29/11/2023 19:15:13
Heat Exchanger - Front Drive Unit (Remove & Replace)
Correction code 39308512 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 to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See to make sure wearing proper PPE 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.
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Set up A/C machine and perform hose flush
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Open LH front door
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Raise and support vehicle
NoteSet air suspension to Jack Mode, Via Controls > Service > Jack Mode, Raise lift until arms contact the lift points
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Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2
Note2x clips, 1x connector, Drive rail must be ON, Toolbox 2 program must be in current service default. Toolbox 2.0 vehicle connection will enable diagnostic mode
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In toolbox, run the refrigerant drain and fill routine to enable A/C filling
NoteClick Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play
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Using MCU open LH falcon door, hood and liftgate
NoteVia center display > Controls > Front Trunk, Trunk, LH Falcon Door
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Open hood
NoteVia center display > Controls > Front Trunk
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Remove underhood aprons
Note4x aprons, LH and RH aprons have 1x clip each
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Remove dust caps from vehicle’s high-side and low-side service ports
Note2x threaded caps
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Connect hoses to vehicle and perform A/C recovery
Note(Touch time only) Ensure quick connects are fully engaged, turn connector dials clockwise to fully connect to A/C service ports
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Remove frunk carpet
Note2x connectors
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Remove underhood storage unit
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
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Remove HEPA filter
NoteLift up from bottom and pull out
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Remove LH outer hood hinge cover
Note2x clips
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Remove RH outer hood hinge cover
Note2x clips
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Disconnect wiper arm hose from cowl
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Remove LH wiper arm
Note1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl
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Remove RH wiper arm
Note2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl
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Release cowl screen washer supply hose
Note1x one way valve
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Remove wiper cowl screen panel
Note5x push clips, 1x windshield washer hose, 1x drain hose clamp
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Remove HEPA filter duct
Note1x clip
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Remove A/C lines from vehicle
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Overlap time for A/C recovery
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Move LH 2nd row seat forward using easy entry mode
NotePress easy entry button located on seat back near headrest, Partially fold upper seat forward to roughly a 45-degree position, Slide seat track forward by pulling seat towards front of vehicle
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Remove LH rear welcome plate
Note8x clips
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Apply tape to LH racetrack to avoid damage
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Remove front screw securing LH lower C-pillar
Note1x screw, T25, 2.5 Nm, Discard patch bolt
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Fold down LH 3rd row seat
NotePress button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
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Remove rear load floor
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Remove LH trunk sill side trim
Note4x clips
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Remove RH trunk sill side trim
Note4x clips
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Remove trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Discard after removal
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Remove trunk board
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Remove trunk floor carpet
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Remove rear load floor support
Note4x push clips, 2x clips
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Remove screw securing LH C-pillar mid trim
Note1x screw, T20, 2 Nm
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Release clips securing LH C-pillar mid trim and remove
Note9x clips
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Remove fasteners securing LH upper C-pillar trim panel
Note1x patch bolt, T25, 3 Nm, 3x screws, T20, 2 Nm
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Release clips and remove LH upper C-pillar trim panel
Note6x clips, 2 clips along front edge and 4 clips along top edge
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Remove load floor support from LH lower C-pillar
Note3x tabs, 1x clip
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Remove screws securing C-pillar lower panel to LH parcel shelf support
Note2x screws, T20, 2 Nm
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Release clips securing LH C-pillar lower panel along front edge and remove panel
Note9x clips, 1x magnet
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Remove vent cover from trunk side carpet
Note8x tabs
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Release clips securing LH rear trunk side carpet panel to bracket
Note5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
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Release load floor support from LH trunk side carpet
Note3x tabs, 1x clip
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Remove LH trunk side carpet panel
Note2x connectors, Disconnect trunk light and 12V outlet connectors before removal, Pull rear lower corner of LH trunk side carpet panel out and downwards to remove panel
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Remove LH mid-zone C-pillar bracket from vehicle
Note2x screws, T20, 2.5 Nm, 3x push clips, 2x edge clips, Release edge clips securing charge port release cables, The following 6 steps apply to vehicles with rear HVAC and can be skipped for 5 seat configuration
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Remove LH minion bracket from vehicle
Note3x push clips
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Fold LH 3rd row seat up
NotePress button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
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Remove bolt securing front edge of LH trunk trim bracket
Note1x bolt, T30, 2.5 Nm
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Fold down LH 3rd row seat
NotePress button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
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Remove fasteners securing LH trunk trim bracket and remove from vehicle
Note2x bolts, T30, 2.5 Nm, 1x push clip
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Remove charger duct
NoteRelease from plastic ducts at top and bottom
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Power down vehicle
NoteVia center display > Controls > Safety > Power Off
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Disconnect 12V negative terminal
Note1x nut, 10mm, 5 Nm
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Disconnect first responder loop
Note1x connector, push to release
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Remove warranty label from charger cover panel
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R1.pdf
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Put on HV insulating gloves and leather over gloves
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Remove charger access panel
Note11x patch bolts, T20, 2 Nm, Discard after removal, Make sure to wear proper PPE
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Release tabs and open small access door
Note2x tabs
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Verify no high voltage
NoteMeasure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, Verify you are using a proper ground and not a coated surface, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work escalate a toolbox session for assistance
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Remove leather over gloves and HV insulating gloves
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Remove coolant reservoir cap
Note1x cap
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Use vacuum suction tool to remove coolant from reservoir
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Remove coolant reservoir cap
Note1x cap
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Disconnect electrical connector for coolant level sensor
Note1x connector
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Remove coolant reservoir fasteners and wire harness edge clip
Note4x bolts, 10mm, 6 Nm, 1x edge clip
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Clamp and remove coolant hose and move reservoir off to the side
Note1x coolant hose, Place absorbent material below hose to capture fluid
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Release the ground connection at the A/C compressor mount bracket
Note1x bolt, T25, 7 Nm
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Disconnect the A/C compressor harness
Note2x connectors, 2x fir clips
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Remove discharge line from compressor
Note1x nut, 10mm, 10 Nm, Discard O-rings after removal
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Move compressor harness away from bracket
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Remove the fir tree clips securing the A/C compressor HV harness to the front drive unit
Note2x fir tree clips
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Disconnect A/C compressor harness at FJB and release cable from drive unit
Note1x connector, 1x fir tree clip
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Remove the fasteners securing the A/C compressor to the FDU
Note3x bolts, E10, 10 Nm
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Support the A/C compressor and remove assembly from the front drive unit
NoteSet A/C compressor/bracket assembly to the side
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Remove the upper fastener securing the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
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Raise vehicle fully and lower onto locks
NoteSet 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
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Remove front aero shield
Note6x bolts, 10mm, 3 Nm, 14x clips
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Remove front bash plate extrusion
Note2x bolts, T30, 16 Nm
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Loosen 21mm bolts securing front of HV battery
Note2x bolts, 21mm, 115 Nm, Discard after removal
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Remove 21mm bolts securing front of HV battery
Note2x bolts, 21mm, 115 Nm, Discard after removal
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Loosen front four HV battery bolts
Note4x patch bolts, 13mm, 30 Nm, Discard after removal
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Remove front four HV battery bolts
Note4x patch bolts, 13mm, 30 Nm, Discard after removal
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Remove skid plate from front subframe
Note2x bolts, 10mm, 9 Nm
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Position the oil drain under oil pump area
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Disconnect the front drive unit oil pump connector
Note1x electrical connector
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Remove the fasteners securing the oil pump to the FDU
Note2x bolts, EP10, 5 Nm + 20 degrees
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Remove the oil pump from the FDU
NotePry the pump away from the FDU with a pry tool or flat blade screwdriver, Ensure the FDU casting is not damaged, Allow the oil to drain from the FDU
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Position fold able funnel
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Remove the oil filter from the FDU
NoteSpin counterclockwise, 3 Nm and 135 degrees, Allow oil to drain,Install a new oil filter after removal
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Remove foldable funnel
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Remove oil drain container from under vehicle
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Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
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Release FDU outlet hose from heat exchanger and plug heat exchanger
Note1x spring clip, Allow excess coolant to fully drain
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Release upper coolant hose from heat exchanger and plug heat exchanger
Note1x spring clip, Allow excess coolant to fully drain
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Release the clip securing the oil pump harness to the heat exchanger
Note1x fir tree clip
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Remove the fir tree clip from the heat exchanger and move hose aside
Note1x fir tree clip
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Remove the lower fastener securing the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
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Remove heat exchanger from FDU assembly
NoteSome oil will spill out of the FDU after removal
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Inspect seals of new heat exchanger
NoteReplace any damaged seals, Lubricate with drive unit oil before installation
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Position heat exchanger onto FDU assembly
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Install the upper fastener securing the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
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Install the lower fastener securing the heat exchanger to the FDU
Note1x bolt, EP10, 5 Nm + 30 degrees
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Install the clip securing the upper coolant hose to the heat exchanger
Note1x fir tree clip
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Secure upper coolant hose onto heat exchanger
Note1x spring clip, Perform push-pull-push test
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Secure FDU outlet hose onto heat exchanger
Note1x spring clip, Perform push-pull-push test
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Install the clip securing the oil pump harness pigtail to the heat exchanger
Note1x fir tree clip
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Remove coolant drain container from under the LH front of the vehicle
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Position the oil drain under oil pump area
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Remove the fill plug from the FDU
Note1x plug, 8mm Allen, 15 Nm
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Inspect seals and o-rings
NoteInspect o-rings on removed parts, 3 o-rings on pump, one o-ring on fill plug, if missing o-ring on pump ensure it is not left in housing, if damaged o-ring on plug replace affected plug, Replace all o-rings on oil pump if damaged, Check seal on oil filter, if missing check if still on housing and remove before install
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Install new oil filter
NoteSpin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation
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Install the oil pump into the FDU
NoteUse residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing
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Install the fasteners securing the oil pump to the FDU
Note2x bolts, EP10, 5 Nm + 20 degrees
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Set up fill kit
NoteSet fluid level to 2000 mL in measuring container
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Install fluid transfer pump
NoteTrim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm
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Set up fill process
NotePlace measured fluid container in drain basket, fully submerge input hose, prime pump with ATF fluid
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Connect the 12V power supply to oil pump
Note1x connector
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Pump ATF fluid into Raven front drive unit
NoteAssistant required, Pump 5 full strokes from fluid container, then run pump via switch box for entire fill and keep running until drain plug installed, Do not run pump when dry, If pump is not running and drain plug not installed fluid will drain from plug within 10 seconds
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Install fill plug into the FDU
Note1x plug, 8mm Allen, 15 Nm
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Disconnect 12V power supply tool from oil pump
Note1x electrical connector
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Connect the front drive unit oil pump connector
Note1x electrical connector
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Spray area with brake cleaner and wipe residual fluid off with towel
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Remove oil drain from under vehicle
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Install skid plate between battery pack and subframe
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Install bolts that secure skid plate to subframe
Note2x bolts, 10mm, 10 Nm
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Install front bolts for HV battery with battery powered drill
Note4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
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Torque the front bolts for HV battery
Note4x bolts, 13mm, 30 Nm
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Install 21mm bolts at front of HV battery with battery powered drill
Note2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
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Torque bolts securing front of HV battery to vehicle
Note2x bolts, 21mm, 115 Nm
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Install front bash plate extrusion
Note2x bolts, T30, 16 Nm
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Install front aero shield
Note6x bolts, 10mm, 3 Nm, 14x clips
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Lower vehicle fully
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Close small access door
Note2x tabs
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Install charger access panel
Note11x patch bolts, T20, 2 Nm, Install new patch bolts
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Clean area around charger access panel prior to installation of new warranty label
NoteAllow IPA to dry for at least 1 minute
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Install new warranty label
NoteClean area with IPA alcohol wipes and allow area to dry before placing new warranty label
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Install A/C compressor
Note3x bolts, E10, 10 Nm
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Install discharge A/C line to compressor
Note1x nuts, 10mm, 10 Nm, Replace the O-rings
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Connect the A/C compressor harness
Note2x electrical connectors, 2x fir clips
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Secure the ground connection at the A/C compressor mount bracket
Note1x bolt, T25, 7 Nm
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Install the fir tree clips securing the A/C compressor HV harness to the front drive unit
Note2x fir tree clips
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Connect A/C compressor harness to FJB
Note1x connector
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Connect coolant hose to reservoir and remove hose clamp
Note1x coolant hose
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Connect coolant reservoir level sensor
Note1x connector
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Install fasteners securing coolant reservoir to shock tower cross member
Note4x bolts, 10mm, 6 Nm
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Install HEPA filter duct
Note1x clip
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Remove wiper cowl screen panel
Note5x push clips, 1x windshield washer hose, 1x drain hose clamp
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Connect cowl drain hose onto cowl trim
Note1x clamp
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Conenct cowl screen washer supply hose
Note1x one way valve
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Install RH wiper arm
Note2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
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Install LH wiper arm
Note1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
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Connect wiper arm hoses to cowl
Note2x washer hoses
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Install LH outer hood hinge cover
Note2x clips
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Install RH outer hood hinge cover
Note2x clips
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Connect first responder loop and then 12V negative terminal
Note1x connector, 1x nut, 10mm, 5 Nm
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Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2
Note2x clips, 1x connector, Drive rail must be ON, Toolbox 2 program must be in current service default. Toolbox 2.0 vehicle connection will enable diagnostic mode
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Perform coolant purge
NoteClick Panels > Thermal > ''Coolant Air Purge'' and press PlayPer current FRT (18300000) 0.15 hrs, Monitor and top off fluid as required
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Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2
Note2x clips, 1x connector, Drive rail must be ON, Toolbox 2 program must be in current service default. Toolbox 2.0 vehicle connection will enable diagnostic mode
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In toolbox, run the refrigerant drain and fill routine to enable A/C filling
NoteClick Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play
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Connect hoses to vehicle and perform A/C vacuum and leak test
Note(Touch time only)30 minute vacuum, 10 minute leak testEnsure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports
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Inject oil into the system
NoteRefill with the amount removed during recovery
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Perform A/C refrigerant refill
NoteRun time, per fluid capacity spec
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Install HEPA filter housing
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Install underhood storage unit
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
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Install frunk carpet
Note2x connectors
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Remove A/C lines from vehicle
NotePress clear lines once lines have been removed
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Install dust caps onto vehicle high and low side service ports
Note2x threaded caps
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Install under hood aprons
Note4x aprons
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Close hood
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Perform A/C hose flush
NoteTouch time only. No overlap from this since the machine is disconnected from the vehicle.
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Test A/C functions in vehicle to ensure cabin cooling functions as designed
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Disconnect laptop from vehicle and install storage cubby
Note1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby
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Calibrate falcon doors via UI
NoteVia Controls > Calibrate, Required after 12V and FRL disconnect
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Remove vehicle from lift
NoteLower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode", Via Controls > Service > Jack Mode
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Reinstall LH rear charger duct
NoteSecure to plastic ducts at top and bottom
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Reinstall LH trunk trim bracket and loosely install fastener
Note1x bolt, T30, 2.5 Nm, 1x push clip
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Fold LH 3rd row seat up
NotePress button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
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Loosely install bolt securing front edge of LH trunk trim bracket
Note1x bolt, T30, 2.5 Nm
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Install LH minion bracket
Note3x clips
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Tighten fasteners securing LH trunk trim bracket
Note2x bolts, T30, 2.5 Nm, 1x push clip
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Fold LH 3rd row seat down
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Install LH mid zone C-pillar bracket and install fasteners
Note2x screws, T20, 2.5 Nm, 3x push clips, Secure 2x edge clips for charge port release cables
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Install LH trunk side carpet panel
Note2x connectors, Reconnect trunk light and 12V outlet connectors before positioning panel, Use caution not to pinch rear PTC harness, See image for details
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Reposition vent cover back bracket, then install vent cover to LH trunk side carpet
Note8x clips
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Install clips securing LH rear trunk side carpet panel to bracket
Note5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
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Verify charge port mechanical release cable is in proper position in trunk side carpet panel
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Install LH trunk side load floor support
Note3x tabs, 1x clip
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Install rear load floor support
Note4x push clips, 2x clips
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Reinstall front lower carpet trim panel
NoteSecure 3rd row seat wiring harnesses to panel
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Install trunk board
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Install rear trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
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Install RH trunk sill side trim
Note4x clips
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Install LH lower C-pillar and secure clips along front edge
Note9x clips, 1x magnet
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Install screws securing C-pillar lower panel to LH parcel shelf support
Note2x screws, T20, 2 Nm
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Install trunk side nub to lower C-pillar
Note3x tabs, 1x clip
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Install bolt securing front of LH lower C-pillar
Note1x patch bolt, T25, 2.5 Nm
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Remove tape from LH racetrack trim
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Install LH welcome plate
Note8x clips
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Install LH upper C-pillar trim panel
Note6x clips
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Install fasteners securing LH upper C-pillar
Note1x patch bolt, T25, 3 Nm, 3x screws, T20, 2 Nm, Install new patched bolt
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Install screw securing LH rear C-pillar mid trim
Note1x screw, T20, 2 Nm
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Install LH trunk sill side trim
Note4x clips
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Install rear load floor
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Fold LH 3rd row seat up
NotePress button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
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Close liftgate
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Move LH and RH 2nd row seat from the easy entry position to the regular upright seating position
NoteSlide seat track backwards by pushing towards rear of vehicle, Fold upper seat backwards until locked in an upright position
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Close LH Falcon door
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Close LH front door