08/09/2022 16:26:07

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

Correction code 33109522 2.46 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.

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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

  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. Open the hood.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  6. Remove the RH wiper arm. See Wiper Arm - RH (Remove and Replace).
  7. Remove the LH wiper arm. See Wiper Arm - LH (Remove and Replace).
  8. Remove the cowl scree panel. See Panel - Cowl Screen (Remove and Replace).
  9. Disconnect LV power. See LV Power (Disconnect and Connect).
  10. Clean the area around the brake fluid reservoir, and then remove the brake reservoir cap.
  11. Remove the brake fluid from the brake reservoir.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use special tool 1541474-00-B - measure & fill kit.
  12. Install the brake reservoir cap.
  13. Remove the bolts (x2) that attach the remote brake fluid reservoir to the LH FST cap.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the reservoir with bracket out of the LH FST cap.
  14. Remove all wheels. See Wheel Assembly (Remove and Install).
  15. Remove the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  16. Disconnect the LH front repeater electrical connectors (x2).
  17. Release the clip that attaches the LH repeater electrical harness to the body.
  18. 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.
  19. 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
  20. Disconnect the hydraulic control unit electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Release the red locking tab, and then rotate the lever upwards to remove it.
  21. Pull the HCU ECU harness and connector through the body into the wheelwell.
  22. Remove 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
  23. Put shop towels underneath the brake lines to catch any brake fluid that may leak.
  24. Disconnect the brake fluid level sensor electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull the red tab to disengage the lock, and then pull again to release the electrical connector. Do not push down on the red tab.
  25. Remove the flexible 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 flex head
  26. Remove the nuts (x4) that attach 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 flex head
  27. Release the brake line retainers (x2) from the underside of the HCU bundle.
  28. Release the brake lines from the LH side of the HCU bundle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Retainers (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Support and shift the HCU with one hand while using the side access hole to release the lines.
  29. Remove the HCU, bracket, and MCYL to HCU 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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care not to bend the brake lines.
  30. Remove the nuts (x2) that attach the flexible master cylinder 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 flex head
  31. Loosen 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
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts do not need to be fully removed since the bracket is slotted.
  32. Release the snapfit pin, and then remove the HCU from the HCU bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pry between the bracket and HCU to release.

Install

  1. Install the ECU to the HCU bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Snapfit pin (x1)
    Informational PurposesAn informational icon, calling your attention
    Note
    Align the bracket to the rubber bushings, and then press together to secure the snapfit pin.
  2. Install 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. Remove the protective tape, and then install the flexible master cylinder 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 flex head
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the protective tape covering the 4 tube outlets to prevent contamination during installation.
  4. Install the HCU, bracket, and MCYL to HCU brake lines to the vehicle as an assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate and lower the assembly down along the brake booster while shifting the 4-tube brake lines over.
    Informational PurposesAn informational icon, calling your attention
    Note
    Take care not to bend the brake lines.
  5. Secure the brake lines to the LH side of the HCU bundle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Retainers (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Support and shift the HCU with one hand while using side access hole to secure the brake lines.
  6. Secure the brake lines to the underside of the HCU bundle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Retainers (x2)
  7. Push the HCU ECU harness and connector through the body into the frunk area.
  8. Connect the HCU electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    Seat the connector, then rotate the lever downward, and then secure the locking tab.
  9. Remove the remaining protective tape, and then 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 flex head
    Informational PurposesAn informational icon, calling your attention
    Note
    Nuts (x4).
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the brake lines with brake cleaner before mating, as needed.
  10. Install the flexible brake lines (x2) to the master cylinder.
    16 Nm (11.8 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 12 mm ratcheting combination wrench flex head
    Informational PurposesAn informational icon, calling your attention
    Note
    Clean the brake lines with brake cleaner before installation.
  11. Connect the brake fluid level sensor electrical connector.
  12. Remove the shop towels from underneath the brake lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    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
    Informational PurposesAn informational icon, calling your attention
    Note
    Start to fasten bolts by hand to prevent cross-threading.
  14. 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
  15. Connect the ground junction connector G500.
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure the red locking tab.
  16. Fasten the LH repeater electrical harness to the body.
  17. Connect the LH front repeater electrical connectors (x2).
    Informational PurposesAn informational icon, calling your attention
    Note
    Support the repeater from the exterior to prevent damage to the retaining clips.
  18. Install the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  19. Install the bolts (x2) that attach the remote brake fluid reservoir to the LH FST cap.
    8 Nm (5.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the reservoir with bracket onto the LH FST cap.
  20. Install the cowl scree panel. See Panel - Cowl Screen (Remove and Replace).
  21. Install the RH wiper arm. See Wiper Arm - RH (Remove and Replace).
  22. Install the LH wiper arm. See Wiper Arm - LH (Remove and Replace).
  23. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace).
  24. Reconnect LV power. See LV Power (Disconnect and Connect).
  25. Bleed the brakes. See Brake Fluid Bleed/Flush (Remove and Replace).
  26. Install all wheels. See Wheel Assembly (Remove and Install).
  27. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  28. Close the hood.
  29. Remove the vehicle from the lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower the rack arms fully and remove them from under the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the air suspension from "Jack Mode."
  30. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors
  31. Perform a road test and ensure proper brake pedal feel and performance.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add correction code (00040100) to account for time.