31/05/2024 13:08:24

ABS Modulator (Heat Pump) (Remove and Replace)

Correction code 33100112 2.70 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.

2023-12-05: Updated brake stiffness routine.

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.

Remove

Raise and support vehicle
Remove LH front wheel center cap

Note
1x cap
Remove LH rear wheel center cap

Note
1x cap
Remove RH rear wheel center cap

Note
1x cap
Remove RH front wheel center cap

Note
1x cap
Loosen RH front wheel

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

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

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

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

Note
If vehicle is being powered down, Latch rear doors to prevent accidental closure
Lower all four windows
Move LH front seat forward
Move RH front seat forward
Remove 2nd row seat cushion and disconnect harness

Note
2x tabs, 2x connectors, Slide locking tabs to left of vehicle while lifting up seat bench. Newer models have connectors on both sides of bench, Older models have 2x connectors on one side of bench
Move LH front seat backward
Open hood

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

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

Note
3x clips, Some configurations may come with 4x clips
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect 12V negative terminal

Note
1x nut, 10mm, 6 Nm, Ensure 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
Lock steering wheel into position
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 HV insulating gloves
Remove closeout panel from frunk assembly

Note
4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab closeout panel from bottom then pull it upward to release clips, Disconnect switch
Remove bolts securing frunk assembly

Note
7x bolts, 10mm, 5 Nm, Lift up RBN covers to access upper fasteners, Newer vehicles may not be equipped with covers
Remove frunk assembly from vehicle

Note
12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles
Remove vent tube hose from LH side of 12V battery

Note
1x tube adapter
Release terminal cover and remove positive terminal

Note
2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut
Remove 12V battery upper tie down strap to AC compressor bracket

Note
1x bolt, 10mm, 5 Nm, Lift battery tie down strap up and remove it from rear tie down hook strap
Remove battery upper tie down strap

Note
Lift battery tie down strap up and remove it from the rear tie down hook strap
Remove 12V battery from vehicle
Remove bolt securing the steering gear assembly to intermediate shaft assembly

Note
1x bolt, 13mm, 18 Nm
Slide the electric steering column upward to remove it from the steering gear assembly

Note
May need to wiggle or use dead blow to help separate
Disconnect the hydraulic control unit connector

Note
1x connector, Disengage locking tab and pull up on connector to release
Remove fasteners securing hydraulic control unit to hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm, Discard nuts after removal
Disconnect harness from LH front rail bracket

Note
1x connector, Red locking tab, Release lock from opposite side of bracket then release connector towards front of vehicle, Image zoomed in for clarity
Release clips securing front harness and coolant hose from brackets

Note
2x clips
Release front harness clip from LH frame rail

Note
1x clip
Disconnect the steering gear assembly connectors

Note
2x connectors, Two stage connectors, Move the red locking tab to the left then depress the connector release to disconnect the connector
Disconnect the logic connectors from steering gear

Note
2x connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Image zoomed out for location reference
Disconnect the HVIL connector

Note
1x locking connector, Do not push down on red tab, Pull red tab to disengage lock, Pull tab again to release connector
Release clip securing HVIL connector harness onto body

Note
1x clip
Disconnect LH front headlamp

Note
1x connector, Pull tab to disengage lock mechanism, Pull again to release connector, Do not press down on tab, Connector style may vary
Remove grounds G098 and G099 from LH side of body

Note
2x bolts, 10mm, 10 Nm, Discard thread-cutting tri-lobular bolts after removal, If equipped with new bolts (1447438-00-A), fasteners can be reused
Remove grounds G011 and G013 from LH frame rail

Note
2x bolts, 10mm, 10 Nm, Discard thread-cutting tri-lobular bolts after removal, If equipped with new bolts (1447438-00-A), fasteners can be reused
Release front harness clips from LH frame rail

Note
3x clips
Loosen upper bolt securing shock tower brace to RH shock tower

Note
1x bolt, 15mm, 67 Nm
Remove bolts securing shock tower brace to RH shock tower

Note
1x bolt, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, see image for torque location
Remove bolts securing shock tower brace to LH shock tower

Note
2x bolts, 15mm, 55 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
Shift shock tower brace assembly to gain clearance

Note
Shift shock tower brace forward, but do not fully remove
Release the master cylinder brake lines from clip at rear of hydraulic control unit bracket

Note
1x harness clip
Raise vehicle partially 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
Remove LH front wheel

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

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

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

Note
5x nuts, 21mm, 175 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
Remove outer fasteners securing front aero shield

Note
9x bolts, 10mm, 5 Nm
Remove remaining nuts and remove front aero shield from vehicle

Note
2x nuts, 15mm, 5 Nm
Remove bolt securing FDU HV harness to the FDU

Note
1x bolt, 10mm, 10 Nm
Disconnect the FDU HV harness connector

Note
1x clip, 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 FDU header are not damaged
Remove the FDU HV harness connector from the FDU and move aside

Note
1x connector
Slide intermediate shaft towards rear of vehicle
Release front harness clips from hydraulic control unit bracket

Note
2x clips
Lower front harness away from hydraulic control unit

Note
Lower front harness to gain enough clearance to hydraulic control unit
Remove lower bolt securing the hydraulic control unit bracket to frame rail

Note
1x bolt, 10mm, 10 Nm
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 the RH front brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the LH rear brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the RH rear brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the LH front brake line tube nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the master cylinder secondary pipe nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the master cylinder primary pipe nut from hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Move master cylinder brake lines out of the way to allow ABS ECU to be removed
Remove upper bolt securing the hydraulic control unit bracket to frame rail

Note
1x bolt, 10mm, 10 Nm
Remove the hydraulic control unit and bracket from vehicle

Note
2x tabs, Slide the HCU toward 12V battery area to remove
Loosen the fasteners securing the hydraulic control unit to the hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm
Pry hydraulic control unit from the bracket

Install

Install hydraulic control unit into hydraulic control unit bracket
Install the fasteners securing the hydraulic control unit to the hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm
Remove tape covering hydraulic control unit brake line orifices
Position the hydraulic control unit and bracket into vehicle for installation

Note
2x tabs, Align hydraulic control unit bracket datums into body
Move master cylinder lines into position for installation
Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket

Note
1x harness clip
Install the master cylinder primary pipe nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the master cylinder secondary pipe nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the LH front brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the RH rear brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the LH rear brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Install the RH front brake line tube nut to hydraulic control unit

Note
1x nut, 12mm, 16 Nm
Remove the fluid catcher from underneath vehicle
Install upper bolt securing the hydraulic control unit bracket to frame rail

Note
1x bolt, 10mm, 10 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
Install lower bolt securing the hydraulic control unit bracket to frame rail

Note
1x bolt, 10mm, 10 Nm
Raise front harness into position for installation
Install clips securing front harness to hydraulic control unit bracket

Note
2x clips
Slide intermediate shaft towards front of vehicle
Install FDU HV harness connector to FDU

Note
1x connector, Ensure the connector is installed far enough on the FDU manifold so the manifold alignment tooth is making contact with the connector lever
Secure FDU HV harness connection to FDU

Note
1x locking connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and engage red locking tab, Do not damage connector or header
Install bolt securing FDU HV harness to FDU

Note
1x bolt, 10mm, 10 Nm
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install the fasteners securing the hydraulic control unit to the hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm
Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket

Note
1x harness clip
Connect the hydraulic control unit connector

Note
1x connector, Gently push connector downward, Engage locking tab
Slide the intermediate shaft assembly downward to install it to the steering gear assembly

Note
Ensure the intermediate shaft is aligned and fully seated, if necessary to align the shaft to steering gear
Install bolt securing the intermediate shaft assembly to the steering gear assembly

Note
1x bolt, 13mm, 18 Nm
Secure front harness clips to LH frame rail

Note
3x clips
Connect LH front headlamp

Note
1x connector, Engage locking tab, Connector style may vary
Install clip securing HVIL connector harness onto body

Note
1x clip
Connect the HVIL connector

Note
1x locking connector, Engage locking tab
Install grounds G011 and G013 to LH frame rail

Note
2x bolts, 10mm, 10 Nm, Discard thread-cutting tri-lobular bolts after removal, If equipped with new bolts (1447438-00-A), fasteners can be reused
Resecure grounds G098 and G099 to the body

Note
2x bolts, 10mm, 10 Nm, Install new bolts if thread-cutting tri-lobular bolts were installed previously, Hand-start bolts at least 6 rotations before applying torque to avoid damaging the weld nut
Connect the logic connectors on steering gear

Note
2x connectors, Engage locking tabs
Connect the steering gear assembly connectors

Note
2x connectors, Engage locking tabs
Install clip securing front harness bracket to LH frame rail

Note
1x clip
Connect harness located at LH front rail bracket

Note
1x connector, Red locking tab, Connect from front of bracket and lock from opposite side of bracket, Image zoomed in for clarity
Install clips securing front harness and coolant hose onto brackets

Note
2x clips
Position shock tower brace assembly back for installation
Install bolts securing shock tower brace to LH shock tower

Note
2x bolts, 15mm, 55 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
Install bolts securing shock tower brace to RH shock tower

Note
1x bolt, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
Torque upper bolt securing shock tower brace to RH shock tower

Note
1x bolt, 15mm, 67 Nm
Install 12V battery into vehicle
Position battery tie down strap onto battery

Note
Hook upper tie down strap into rear tie down hook strap and position for installation
Install bolt securing upper tie down strap to AC compressor bracket

Note
1x bolt, 10mm, 5 Nm
Install vent tube hose in 12V battery
Install positive terminal and terminal cover

Note
1x nut, 10mm, 6 Nm, 2x clips
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
Install frunk assembly to vehicle

Note
12x clips, Make sure frunk assembly is fully seated onto clips, Number of clips may vary on older vehicles. Ensure A/C compressor HVIL harness is not pinched between frunk assembly and thermal beam
Install bolts securing frunk assembly

Note
7x bolts, 10mm, 5 Nm, Lower RBN covers after installing upper fasteners, Newer vehicles may not be equipped with covers
Install frunk close out panel

Note
4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align 3x tabs then push downward to secure clips
Install cabin intake upper duct assembly

Note
3x clips, Some configurations may come with 4x clips
Remove the steering wheel holder
Move LH front seat forward
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 RH front seat to original position
Move LH front seat to original position
Reinstall the vehicle software. See Software Reinstall - Touchscreen.
Clean area around brake fluid reservoir and remove brake reservoir cap
Top off brake fluid reservoir

Note
If necessary
Fill brake bleeder reservoir to full level
Install pressure bleeder adapter onto reservoir
Setup brake bleeder

Note
Connect power supply to bleeder and turn on the power to set pressure to 30 psi, Attach the brake reservoir hose to the brake adapter at this time
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 and search for "bleed"
Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open the LH front brake caliper outer bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEED and select Run to start the ESP and then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers, PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEED
Repeat the above step till clear fluid and no air bubble come out of the LH front brake caliper bleeding valve

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers, 2x covers
Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open the RH front brake caliper outer bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEED and select Run to start the ESP and then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers, PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEED
Repeat the above step till clear fluid and no air bubble come out of the RH front brake caliper bleeding valve

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers, 2x covers
Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open the RH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEED and select Run to start the ESP and then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper, PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEED
Repeat the above step till clear fluid and no air bubble come out of the RH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper, 1x cover
Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open the LH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEED and select Run to start the ESP and then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper, PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEED
Repeat the above step until clear fluid and no air bubble come out of the LH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper, 1x cover
Remove pressure bleeder adapter from reservoir
Check fluid level

Note
Top off if necessary
Install brake reservoir cap
Pump the brake pedal to ensure the brake pedal feels normal
Using Toolbox 3:
1. Select the Actions tab and search for "Stiffness".
2. Select the ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICE, and then click the link of the routine.
3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
4. Click RUN, and allow the routine to complete.
  
  Note
  Do not press the brake pedal during the test.
Remove fluid catcher from underneath vehicle
Install rear apron

Note
12x clips
Close hood
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
Position front aero shield to vehicle and install nuts

Note
2x nuts, 15mm, 5 Nm
Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield

Note
9x bolts, 10mm, 5 Nm
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 front wheel

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

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

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

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Lower vehicle until tires are touching ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Torque LH front wheel

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

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

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

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

Note
1x cap, Verify emblem is aligned with valve stem
Install LH front wheel center cap

Note
1x cap, Verify emblem is aligned with valve stem
Remove vehicle from lift

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

Note
Unlatch rear doors before closing
Perform a road test and burnish brakes

Note
Ensure proper brake pedal feel and performance Add correction code 00040100 as needed

Model 3 Service Manual

ABS Modulator (Heat Pump) (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3