19/05/2023 20:17:38

Inverter Air Leak Test

Correction code 40202020 0.10 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.

  • 2023-05-18: Updated tools list and added photos for 4DU adapter and plug.
  • 1450875-00-A Kit, Inverter Leak Test Adapter, M3
  • 1026636-00-A Pack Enclosure Leak Tester, HV Battery
  • 1140311-00-A Lever Lock, HV Connector, Model 3
  • 1880705-00-A 4DU Inverter Leak Test Plug Assembly
  • 1942298-00-A 4DU Inverter Leak Test Adapter

Procedure

  1. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure.
  2. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  3. Disconnect the electrical harness from the inverter logic connector.
  4. Install the logic connector dummy plug into the logic connector.
    Figure 1. 3DU
    Figure 2. 4DU
  5. Slide the release to unlock the rear drive unit HV connector handle of the rear drive unit to HV battery harness from the secured position.
  6. Fully raise the handle on the rear drive unit HV connector.
  7. Remove the rear drive unit HV connector from the rear drive unit HV header.
  8. Install the leak test adapter into the rear drive unit HV header.
    Figure 3. 3DU
    Figure 4. 4DU
  9. Connect the pack enclosure leak tester to the leak test adapter on the rear drive unit HV header.
  10. Close both valves on the pack enclosure leak tester, and then connect a compressed air supply line.
  11. Fully close the regulator, and then open the inlet valve.
  12. Set the regulator to 1 psi.
  13. Open the outlet valve, and allow at least 45 seconds for the pressure to stabilize to 1 psi.
  14. Close the inlet valve, record the starting pressure displayed, and then start a 60-second timer.
  15. After 60 seconds record the ending pressure displayed.
  16. Subtract the ending pressure from the starting pressure: the acceptable pressure difference is 0.2 psi or less.
    • If the difference is 0.2 psi or less, continue the procedure.
    • If the difference is more than 0.2 psi, check the hose, adapter, and plug fittings, close the outlet valve and open the inlet valve, check the regulator pressure, and then retest from step 13. If the difference is still more than 0.2 psi, refer to Toolbox article 6415200 (Tesla Internal) or 6415200 (External parties).
  17. Disconnect the air supply from the pack enclosure leak tester.
  18. Open the inlet valve, and then disconnect the pack enclosure leak tester from the leak test adapter on the rear drive unit HV header.
  19. Remove the leak test adapter from the rear drive unit HV header.
    Figure 5. 3DU
    Figure 6. 4DU
  20. Fully raise the handle on the rear drive unit HV connector of the rear drive unit to HV battery harness.
  21. Install the HV connector special tool onto the rear drive unit HV connector.
  22. Use both hands to firmly connect the rear drive unit HV connector of the rear drive unit to HV battery harness to the rear drive unit HV header.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the connector fits the header squarely and tightly, and that both retention pins enter the handle.
  23. Remove the HV connector special tool from the rear drive unit HV connector.
  24. While pressing the rear drive unit HV connector onto the rear drive unit HV header, fully lower the handle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the handle does not bind as it is lowered.
  25. Slide the release to lock the rear drive unit HV connector handle in the secured position.
  26. Verfiy that the rear drive unit HV connector is fully seated, and compare both sides of the connector that it is properly secured in place.
    Informational PurposesAn informational icon, calling your attention
    Note
    An improperly seated connector might lead to connector damage and rear drive unit problems later on.
  27. Remove the logic connector dummy plug from the logic connector.
    Figure 7. 3DU
    Figure 8. 4DU
  28. Connect the electrical harness to the inverter logic connector.
  29. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  30. Connect 12V power. See 12V/LV Power (Disconnect and Connect).