23/07/2024 17:30:54

Heat Exchanger - Rear Drive Unit - LH (Tri Motor) (Remove and Replace)

Correction code N/A 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.

Warning

Cybertruck electronics are powered by a 48V "mid voltage" or "MV" architecture that is designed to improve efficiency. Servicing MV components requires extra knowledge and care in order to avoid personal and/or vehicular harm. Read and understand MV precautions in Electrical Precautions and make sure any required MV-related training courses have been completed, as applicable.

Open LH front door

Note
Push LH B-pillar door trigger to release
Lower LH front window
Raise and support vehicle

Note
Set air suspension to "Jack Mode"
Open powered front trunk

Note
Via exterior switch or UI
Open tonneau cover

Note
Press forward arrow on LH bed rail
Open tailgate

Note
Press button to release
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
Access thermal system routines using the UI

Note
Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock
Select 'Coolant System' to enter coolant circuit screen, Select 'Coolant Fill/Drain' using the UI and
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Start Thermal Fill/Drain
Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid 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
Power down vehicle via UI

Note
Verify EPBs are engaged, Select charge port icon to ensure drive state is disengaged then power down vehicle via Controls > Safety > Power Off
Remove rear underhood apron

Note
9x clips
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

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm
Remove rear aero shield

Note
5x bolts, 10mm, 6 Nm, 2x guides
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Position coolant catcher below rear drive unit
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
Remove fastener covers from bed floor assembly

Note
6x covers
Remove bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open anchors as needed, Lift front edge with trim tool then remove panel, Recommend assistance
Place shop rags underneath RDU LH heat exchanger
Release RDU return hose from LH heat exchanger

Note
1x spring clip, 1x tree clip, Plug coolant connections as needed, Move aside as needed
Release LH RDU inverter to chiller hose from heat exchanger

Note
1x spring clip, Clip will clash with casting but release enough to release connection, Plug coolant connections as needed
Remove RDU LH heat exchanger

Note
2x bolts, EP10, 5 Nm +30 degrees
Clean area underneath RDU LH heat exchanger
Install RDU LH heat exchanger

Note
2x bolts, EP10, 5 Nm +30 degrees, 2x O-rings, Lubricate O-rings with drive unit oil as needed, Verify seals are not damaged
Secure LH RDU inverter to chiller hose onto heat exchanger

Note
1x spring clip, Remove plugs as needed
Secure RDU return hose onto LH heat exchanger

Note
1x spring clip, 1x tree clip, Remove plugs as needed
Remove shop rags from underneath RDU LH heat exchanger
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Position oil drain underneath RDU
Placeholder - Remove oil fill plug from RDU

Note
1x plug, 8mm Allen, 15 Nm, Verify O-ring is not damaged, Replace O-ring as needed, Tooling used for torque is still in development
Set up fill kit with KAF1

Note
Add extra oil to container as it will prevent underfill and additional air being injectedOnly use KAF1 fluid, Do not interchange or mix oil types
Position oil pump hose into fill hole
Pump fluid into rear drive unit

Note
Pump fluid into drive unit until fluid spills outUse excess gearbox fluid in fill container to allow oil pump to dispense fluid without drawing air, Make sure that there is less than 200mL left when completed
Remove oil pump hose from fill port

Note
Turn knob to off and remove from fill hole
Spray area with brake cleaner and wipe any residual fluid
Placeholder - Secure oil fill plug onto RDU

Note
1x plug, 8mm Allen, 15 Nm, Verify O-ring is not damaged, Replace O-ring as needed, Tooling used for torque is still in development
Remove oil drain from underneath vehicle
Lower vehicle partially and set lift onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
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
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
Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete

Note
Select 'Close' once complete
Select ‘Coolant Air Purge’, click ‘Run’, and allow routine to complete
Perform Thermal Performance through the UI

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

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

Note
Via exterior switch or UI
Install bed floor assembly

Note
10x bolts, 15mm, 56 Nm, 4x anchors, Open and close anchors as needed, Recommend assistance
Install fastener covers onto bed floor assembly

Note
6x covers
Raise vehicle fully

Note
Set to a comfortable working height, Lower to locks, Ensure locks engage on both sides to prevent tilting
Remove coolant catcher from below vehicle
Install rear aero shield

Note
5x bolts, 10mm, 6 Nm, 2x guides
Install Mid-aero shield

Note
6x clips, 3x bolts, 15mm, 42 Nm, 5x bolts, 13mm, 28 Nm, 2x bolts, 10mm, 6 Nm, Apply Loctite 222 onto mid aeroshield bolts and install fasteners
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
Remove vehicle from lift

Note
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
Close tonneau cover
Close tailgate

Cybertruck Service Manual

Heat Exchanger - Rear Drive Unit - LH (Tri Motor) (Remove and Replace)

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