
  34. Install the RH drive unit mount bolt.
    90 Nm (66.4 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Position as required to align the bolt hole.
  35. Install the LH FDU mount bolt.
    85 Nm (62.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • External Torx E18
    Informational PurposesAn informational icon, calling your attention
    Note
    Access through the hole in the HCU bracket.
  36. Lower and remove the underhoist stand.
  37. Install the bolts (x2) that attach the front drive unit gearcase bushing.
    110 Nm (81.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 18 mm socket
  38. Install the RH mount bolts (x2).
    35 Nm (25.8 lbs-ft) +55 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 bolts, E14
    Informational PurposesAn informational icon, calling your attention
    Note
    Install 2 foremost bolts.
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque lower bolt at this time.
  39. Connect the inverter coolant return hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    x1 spring clip
  40. Secure the NVH cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    x2 ball and socket clips
  41. Install the cooling fan module. See Fan and Radiator - Cooling Fan Module (Remove and Install).
  42. Install the front fascia. See Front Bumper Fascia - Front Fascia (Remove and Install).
  43. Install the front center applique. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
  44. Install the front aeroshield. See Undertray - Front Aeroshield (Remove and Install).
  45. Position the undertray skid plate to the vehicle, and then install the push clips (x4) and bolts (x8) that attach the skid plate to the vehicle.
    4 Nm (2.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure all the tabs (x8) are fully engaged before installing the fasteners.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  46. Install the frunk assembly. See Frunk Assembly (Remove and Install).
  47. Remove coolant bottle cap
  48. Install vacuum refill cap onto coolant bottle assembly
  49. Place empty coolant container into front storage area
    Informational PurposesAn informational icon, calling your attention
    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
  50. Fill container with at least 15L of coolant
  51. Place filled coolant container onto coolant drain & fill cart
    Informational PurposesAn informational icon, calling your attention
    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
  52. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  53. Install vacuum refill hose to refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  54. Position overflow hose into empty container
  55. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  56. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  57. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  58. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  59. Once the gauge reads zero, close the coolant refill valve
  60. Remove shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  61. Remove coolant refill hose from coolant container
  62. Remove coolant overflow hose from coolant container
  63. Remove vacuum refill hose from refill cap on coolant bottle
  64. Remove vacuum refill cap from coolant bottle assembly
  65. Remove coolant refill tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Move coolant drain & fill cart away from vehicle
  66. Remove coolant container from inside underhood area
  67. Reconnect MV power. See Disconnect MV Power.
  68. Select "Stop Thermal Fill Drain" through UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow routine to complete, ensure routine is successful
  69. Select "Restore Bootloader Data after Perform CAN Redeploy", click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 'Close' once complete
  70. Select "Restore Application Data", click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 'Close' once complete
  71. Select "Start Coolant Air Purge" using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only, wait until coolant pumps stop running (audible noise), Routine Passed will appear, but pumps will run for 10 minutes, If you start next another routine during this time it will fail, Make sure vehicle is not in "Drive", Routine is still running despite the completed message, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valves between SERIES and PARALLEL, Putting vehicle into "Drive" will stop this routine, If speeds hover at 7000 RPM, this indicates the pumps are air locked, perform a vacuum fill, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle
  72. Select ‘Thermal System Performance Test ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select 'Close' once complete
  73. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  74. Install coolant bottle cap
  75. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn
    Informational PurposesAn informational icon, calling your attention
    Note
    Use safety stanchions to section off vehicle before driving vehicle on a lift
  76. Raise vehicle partially and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  77. Select ‘Resolver Error Learn’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Read the instructions thoroughly, Follow the appropriate safety precautions, Vehicle needs to be driven on a lift, Verify wheels are clear of contacting ground, Read the instructions thoroughlyFirmware must be on 2022.16.2 or later for routine to operateStart routine and shift into Drive, Drive vehicle on a lift until the desired speed is reached, Vehicle will begin to coast down automatically, Release accelerator and allow vehicle to spin down, Do not slam on brakes, When axles have stopped spinning then put the vehicle into Park
  78. Remove safety stanchions from around vehicle after resolver learn is completed
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove all stanchions after vehicle is finished with the resolver error learn
  79. Place stanchions around vehicle and set up a safety perimeter before performing resolver error learn.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use safety stanchions to section off vehicle before driving vehicle on a lift.
  80. Partially raise the vehicle.
  81. Touch Rear INVERTER - resolver error learn. Touch Run Network and navigate through the dialog boxes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Follow the appropriate safety precautions. Vehicle needs to be driven on a lift. Verify wheels are clear of contacting ground. Read the instructions thoroughly. Firmware must be on 2022.16.2 or later for routine to operate. Start routine and shift into Drive. Drive vehicle on a lift until the desired speed is reached. Vehicle will begin to coast down automatically. Release accelerator and allow vehicle to spin down. Do not slam on brakes. When the axles have stopped spinning then put the vehicle into Park.
  82. Remove the safety stanchions from around vehicle after resolver learn is completed.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove all stanchions after vehicle is finished with the resolver error learn.
  83. Install the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  84. Close the powered frunk.
  85. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  86. Raise the LH front window and close the LH front door.