28/02/2024 08:56:24

Heat Exchanger - Front Drive Unit (3DU) (Remove and Replace)

Correction code 3901010042 FRT 1.02 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.

  • 2024-02-27: Updated gearbox fluid to KAF 1.
  • 1080568-00-A Fluid Catcher
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
Table 1. Torque Specifications: Heat Exchanger - Front Drive Unit (3DU) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts that attach the heat exchanger to the front drive unit
5 Nm (3.7 lbs-ft)
  • Flex head ratchet/flex head torque wrench
  • 3 in extension
  • Torque wrench with angle measurement
  • Socket 3/8 in Dr EP10
 Reuse

Remove

  1. Raise and support the vehicle. See GUID-0ECF2493-88F6-48E9-ADBB-9AE1D52E217C.html.
  2. Open the LH front door and lower the LH front window.
  3. Disconnect the LV battery power. See LV Battery - Li-lon (Disconnect and Connect).
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  5. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  6. Lower the vehicle fully.
  7. Position a fluid catcher (1080568-00-A) underneath the front of the vehicle.
  8. Release the spring clip and the plugs (x2) to disconnect the front drive unit powertrain return hose from the front drive unit heat exchanger, and then plug the ends of both fittings as soon as possible to avoid coolant loss (1135762-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  9. Release the spring clip and the plugs (x2) to disconnect the front drive unit inverter inlet hose from the front drive unit heat exchanger, and then plug the ends of both fittings as soon as possible to avoid coolant loss (1135762-00-A).
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant loss greater than 1L requires vacuum fill.
  10. Remove the bolts (x2) that attach the heat exchanger to the front drive unit, and then remove the heat exchanger from the front drive unit.
    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 3 in extension
    • Torque wrench with angle measurement
    • Socket 3/8 in Dr EP10

Install

  1. Install the bolts (x2) that attach the heat exchanger to the front drive unit to install the heat exchanger.
    5 Nm (3.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note

    Lightly coat the O-rings with clean KAF 1 gearbox fluid.

    Do not pinch or deform the O-rings during installation.

    Do not allow the coolant to enter oil passages of the drive unit to avoid cross-contamination.

    Tip: Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 3 in extension
    • Torque wrench with angle measurement
    • Socket 3/8 in Dr EP10
  2. Remove the plugs on the ends of fittings, and then secure the spring clip to connect the front drive unit inverter inlet hose to the front drive unit heat exchanger.
    Informational PurposesAn informational icon, calling your attention
    Note

    Perform a push-pull-push test to make sure that the hose is fully secured.

    Coolant loss greater than 1L requires vacuum fill.

  3. Remove the plugs on the ends of fittings, and then install the spring clip and the plug to connect the front drive unit powertrain return hose to the front drive unit heat exchanger.
    Informational PurposesAn informational icon, calling your attention
    Note

    Perform a push-pull-push test to make sure that the hose is fully secured.

    Installing the chiller side of hose first will eliminate the coolant loss when connecting to the supermanifold.

  4. Remove the fluid catcher from underneath the vehicle.
  5. Drain and refill the front drive unit gearbox fluid. See Gearbox Fluid - Front Drive Unit (3DU) (Drain and Refill).
  6. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge > Run and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  7. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  8. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  9. Disable Service Mode. See Service Mode.
  10. Raise the LH front window and close the LH front door.
  11. Remove the lift arms from below the vehicle.