29/05/2024 18:09:31

Front Drive Unit Assembly - Heat Exchanger, C1 (Remove and Install)

Correction code 3901049081 3901049082 FRT 1.14 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.

Raise and support vehicle

Note
Set air suspension to "Jack Mode"
Open LH front door

Note
Push LH B-pillar door trigger to release
Lower LH front window
Place vehicle in service mode

Note
Via UI > Controls > Software, Touch and hold "Cybertruck" for 2 seconds then release, Use screen keyboard to type "service" into dialog box then select OK
Unlock vehicle gateway

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information
Navigate to Refrigerant System through UI

Note
Select Service Mode > Thermal > Refrigerant System
Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT window will appear, Select 'Run'

Note
Verify indicator displays green for Coolant readiness, Thermal Fill Drain routine has a 50 minute time limit
Open powered front trunk

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Via exterior switch or UI
Remove rear underhood apron

Note
9x clips
Power down vehicle via UI

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Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Unlock fireman's loop connector and disconnect, Slide eCPA to left on the MV battery connector then lift lever to release

Note
2x connectors, Unlock fireman's loop connector and disconnect, Release eCPA by pushing down to unlock and slide red locking tab to left, Wait 2 minutes for electrical circuits to discharge before disconnecting modules
Raise vehicle fully

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Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Release covers to expose bolts
Remove front aero shield

Note
11x bolts, 10mm, 6 Nm
Disconnect CFM connectors

Note
2x connectors, 2x clips
Place coolant catcher below RH front of vehicle
Lower vehicle until tires are touching the ground

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Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove frunk assembly

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6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Remove bolt covers from frunk floor, Remove washer fluid cap by gently prying upwards, Rotate bumpstops counter clockwise to release, the 25mm socket from PT Sensor kit can be used, Avoid straining emergency frunk release connector
Remove front center applique

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8x tabs, 1x connector, Release upper 4 tabs by pushing down then gently pull away, Release frunk release trigger connector
Remove front fascia fasteners

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2x covers, 4x bolts, 10mm, 4 Nm, Remove tow hook covers to expose bolts
Release clips securing front portion of the LH front wheel house liner

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4x clips
Remove front fascia LH side fastener

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1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Release clips securing front portion of the RH front wheel house liner

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4x clips
Remove front fascia RH side fastener and connectors

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1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Pull red locking tab to release, Do not push down on locking tab
Remove front lower fascia assembly

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Place on suitable protective surface
Remove lower CFM fasteners

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2x bolts, 10mm, 10 Nm
Remove fore crossmember

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2x bolts, 18mm, 90 Nm, Push up on CFM, Use hammer if needed, Recommend assistance
Disconnect radiator to manifold hose from radiator

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1x spring clip, Remove from vehicle, Plug hoses
Disconnect manifold to radiator hose from radiator

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1x spring clips, Plug hoses
Release harness from CFM

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1x grommet, 2x connectors, 5x harness clips, Pull red locking tab to disengage louver connector, Release temperature sensor then disconnect, Release grommet and pull harness through from frunk area
Remove upper CFM fasteners

Note
2x bolts, 10mm, 10 Nm
Remove CFM

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Recommend assistance, Remove from below impact beam, Ensure harness is not pinched during removal
Disconnect coolant hoses from FDU heat exchanger

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2x spring clips
Remove FDU heat exchanger

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2x bolts, EP10, 5 Nm, Ensure O-rings do not remain on drive unit
Install FDU heat exchanger

Note
2x bolts, EP10, 5 Nm, Ensure O-rings are not pinched
Connect coolant hoses to FDU heat exchanger

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2x spring clips, Perform a push-pull-push test to ensure hoses are fully seated
Install CFM

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Install from bottom, Assistance recommend Manipulate as required, Ensure harness is not pinched during install
Connect CFM connectors

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2x connectors, Engage locking tab
Install upper CFM fasteners

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2x bolts, 10mm, 10 Nm
Secure harness to CFM

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1x grommet, 2x connector, 1x harness clip, Secure grommet then connect temperature sensor, Engage locking tab on louver connector
Connect radiator inlet coolant hose

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1x spring clips,Ensure hose is fully engaged with a push-pull-push test
Connect radiator to manifold hose to radiator

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1x spring clip, Ensure hose is fully engaged with a push-pull-push test
Install fore crossmember

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2x bolts, 18mm, 90 Nm, Lift CFM away from beam to aid in clearance, Install beam by sliding rewards
Install lower CFM fasteners

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2x bolts, 10mm, 10 Nm
Install front lower fascia assembly

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Ensure no harnesses are pinched
Install RH fascia fastener and connectors

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1x bolt, 10mm, 6 Nm, 1x clip, 3x connectors, Pull wheel liner back for access, Engage locking tab
Secure RH wheel liner

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4x clips
Install LH fascia fastener

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1x bolt, 10mm, 6 Nm, Pull wheel liner back for access
Secure LH wheel liner

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4x clips
Install front fascia fasteners and covers

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2x covers, 4x bolts, 10mm, 4 Nm, Install tow hook covers
Install front center applique

Note
8x tabs, 1x connector, Ensure all tabs engage, Secure frunk release trigger connector
Perform cooling system vacuum fill. See Cooling System (Vacuum Refill).
Slide eCPA to the right and ensure it is seated against the black lever, Connect fireman's loop 20 seconds after eCPA engagement

Note
2x connectors, Slide and secure red locking tab on top of release lever, Lock fireman's loop connection, If power cycling vehicle ensure at least 60 seconds has passed since powering down
Access thermal system routines using the UI

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Select quick controls > Service mode > Thermal > Actions
Select "Stop Thermal Fill Drain" through UI

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Allow routine to complete, ensure routine is successful
Select "Start Coolant Air Purge" using the UI

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
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Install front aero shield

Note
11x bolts, 10mm, 6 Nm, Apply loctite 222 to aeroshield fasteners
Install lower valence fasteners

Note
2x clips, 2x covers, 6x bolts, 10mm, 6 Nm, Secure covers
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Perform Thermal Performance through the UI

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Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed, if thermal test fails follow https://toolbox.teslamotors.com/articles/206000
Install frunk assembly

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6x bolts, 10mm, 12 Nm, 2x bolt caps, 2x bumpstops, 1x connector, Install bolt covers to frunk floor, Install washer fluid cap, Install bumpstops by aligning tabs then turning clockwise, Ensure emergency frunk release functions
Install rear underhood apron

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9x clips, Adjust windshield seal as required
Close powered front trunk

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Via exterior switch or UI
Remove vehicle from lift

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Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Exit Service Mode

Note
Via UI > Service > Exit, Press and hold "Exit Service Mode" button
Raise LH front window
Close LH front door