23/05/2024 08:32:31

Cover - Inverter - Drive Unit - Front (Remove and Replace)

Correction code 39201002 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.

  • 2023-04-25: Updated "screw clip" to "brush clip".
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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. Move the vehicle to a 2 post lift. See Raise Vehicle - 2 Post Lift.
  2. On the touchscreen, enable Service Mode. See Service Mode (Enable and Disable).
  3. Set the steering wheel straight ahead, place a protector sheet onto the driver seat, and then install the steering wheel lock.
  4. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  5. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  6. Disconnect LV power. See LV Power (Disconnect and Connect).
  7. Set the high voltage multimeter to DC voltage, lightly touch the probes to the auxiliary battery connector contacts, and verify that the multimeter displays a voltage.
    Informational PurposesAn informational icon, calling your attention
    Note
    Battery voltage is typically 14.5 to 15.5 volts.
  8. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the leather glove protectors and the HV insulating gloves.
  11. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  12. Remove the bolt that attaches the steering column intermediate shaft to the steering rack input shaft.
  13. Slide the steering column intermediate shaft up and off of the steering rack input shaft.
  14. Pull the red tab, and then pull the red tab again to disconnect the electrical harness from the A/C compressor logic connector.
  15. Release the clip that attaches the electrical harness to the A/C compressor HV harness bracket.
  16. Remove the bolt that attaches the ground strap to the A/C compressor, and then remove the ground strap from the compressor.
  17. Remove the bolt that attaches the A/C compresor HV harness bracket to the A/C compressor.
  18. Slide the black locking tab, press the release, and disconnect the HV harness from the A/C compressor HV header.
  19. Release the HV heat pump bracket tab, rotate the HV heat pump bracket rearward and upward to release the bracket from the A/C compressor eyelet.
  20. Move the HV heat pump bracket out from under the A/C compressor discharge pipe, and then move to the LH side.
  21. Release the clip that attaches the coolant hose to the A/C compressor bracket.
  22. Slide the powertrain coolant pump away from the A/C compressor, and off of the A/C compressor lower bracket.
  23. With the help of an assistant, remove the bolts (x2) that attach the A/C compressor bracket to the multi-system beam, and then move the A/C compressor out from under the multi-system beam.
  24. Remove the bolt that attaches the front drive unit ground strap to the front drive unit.
  25. Setup and tighten ratchet straps so that the multi-system beam supports the LH side of the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the straps do not route over air suspension lines, coolant hoses, or electrical harnesses.
  26. Remove the bolts (x2) that attach the LH clevis mount to the LH frame rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the steering rack and front drive unit to help with bolt removal.
  27. Remove the bolts (x2) that attach the LH clevis mount to the LH isolator mount.
  28. Remove the bolts (x3) that attach the LH isolator mount to the front drive unit, and then remove the isolator mount from the drive unit.
  29. Move a coolant catcher under the LH front of the vehicle.
  30. Release the clip, disconnect the front drive unit inverter to heat exchanger hose from the front drive unit inverter outlet, and then immediately plug both fittings.
  31. Release the clip, disconnect the front drive unit inverter inlet hose from the front drive unit inverter, and then immediately plug both fittings.
  32. Release the fir tree clip that attaches the front drive unit inverter inlet hose to the front drive unit inverter.
  33. Release the locking tab, push the handle downward, and then disconnect the front subframe electrical harness from the front drive unit inverter logic connector.
  34. Release the clip that attaches the front subframe electrical harness to the front drive unit inverter.
  35. Remove the bolt that attaches the front drive unit HV harness bracket to the front drive unit inverter.
  36. Slide the red locking tab, raise the black handle, disconnect the front drive unit HV harness from the front drive unit inverter HV header,and then set the HV harness aside.
  37. Remove the brush clips (x2) that attach the front drive unit inverter cover to the front drive unit inverter, and then remove the cover from the inverter.

Install

  1. Install the front drive unit inverter cover to the front drive unit inverter, and then install the brush clips (x2) that attach the cover to the inverter.
  2. Verify that the black release lever of the front drive unit HV harness connector is in the open position, install the connector flat and square to the front drive unit inverter HV header, secure the release lever to the closed position, and then slide the red connector locking tab.
  3. Install the bolt that attaches the front drive unit HV harness bracket to the front drive unit inverter.
    10 Nm (7.4 lbs-ft)
  4. Fasten the clip that attaches the front subframe electrical harness to the front drive unit inverter.
  5. Connect the front subframe electrical harness to the front drive unit inverter logic connector, raise the handle upward, and fasten the locking tab.
  6. Fasten the fir tree clip that attaches the front drive unit inverter inlet hose to the front drive unit inverter.
  7. Remove the plugs from the fittings, immediately connect the front drive unit inverter inlet hose to the front drive unit inverter, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  8. Remove the plugs from the fittings, immediately connect the front drive unit inverter to heat exchanger hose to the front drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
  9. Move the coolant catcher out from under the vehicle.
  10. Install the LH isolator mount to the front drive unit, install and hand-tighten the bolts (x3) that attach the isolator mount to the drive unit.
  11. Tighten the front side bolts (x2) that attach the isolator mount to the drive unit.
    35 Nm (25.8 lbs-ft) +55 deg
    Informational PurposesAn informational icon, calling your attention
    Note
    The third bolt is torqued in a later step.
  12. Install the LH clevis mount to the LH isolator mount, and then install and hand-tighten the bolts (x2) that attach the clevis mount to the isolator mount.
  13. Install and hand-tighten the bolts (x2) that attach the LH clevis mount to the LH frame rail.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a pry bar between the steering rack and front drive unit to help with bolt installation.
  14. Tighten the forward bolt that attaches the clevis mount to the frame rail.
    65 Nm (47.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    The rearward bolt is tightened in a later step.
  15. Tighten the bolts (x2) that attach the LH clevis mount to the LH isolator mount.
    62 Nm (45.7 lbs-ft)
  16. Tighten the rear bolt that attaches the LH isolator mount to the front drive unit.
    35 Nm (25.8 lbs-ft) +55 deg
  17. Tighten the rearward bolt that attaches the LH clevis mount to the LH frame rail.
    65 Nm (47.9 lbs-ft)
  18. Slide the steering column intermediate shaft down and onto the steering rack input shaft.
  19. Install the bolt that attaches the steering column intermediate shaft to the steering rack input shaft.
    30 Nm (22.1 lbs-ft)
  20. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  21. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  22. Install the front drive unit ground strap to the front drive unit, and then install the bolt that attaches the ground strap to the drive unit.
    6 Nm (4.4 lbs-ft)
  23. With the help of an assistant, install the A/C compressor in under the multi-system beam, and then install and hand-tighten the bolts (x2) that attach the A/C compressor bracket to the multi-system beam.
  24. Tighten the bolts (x2) that attach the A/C compressor bracket to the multi-system beam.
    31 Nm (22.9 lbs-ft)
  25. Slide the powertrain coolant pump onto the A/C compressor lower bracket toward the A/C compressor.
  26. Fasten the clip that attaches the coolant hose to the A/C compressor bracket.
  27. Move the HV heat pump bracket in to under the A/C compressor discharge pipe.
  28. Rotate the HV heat pump bracket rearward and down to hook the bracket onto the A/C compressor eyelet, and then rotate the HV heat pump bracket down and against the A/C compressor.
  29. Connect the HV harness from the A/C compressor HV header, and then slide the black locking tab.
  30. Install the bolt that attaches the A/C compresor HV harness bracket to the A/C compressor.
    9 Nm (6.6 lbs-ft)
  31. Install the ground strap to the A/C compressor, and then install the bolt that attaches the ground strap to the compressor.
    7 Nm (5.2 lbs-ft)
  32. Fasten the clip that attaches the electrical harness to the A/C compressor HV harness bracket.
  33. Connect the electrical harness to the A/C compressor logic connector, and then push the red tab to secure the connector.
  34. Remove the ratchet strap supporting the LH side of the front drive unit from the multi-system beam.
  35. Connect LV power. See LV Power (Disconnect and Connect).
  36. Remove the steering wheel lock and remove the protector sheet from the driver seat.
  37. Remove the coolant reservoir cap and add coolant to the MAX line.
  38. On the touchscreen, touch the wrench icon > Diagnostics > Thermal > Actions.
    Informational PurposesAn informational icon, calling your attention
    Note
    Alternatively, touch Controls (vehicle icon) > Service Mode > Diagnostics > Thermal > Actions.
  39. Hold up on the turn signal stalk, and then press and hold the brake pedal at the same time for 10 seconds to authorize.
  40. On the touchscreen, touch START to the left of “Start Coolant Air Purge” and wait for the task to complete (10 minutes).
    Informational PurposesAn informational icon, calling your attention
    Note
    Alternatively, touch START to the left of “Start Coolant Air Purge”, touch RUN TASK, wait for the task to complete (10 minutes), then touch X in the upper left corner.
  41. Add coolant to the reservoir as necessary, and install the coolant reservoir cap.
  42. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  43. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  44. On the touchscreen, disable service mode. See Service Mode (Enable and Disable).
  45. Remove the vehicle from the 2 post lift. See Raise Vehicle - 2 Post Lift.