06/01/2023 16:08:09

HV Header - Inverter - Front Drive Unit (Remove and Replace)

Correction code 39206302 5.04 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

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

Remove the HV battery. See HV Battery (AWD) (Remove and Install).
Lower vehicle until tires are touching the ground.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Lock steering wheel into position.
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.
Remove AC compressor ground strap.

Note
1x bolt, T25, 7 Nm.
Release AC compressor HV harness clip from body.

Note
1x clip.
Release bolts securing AC compressor bracket to multi system beam.

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Carefully support the AC compressor assembly and allow it to hang, Prevent damage to any components.
Release FDU logic connector.

Note
1x locking connector, Disengage lock and remove, Maneuver compressor assembly away as needed.
Install leak test adapter plug to 12V connector at inverter.

Note
Inspect O-ring and replace if necessary.
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.
Remove bolt securing steering gear assembly to electric steering column.

Note
1x bolt, 13mm, 30 Nm.
Remove LH toeboard brace.

Note
3x bolts, 15mm, 30 Nm.
Position coolant drain container under the front of the vehicle to catch vehicle coolant.
Release rear PT hose from FDU inverter.

Note
1x hose clip, Plug both ends as needed.
Remove FDU HV harness.

Note
1x bolt, EP10, 10 Nm, 1x connector, Release red locking tab and carefully disengage lever to remove connector, Release clip from drive unit.
Remove bolts securing HV header to FDU inverter.

Note
2x bolts, T25, 6 Nm, Discard fasteners after removal.
Remove HV header using removal tool.

Note
2x datums, Line up drive unit header removal tool, Firmly engage lever inwards to release the locking tabs, It may take some maneuvering to achieve, With locks disengaged, Remove header with tool from inverter, Use plastic trim tool to aid if required.
Remove retainer from LH rear inverter.

Note
6x clips, Take note of original position, Carefully use a pick to remove and save the retainer.
Separate HV header from housing and retainer.

Install

Secure retainer onto HV header.

Note
6x clips.
Secure HV header on FDU inverter.

Note
2x datums, Seat header with retainer and press in, Audible click should be heard, Perform push pull push test and verify it is properly seated before installing bolts.
Install bolts securing header to inverter.

Note
2x bolts, T25, 6 Nm, Install new fasteners.
Install leak test adapter to FDU HV connector.
Connect regulator to leak test adapter.
Close both valves on the regulator test tool.

Note
Verify valves are closed.
Connect regulator to air supply.
Turn on regulator and open valve closest to regulator.
Set regulator to 1 psi.
Open the 2nd valve to inject air into the inverter.

Note
Close valve when pressure reaches 1 psi and stable.
Wait 45 seconds for pressure to settle.
Record start pressure valve.
Wait 60 seconds for test.
Record end pressure valve.

Note
If pressure did not drop more than 0.04 psi, continue to next step. If pressure dropped more than 0.04 psi, then inspect for leaks.
Disconnect air supply from regulator tool.
Disconnect regulator from leak test adapter.
Install FDU HV harness.

Note
1x bolt, EP10, 10 Nm, 1x connector, 1x tab, 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, Engage clip on drive unit.
Secure rear PT hose to FDU inverter.

Note
1x hose clips, Perform push-pull-push test, Remove any plugs.
Remove coolant drain container from underneath vehicle.
Install LH toeboard brace.

Note
3x bolts, 15mm, 30 Nm.
Slide lower electric steering column onto steering gear and install bolt.

Note
1x bolt, 13mm, 30 Nm.
Lower vehicle until tires are touching the ground.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Remove leak test adapter plug from 12V connector at inverter.

Note
Carefully remove leak test adapter.
Secure FDU logic connector.

Note
1x locking connector, Secure connector and engage locking tab.
Install bolts securing AC compressor bracket to multi system beam.

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Carefully support the AC compressor assembly and secure assembly, Prevent damage to any components, Remove any bungee cords.
Secure AC compressor HV harness clip from body.

Note
1x clip.
Install AC compressor ground strap.

Note
1x bolt, T25, 7 Nm.
Remove steering wheel holder from vehicle.
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 the HV battery. See HV Battery (AWD) (Remove and Install).