25/03/2024 17:24:44

Hose - Inverter to Heat Exchanger - Rear Drive Unit (3DU) (Remove and Replace)

Correction code 18300192 2.76 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.

2023-08-25: Updated EPB Service Mode reference.

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
Open all four doors and lower all four windows.
Enable the EPB Service Mode. See Parking Brake - Caliper - Rear - LH (Release).
Move both front seats forward
Remove 2nd row seat cushion and disconnect harness

Note
2x tabs, 2x connectors, Press tab toward LH side of vehicle on each side to release front edge of seat cushion
Open hood

Note
Press "Open" button on the touchscreen to release the latch, Lift the lid manually
Remove rear apron

Note
12x clips, Only store rear apron visible face upwards
Remove cabin intake upper duct assembly

Note
4x clips, Heat pump vehicles have 3x clips
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box
Disconnect 12V negative terminal

Note
1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
Disconnect first responder loop

Note
1x connector, Release locking tab
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
Verify no high voltage

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no damage is present, Seal can be re-used
Install bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners
Remove LH rear wheel center cap

Note
1x cap
Remove RH rear wheel center cap

Note
1x cap
Loosen RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Loosen LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Close all four doors

Note
Make sure all windows are lowered and rear doors are latched to prevent accidental closure when vehicle is powered down
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a 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
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove RH rear brake caliper from knuckle and hang from body

Note
2x bolt, E18, 83 Nm, Discard bolts after removal, Hand tighten lug nut to secure rotor on early production vehicles
Remove LH rear brake caliper from knuckle and hang from body

Note
2x bolts, E18, 83 Nm, Discard after removal, Hand tighten lug nut to secure rotor on early production vehicles
Raise vehicle fully and lower lift onto locks

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, Verify doors are clear of surrounding objects
Remove mid aero shield

Note
13x bolts, 10mm, 5 Nm
Remove bolts securing the rear diffuser to body

Note
6x bolts, 10mm, 4 Nm, 2x fastener covers
Remove outer bolts securing rear diffuser to rear fascia assembly

Note
4x bolts, 10mm, 3 Nm
Remove bolts securing rear lower fascia to rear fascia diffuser

Note
2x bolts, 10mm, 3 Nm
Release tabs securing rear diffuser to rear fascia and remove from vehicle

Note
10x tabs, Start from one side and work your way across while releasing tabs
Remove LH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Remove RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
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
Install spring compressor onto LH rear coil spring

Note
Tooling may vary per service center, Reference photos for clarification
Unbolt LH strut from body at top mount

Note
2x bolts, 15mm, 41 Nm
Install spring compressor onto RH rear coil spring

Note
Tooling may vary per service center, Reference photos for clarification
Unbolt RH strut from body at top mount

Note
2x bolts, 15mm, 41 Nm
Raise vehicle fully and lower lift onto locks

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, Verify doors are clear of surrounding objects
Disconnect RH side 12V subframe harness connector

Note
1x connector, Release locking tab
Remove RH side 12V subframe harness clip from body

Note
1x barrel clip
Disconnect LH side 12V subframe harness connector

Note
1x connector
Remove LH side 12V subframe harness clip from body

Note
1x barrel clip
Remove nut securing RDU ground strap to vehicle

Note
1x nut, 10mm, 10 Nm, Located at LH rear wheel well area
Remove nut securing LH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from LH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link
Remove nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from RH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link
Position support stand to support front portion of rear subframe
Remove bolts securing rear stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal
Lower support stand and remove stabilizer bar from vehicle
Remove support stand from under vehicle
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate enclosure

Note
2x fir tree clips
Release clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Remove lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Older VINs may be equipped with additional fastener count
Remove upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles
Remove upper bolts securing HV battery rear skid plate enclosure

Note
4x bolts, 13mm, 35 Nm
Remove HV battery rear skid plate enclosure
Position coolant drain container underneath LH rear of HV battery
Disconnect RDU inverter inlet tube from LH rear of HV battery

Note
1x spring clip, 2x plugs, Plug HV battery and hose
Position coolant drain container underneath RH rear of vehicle
Disconnect RDU outlet hose from PT return tube and plug both hose ends

Note
1x spring clip, 2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary
Remove coolant drain container from underneath vehicle
Remove nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary
Disconnect RDU HV cable from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Place subframe lifting tool into position underneath rear subframe
Connect air supply to subframe lifting tool
Raise subframe lifting tool to support rear subframe

Note
3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance
Remove smaller fasteners securing LH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Remove smaller fasteners for RH shear plate

Note
2x bolts, 13mm, 35 Nm
Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm, Discard after removal
Remove LH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm, Discard after removal
Remove RH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm, Discard after removal
Lower subframe and rear drive unit assembly from vehicle

Note
Use caution while lowering subframe to avoid damage to surrounding components
Disconnect air supply from subframe lifting tool
Release RDU inverter to oil cooler hose

Note
1x hose clip, Image zoomed in for clarity
Release clips securing RDU inverter to oil cooler hose from RDU assembly

Note
4x clips
Disconnect RDU inverter coolant hose from heat exchanger and remove hose

Note
1x spring clip,1x plug, Clean excess coolant from area
Secure RDU inverter to oil cooler hose onto heat exchanger

Note
1x spring clip, 1x plug, Clean excess coolant from area, Perform push-pull-push test to make sure hose is fully engaged
Secure clips holding inverter to coolant hose to RDU

Note
4x clips
Secure inverter to cooler hose to inverter

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully engaged
Position subframe and rear drive unit assembly under vehicle
Connect air supply to subframe lifting tool
Raise subframe and rear drive unit assembly into position

Note
Use caution to not damage components while raising subframe
Install RH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
Install LH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step
Install LH front bolt and shear plate to rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing LH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm
Install RH front bolt and shear plate to rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm
Torque bolts securing shear plates to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque bolt securing subframe and LH shear plate to body

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque
Torque bolt securing subframe and RH shear plate to body

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque
Torque bolt securing RH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Torque bolt securing LH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Lower rear subframe lifting tool from vehicle

Note
Verify yellow safety straps are removed from subframe
Disconnect air supply from subframe lifting tool
Remove subframe lifting tool from underneath vehicle
Connect RDU HV cable to HV battery

Note
1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position
Install nut securing RDU HV cable bracket to HV battery

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary
Position coolant drain container underneath RH rear of vehicle
Remove hose plugs and connect RDU outlet hose to PT return tube

Note
1x spring clip, 2x plugs, Perform push-pull-push test to make sure hose is fully engaged, Use shop towel to clean any coolant residue if necessary
Position coolant drain container underneath LH rear of HV battery
Remove plugs and connect RDU inverter inlet hose to LH rear of HV battery

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully engaged
Remove coolant drain container from underneath vehicle
Position HV battery rear skid plate enclosure onto HV battery for installation

Note
Recommend assistance if needed
Install upper bolts securing HV battery rear skid plate enclosure hand tight

Note
4x bolts, 13mm, 35 Nm, Torque at later step
Install upper nut securing HV battery rear skid plate enclosure hand tight

Note
1x nut, 10mm, 13 Nm, Torque at later step
Install lower bolts securing HV battery rear skid plate enclosure

Note
2x bolts, EP10, 13 Nm, Earlier VINs may be equipped with additional bolts
Torque bolts securing HV battery rear skid plate enclosure to vehicle

Note
4x bolts, 13mm, 35 Nm
Torque upper nut securing HV battery rear skid plate enclosure

Note
1x nut, 10mm, 13 Nm
Install clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Install RH side hose clips to HV battery rear skid plate enclosure

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Place stabilizer bar into position for installation and raise stand to support stabilizer bar
Install bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Install new patch bolts
Position LH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing LH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Position RH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing RH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Remove support stand from under vehicle
Install RDU ground strap

Note
1x bolt, 10mm, 10 Nm, Re-install 1x washer if vehicle had this washer during removal, Located at LH rear wheel well area
Install LH side 12V subframe harness clip to body

Note
1x barrel clip
Connect LH side 12V subframe harness connector

Note
1x connector
Install RH side 12V subframe harness clip to body

Note
1x barrel clip
Connect RH side 12V subframe harness connector

Note
1x connector
Lower vehicle partially and set 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
Install bolts securing LH damper to body at top mount

Note
2x bolts, 15mm, 41 Nm
Install bolts securing RH damper to body at top mount

Note
2x bolts, 15mm, 41 Nm
Remove bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm, Remove lug nut previously installed for early production vehicles
Install hub jack adapter onto LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Position and raise support stand to simulate RH rear suspension at ride height
Use rear ride height torque gauge to verify RH suspension is set to ride height specification

Note
May need to slightly adjust stand or spring compressor
Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height

Note
Distance should be 378 mm
Torque bolt securing RH rear toe link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear upper fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing RH rear upper aft link to knuckle

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen
Remove support stand from underneath RH suspension
Remove hub jack adapter from LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install bolt securing RH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Remove spring compressor from RH rear coil spring

Note
Tooling may vary per service center, Reference photos for clarification.
Remove bolt securing LH rotor to hub

Note
1x bolt, 10mm, 5 Nm, Remove lug nut previously installed for early production vehicles
Install hub jack adapter onto LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Position and raise support stand to simulate LH rear suspension at ride height
Use rear ride height torque gauge to verify LH suspension is set to ride height specification

Note
May need to slightly adjust stand or spring compressor tool
Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height

Note
Distance should be 378 mm
Torque bolt securing LH rear toe link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing LH rear upper fore link to knuckle

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen
Torque bolt securing LH rear upper aft link to knuckle

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen
Remove support stand from underneath LH rear suspension
Remove hub jack adapter from LH rear hub

Note
5x lug nuts, 21mm, Hand tight
Install bolt securing LH rotor to hub

Note
1x bolt, 10mm, 5 Nm
Remove spring compressor from LH rear coil spring
Raise vehicle fully and lower lift onto locks

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
Install RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Install LH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Install rear diffuser to vehicle then engage tabs securing it to fascia

Note
10x tabs
Install the bolts securing the rear diffuser to inner rear fascia

Note
2x bolts, 10mm, 3 Nm
Install outer bolts securing rear diffuser to rear fascia assembly

Note
4x bolts, 10mm, 3 Nm
Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body

Note
6x bolts, 10mm, 4 Nm, 2x fastener covers, Number of bolts may vary on newer vehicles
Lower vehicle partially and set 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
Install RH rear brake caliper onto knuckle

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
Install LH rear brake caliper onto knuckle

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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
Torque LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Install LH rear wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Install RH rear wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Remove coolant bottle cap
Connect first responder loop

Note
1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer
Connect 12V negative terminal

Note
1x nut, 10mm, 6 Nm
Place vehicle into Park
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
Select ‘Actions/Autodiag’ tab and search for ‘Purge'
Select ‘
TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
via Toolbox: (link)via Service Mode:
Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
Thermal ➜ Coolant System ➜ Coolant Purge Start
via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
’, click ‘Run’, and allow routine to complete
Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
Connect 2nd row seat cushion harness and install 2nd row seat cushion

Note
2x connectors, Both connectors are located on LH side of vehicle, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips
Move LH front seat to original position
Move RH front seat to original position
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Inspect coolant level and top off as necessary

Note
Ensure that fluid level is at Max line
Install coolant bottle cap
Install cabin intake upper duct assembly

Note
4x clips, Heat pump vehicles have 3x clips
Install rear apron

Note
12x clips
Close hood
Remove lift arms from below vehicle

Note
Lower rack arms fully and remove them from under vehicle
Raise all windows
Close all four doors

Note
Unlatch rear doors before closing
Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.

Model 3 Service Manual

Hose - Inverter to Heat Exchanger - Rear Drive Unit (3DU) (Remove and Replace)

Figure 1

Figure 2

Figure 3