23/11/2022 10:15:32

Hydraulic Control Unit (HCU) - Brake (Remove and Replace)

Correction code 33109522 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 proper PPE is worn when performing the below procedure.

Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Special tool required: 1541474-00-B - Measure and fill kit

Remove

  1. Open the LH front door and lower the LH front window.
  2. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  3. Remove all wheels. See Wheel Assembly (Remove and Install).
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Disconnect LV power. See LV Power (Disconnect and Connect).
  6. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  7. Remove the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace).
  8. Remove the LH and RH shock tower covers. See .
  9. Remove the wiper cowl screen panel. See .
  10. Remove the bolts (x3) that attach the LV battery, and then move the LV battery aside.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm ratcheting combination wrench
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Take note of the datums and carefully move the LV battery aside.
  11. Remove the LH shock tower V-brace. See V Brace - Shock Tower - LH (Remove and Replace).
  12. Clean the area around the brake fluid reservoir, and then remove the brake reservoir cap.
  13. Remove brake fluid from the brake reservoir using the measure and fill kit (1541474-00-B).
  14. Install the brake reservoir cap.
  15. Disconnect the air quality sensor electrical connector.
  16. Remove the HEPA filter assembly cover.
    Informational PurposesAn informational icon, calling your attention
    Note
    Tabs (x2), datums (x2), slots (x2)
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not damage the mounting clips. Maneuver the cover forward and up in front of the V-brace cross member.
  17. Remove the battery controller module. See Module - Battery Controller (Remove and Replace).
  18. Remove the LH front wheel arch liner. See .
  19. Disconnect the LH front repeater electrical connectors (x2).
  20. Release the clip that attaches the LH repeater electrical harness to the body.
  21. Disconnect the LH front ride height sensor electrical connector.
  22. Disconnect the ground junction connector G500.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab. Press the black tab and rotate the lever to release it.
  23. Remove the bolt that attaches the junction ground terminal to the body.
    15 Nm (11.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  24. Push the LH wheelwell section of the front main harness through the body into the frunk.
  25. Remove the bolts (x3) that attach the Hydraulic Control Unit (HCU) bracket to the vehicle.
    8.5 Nm (6.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • Torx T40 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt location may vary in early production models.
  26. Place shop rags beneath the brake lines to catch any fluid lost.
  27. Disconnect the brake fluid level sensor electrical connector.
  28. Disconnect the brake lines (x2) from the master cylinder.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
  29. Remove the 4-tube bundle brake lines from the HCU.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
  30. Disconnect the electrical connector from the HCU.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab and rotate the lever upward to disconnect.
  31. Apply tape to the HCU harness connector to prevent brake fluid leaking into the connector.
  32. Release the clips (x2) that attach the brake lines to the bottom of the HCU bundle.
  33. Release the clips (x2) that attach the brake lines to the LH side of HCU bundle.
    Tip: Support the HCU with one hand while using side the access hole to release the lines.
  34. Remove the HCU, bracket and brake lines from vehicle as an assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate and lift assembly up along the brake booster while shifting 4-tube brake lines aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not bend the brake lines.
  35. Remove the master cylinder brake lines (x2) from the HCU.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
  36. Loosen the nuts that attach the HCU to the HCU bracket.
    Tip: The nuts do not need to be fully removed because the bracket is slotted.
  37. Remove the pin that attaches the HCU to the HCU bracket.
    Tip: Pry between bracket and HCU to release the pin.

Install

  1. Position the HCU to the HCU bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the bracket to the rubber bushings and press together to attach the snapfit pin.
  2. Tighten the nuts (x2) that attach the HCU to the HCU bracket.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  3. Peel back the protective tape, and then install the master cylinder brake lines (x2) to the HCU.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
    • 12 mm open crowfoot socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the tape covering the 4-tube outlets to prevent contamination during installation.
  4. Install the HCU assembly to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate and lower the assembly down along the brake booster while shifting 4-tube brake lines over.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not bend the brake lines.
  5. Position the clips (x2) that attach the brake lines to LH side of the HCU bundle.
    Tip: Support the HCU with one hand while using side the access hole to attach the brake lines to the clips.
  6. Attach the brake lines (x2) to the bottom of the HCU bundle.
  7. Remove the tape from the HCU harness connector.
  8. Connect the HCU electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat the connection and rotate the lever downward, then insert the red locking tab.
  9. Remove the remaining protective tape and install the 4-tube bundle brake lines to the HCU.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
    • 12 mm open crowfoot socket
    Tip: Clean the threads of the brake lines with brake cleaner before mating.
  10. Install the brake lines to the master cylinder.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench
    • 12 mm open crowfoot socket
    Tip: Clean the threads of the brake lines with brake cleaner before mating.
  11. Connect the brake fluid level sensor electrical connector.
  12. Remove the shop rags from beneath the brake lines, and then clean up any residual fluid lost.
  13. Install the bolts (x3) that attach the HCU bracket.
    8.5 Nm (6.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    • Torx T40 socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start the bolts to prevent cross-threading.
    Informational PurposesAn informational icon, calling your attention
    Note
    The bolt location may vary in early production models.
  14. Route the LH wheelwell section of the front main harness through the body.
  15. Install the bolt that attaches the junction ground terminal to the body.
    15 Nm (11.1 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
  16. Connect the ground junction connector G500.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the red locking tab.
  17. Connect the LH front ride height sensor electrical connector.
  18. Insert the clip that attaches the LH repeater harness to the body.
  19. Connect the electrical connectors (x2) to the LH front repeater.
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the repeater from exterior to prevent damage to the retaining clips.
  20. Install the LH front wheel arch liner. See .
  21. Install the battery controller module. See Module - Battery Controller (Remove and Replace).
  22. Install the HEPA filter assembly cover. See Filter - HEPA (Remove and Replace).
  23. Install the LH shock tower V-brace. See V Brace - Shock Tower - LH (Remove and Replace).
  24. Install the cowl screen panel. See .
  25. Install the LV battery. See Battery - LV (Remove and Replace).
  26. Install the LH and RH wiper arms. See Wiper Arm - LH (Remove and Replace).
  27. Install the LH and RH shock tower covers. See .
  28. Connect LV power. See LV Power (Disconnect and Connect).
  29. Connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  30. Perform a firmware reinstall. See Firmware Reinstall - Toolbox.
  31. Perform a brake fluid flush. See Brake Fluid Bleed/Flush (Remove and Replace).
  32. Disconnect the laptop from the vehicle. See Toolbox 3 (Connect and Disconnect).
  33. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  34. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  35. Install all wheels. See Wheel Assembly (Remove and Install).
  36. Perform a vehicle road test. Make sure proper brake pedal feel and performance is achieved.