23/10/2024 06:30:49

Hose - Inverter to Heat Exchanger - Front Drive Unit (Remove and Replace)

Correction code 18300132 1.80 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. Raise and support vehicle.
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    Note
    Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads, DO NOT position the lift arm pads under the battery or side rails, as shown in red.
  2. Open hood.
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    Note
    Via center display > Controls > Frunk Open.
  3. Power off vehicle via center display.
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    Note
    Controls > Safety & Security > Power Off.
  4. Remove rear underhood apron.
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    Note
    11x clips, 2x datums.
  5. Remove RH underhood apron.
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    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
  6. Remove LH underhood apron.
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    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
  7. Remove front underhood apron.
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    Note
    12x clips, 3 datums.
  8. Remove frunk access panel.
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    Note
    3x clips, 3x hooks, 1x connector.
  9. Remove frunk carpet.
  10. Remove frunk assembly.
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    Note
    8x bolts, 10mm, 5 Nm .
  11. Disconnect LV battery connector and First Responder Loop.
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    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL.
  12. Verify operation of multimeter.
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals.
  13. Raise vehicle fully and lower lift onto locks.
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    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.
  14. Remove clips securing mid aeroshield.
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    Note
    4x push clips.
  15. Remove bolts securing mid aeroshield and remove from vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  16. Install amp clamp to LH RDU HV harness.
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    Note
    Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down.If current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
  17. Remove all items from pockets and ensure not wearing metal items.
  18. Inspect HV insulating gloves.
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    Note
    Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves.
  19. Put on HV insulating gloves and leather over gloves.
  20. Release LH RDU HV harness from HV battery.
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    Note
    1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up.
  21. Verify no high voltage at LH rear RDU HV header.
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    Note
    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, 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.
  22. Remove leather over gloves and HV insulating gloves.
  23. Remove clips securing front aero shield.
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    Note
    5x push clips.
  24. Remove bolts securing front aero shield and remove from vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  25. Release clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  26. Remove bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  27. Remove bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  28. Remove bolts securing front skid plate to front subframe and remove skid plate.
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    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
  29. Position coolant drain container underneath front of vehicle.
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    Note
    Position to catch all coolant loss.
  30. Release clips securing FDU Inverter to oil cooler hose .
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    Note
    4x clips.
  31. Release FDU inverter hose from heat exchanger and allow hose to drain.
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    Note
    1x hose clip, Plug heat exchanger but allow inverter hose to drain fully.
  32. Remove coolant drain container from underneath vehicle.
  33. Place absorbent material underneath LH area of FDU.
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    Note
    Place absorbent material under LH front area of FDU, Prevent coolant spillage onto top of the HV battery.
  34. Lower vehicle until tires are touching the ground.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  35. Disconnect AC compressor logic connector.
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    Note
    1x locking electrical connector, Do not push down on red tab, Pull to disengage lock, Pull again to release connector .
  36. Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket.
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    Note
    1x fir tree clip.
  37. Remove fastener securing AC compressor HV harness bracket to AC compressor .
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    Note
    1x bolt, 13mm, 9 Nm.
  38. Disconnect HV harness connector from AC compressor.
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    Note
    1x locking electrical connector, Move black locking tab away form the AC compressor, Push down on locking connector to release and pull straight out of socket.
  39. Remove AC compressor ground strap.
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    Note
    1x bolt, T25, 7 Nm.
  40. Release clip securing the coolant hose to the AC compressor bracket.
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    Note
    1x fir tree clip.
  41. Remove PT coolant pump from AC compressor bracket.
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    Note
    Slide pump assembly away from compressor off lower bracket.
  42. Release the HV heat pump bracket from the compressor eyelet.
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    Note
    1x tab, Release bracket tab and rotate rearward and up to clear compressor eyelet.
  43. Set HV heat pump bracket aside.
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    Note
    Negotiate underneath high pressure pipe.
  44. Release compressor bracket from multi-system beam.
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    Note
    2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle and under the multi-system beam, Be cautious around the coolant hose and supermanifold harness, Place fender cover on fan housing and gently place AC compressor assembly down.
  45. Release inverter to oil cooler hose from FDU and remove hose.
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    Note
    1x hose clip, Plug inverter and prevent coolant spillage on top of the HV battery, Remove hose from vehicle.

Install

  1. Install FDU inverter to oil cooler hose into vehicle and secure hose.
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    Note
    1x hose clip, Route hose and install, Remove any plugs, Perform push-pull-push test.
  2. Position AC compressor bracket assembly into vehicle and secure AC compressor assembly to multi-system beam .
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    Note
    2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Carefully install the AC compressor and AC compressor bracket towards the rear of the vehicle and under the multi-system beam, Negotiate bracket around coolant hose and supermanifold harness, Hand start bolts.
  3. Torque AC compressor bracket bolts to multi-system beam.
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    Note
    2x bolts, 15mm, 31 Nm.
  4. Position HV heat pump bracket.
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    Note
    Negotiate underneath high pressure pipe.
  5. Secure HV heat pump bracket to AC compressor eyelet.
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    Note
    Ensure locking tab engages eyelet.
  6. Connect HV harness connector to AC compressor.
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    Note
    1x locking electrical connector, 3 stage locking connector, After fully seating the connector onto the AC compressor engage the black locking tab by pushing toward the AC compressor, Perform push-pull-push test to ensure proper seating.
  7. Install fastener securing AC compressor HV harness bracket to AC compressor .
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    Note
    1x bolt, 13mm, 9 Nm.
  8. Install AC compressor ground strap.
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    Note
    1x bolt, T25, 7 Nm.
  9. Secure PT coolant pump onto AC compressor bracket.
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    Note
    Slide pump assembly onto compressor lower bracket.
  10. Install clip securing the coolant hose to the AC compressor bracket.
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    Note
    1x fir tree clip.
  11. Raise vehicle fully and lower lift onto locks.
    Informational PurposesAn informational icon, calling your attention
    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.
  12. Remove absorbent material underneath LH area of FDU.
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    Note
    Remove absorbent material.
  13. Secure clips for the FDU Inverter to oil cooler hose .
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    Note
    4x clips.
  14. Secure FDU inverter hose onto heat exchanger.
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    Note
    1x hose clip, Remove any plugs, Perform push-pull-push test.
  15. Clean area and wipe away any residual fluid.
  16. Position front skid plate for installation and thread in all bolts .
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    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 15mm, 60 Nm, 2x bolts, 15mm, 30 Nm, 2x bolts, 10mm, 10 Nm, Torque at later step.
  17. Torque bolts securing front skid plate to body casting.
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    Note
    2x bolts, 15mm, 60 Nm.
  18. Torque bolts securing front skid plate to body sill.
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    Note
    2x bolts, 15mm, 30 Nm.
  19. Torque bolts securing front skid plate to front subframe.
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 15mm, 70 Nm, 2x bolts, 10mm, 10 Nm.
  20. Secure clips securing wheel house liner to front skid plate.
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    Note
    4x clips.
  21. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.
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    Note
    9x bolts, 10mm, 6 Nm.
  22. Install clips securing front aero shield.
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    Note
    5x push clips.
  23. Secure LH RDU HV harness to battery pack.
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    Note
    1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins.
  24. Apply Loctite 222 onto mid aeroshield bolts and install fasteners securing mid aeroshield to vehicle.
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    Note
    16x bolts, 10mm, 6 Nm.
  25. Install clips securing mid aeroshield.
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    Note
    4x push clips.
  26. Lower vehicle fully.
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
  27. Remove coolant bottle cap.
  28. Inspect coolant level and top off as necessary.
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required.
  29. Connect First Responder Loop and LV battery connector.
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    Note
    2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage upper locking tab when fully seated.
  30. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia 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
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    Note
    Make sure vehicle is not in drive state, Routine is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required.
  31. Inspect coolant level and top off as necessary.
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required.
  32. Install coolant bottle cap.
  33. Install frunk assembly.
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    Note
    8x bolts, 10mm, 5 Nm.
  34. Install frunk carpet.
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    Note
    Verify carpet is properly seated under the seal.
  35. Install frunk access panel.
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    Note
    3x clips, 3x hooks, 1x connector.
  36. Install front underhood apron.
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    Note
    12x clips, 3x datums.
  37. Install LH underhood apron.
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    Note
    11x clips, 2 datums.
  38. Install RH underhood apron.
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    Note
    11x clips, 2x datums.
  39. Install rear underhood apron.
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    Note
    11x clips, 2x datums.
  40. Close hood.
  41. Remove vehicle from lift.
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode".
  42. Calibrate the rear doors.
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    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.