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.

Set up A/C machine and perform hose flush
Open LH front door
Raise and support vehicle

Note
Set air suspension to Jack Mode, Via Controls > Service > Jack Mode, Raise lift until arms contact the lift points
Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2

Note
2x 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
In toolbox, run the refrigerant drain and fill routine to enable A/C filling

Note
Click Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play
Using MCU open LH falcon door, hood and liftgate

Note
Via center display > Controls > Front Trunk, Trunk, LH Falcon Door
Open hood

Note
Via center display > Controls > Front Trunk
Remove underhood aprons

Note
4x aprons, LH and RH aprons have 1x clip each
Remove dust caps from vehicle’s high-side and low-side service ports

Note
2x threaded caps
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
Remove frunk carpet

Note
2x connectors
Remove underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Remove HEPA filter

Note
Lift up from bottom and pull out
Remove LH outer hood hinge cover

Note
2x clips
Remove RH outer hood hinge cover

Note
2x clips
Disconnect wiper arm hose from cowl
Remove LH wiper arm

Note
1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl
Remove RH wiper arm

Note
2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl
Release cowl screen washer supply hose

Note
1x one way valve
Remove wiper cowl screen panel

Note
5x push clips, 1x windshield washer hose, 1x drain hose clamp
Remove HEPA filter duct

Note
1x clip
Remove A/C lines from vehicle
Overlap time for A/C recovery
Move LH 2nd row seat forward using easy entry mode

Note
Press 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
Remove LH rear welcome plate

Note
8x clips
Apply tape to LH racetrack to avoid damage
Remove front screw securing LH lower C-pillar

Note
1x screw, T25, 2.5 Nm, Discard patch bolt
Fold down LH 3rd row seat

Note
Press button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
Remove rear load floor
Remove LH trunk sill side trim

Note
4x clips
Remove RH trunk sill side trim

Note
4x clips
Remove trunk sill trim

Note
4x clips, 2x patch bolts, T25, 2.5 Nm, Discard after removal
Remove trunk board
Remove trunk floor carpet
Remove rear load floor support

Note
4x push clips, 2x clips
Remove screw securing LH C-pillar mid trim

Note
1x screw, T20, 2 Nm
Release clips securing LH C-pillar mid trim and remove

Note
9x clips
Remove fasteners securing LH upper C-pillar trim panel

Note
1x patch bolt, T25, 3 Nm, 3x screws, T20, 2 Nm
Release clips and remove LH upper C-pillar trim panel

Note
6x clips, 2 clips along front edge and 4 clips along top edge
Remove load floor support from LH lower C-pillar

Note
3x tabs, 1x clip
Remove screws securing C-pillar lower panel to LH parcel shelf support

Note
2x screws, T20, 2 Nm
Release clips securing LH C-pillar lower panel along front edge and remove panel

Note
9x clips, 1x magnet
Remove vent cover from trunk side carpet

Note
8x tabs
Release clips securing LH rear trunk side carpet panel to bracket

Note
5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
Release load floor support from LH trunk side carpet

Note
3x tabs, 1x clip
Remove LH trunk side carpet panel

Note
2x 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
Remove LH mid-zone C-pillar bracket from vehicle

Note
2x 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
Remove LH minion bracket from vehicle

Note
3x push clips
Fold LH 3rd row seat up

Note
Press button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
Remove bolt securing front edge of LH trunk trim bracket

Note
1x bolt, T30, 2.5 Nm
Fold down LH 3rd row seat

Note
Press button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
Remove fasteners securing LH trunk trim bracket and remove from vehicle

Note
2x bolts, T30, 2.5 Nm, 1x push clip
Remove charger duct

Note
Release from plastic ducts at top and bottom
Power down vehicle

Note
Via center display > Controls > Safety > Power Off
Disconnect 12V negative terminal

Note
1x nut, 10mm, 5 Nm
Disconnect first responder loop

Note
1x connector, push to release
Remove warranty label from charger cover panel
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check 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
Put on HV insulating gloves and leather over gloves
Remove charger access panel

Note
11x patch bolts, T20, 2 Nm, Discard after removal, Make sure to wear proper PPE
Release tabs and open small access door

Note
2x tabs
Verify no high voltage

Note
Measure 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
Remove leather over gloves and HV insulating gloves
Remove coolant reservoir cap

Note
1x cap
Use vacuum suction tool to remove coolant from reservoir
Remove coolant reservoir cap

Note
1x cap
Disconnect electrical connector for coolant level sensor

Note
1x connector
Remove coolant reservoir fasteners and wire harness edge clip

Note
4x bolts, 10mm, 6 Nm, 1x edge clip
Clamp and remove coolant hose and move reservoir off to the side

Note
1x coolant hose, Place absorbent material below hose to capture fluid
Release the ground connection at the A/C compressor mount bracket

Note
1x bolt, T25, 7 Nm
Disconnect the A/C compressor harness

Note
2x connectors, 2x fir clips
Remove discharge line from compressor

Note
1x nut, 10mm, 10 Nm, Discard O-rings after removal
Move compressor harness away from bracket
Remove the fir tree clips securing the A/C compressor HV harness to the front drive unit

Note
2x fir tree clips
Disconnect A/C compressor harness at FJB and release cable from drive unit

Note
1x connector, 1x fir tree clip
Remove the fasteners securing the A/C compressor to the FDU

Note
3x bolts, E10, 10 Nm
Support the A/C compressor and remove assembly from the front drive unit

Note
Set A/C compressor/bracket assembly to the side
Remove the upper fastener securing the heat exchanger to the FDU

Note
1x bolt, EP10, 5 Nm + 30 degrees
Raise vehicle fully and lower 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 front aero shield

Note
6x bolts, 10mm, 3 Nm, 14x clips
Remove front bash plate extrusion

Note
2x bolts, T30, 16 Nm
Loosen 21mm bolts securing front of HV battery

Note
2x bolts, 21mm, 115 Nm, Discard after removal
Remove 21mm bolts securing front of HV battery

Note
2x bolts, 21mm, 115 Nm, Discard after removal
Loosen front four HV battery bolts

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal
Remove front four HV battery bolts

Note
4x patch bolts, 13mm, 30 Nm, Discard after removal
Remove skid plate from front subframe

Note
2x bolts, 10mm, 9 Nm
Position the oil drain under oil pump area
Disconnect the front drive unit oil pump connector

Note
1x electrical connector
Remove the fasteners securing the oil pump to the FDU

Note
2x bolts, EP10, 5 Nm + 20 degrees
Remove the oil pump from the FDU

Note
Pry 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
Position fold able funnel
Remove the oil filter from the FDU

Note
Spin counterclockwise, 3 Nm and 135 degrees, Allow oil to drain,Install a new oil filter after removal
Remove foldable funnel
Remove oil drain container from under vehicle
Position coolant drain container under the LH front corner of the vehicle to catch vehicle coolant
Release FDU outlet hose from heat exchanger and plug heat exchanger

Note
1x spring clip, Allow excess coolant to fully drain
Release upper coolant hose from heat exchanger and plug heat exchanger

Note
1x spring clip, Allow excess coolant to fully drain
Release the clip securing the oil pump harness to the heat exchanger

Note
1x fir tree clip
Remove the fir tree clip from the heat exchanger and move hose aside

Note
1x fir tree clip
Remove the lower fastener securing the heat exchanger to the FDU

Note
1x bolt, EP10, 5 Nm + 30 degrees
Remove heat exchanger from FDU assembly

Note
Some oil will spill out of the FDU after removal
Inspect seals of new heat exchanger

Note
Replace any damaged seals, Lubricate with drive unit oil before installation
Position heat exchanger onto FDU assembly
Install the upper fastener securing the heat exchanger to the FDU

Note
1x bolt, EP10, 5 Nm + 30 degrees
Install the lower fastener securing the heat exchanger to the FDU

Note
1x bolt, EP10, 5 Nm + 30 degrees
Install the clip securing the upper coolant hose to the heat exchanger

Note
1x fir tree clip
Secure upper coolant hose onto heat exchanger

Note
1x spring clip, Perform push-pull-push test
Secure FDU outlet hose onto heat exchanger

Note
1x spring clip, Perform push-pull-push test
Install the clip securing the oil pump harness pigtail to the heat exchanger

Note
1x fir tree clip
Remove coolant drain container from under the LH front of the vehicle
Position the oil drain under oil pump area
Remove the fill plug from the FDU

Note
1x plug, 8mm Allen, 15 Nm
Inspect seals and o-rings

Note
Inspect 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
Install new oil filter

Note
Spin clockwise, 3 Nm and 135 degrees, Lubricate seal prior to installation
Install the oil pump into the FDU

Note
Use residual oil in the oil pump cavity to lubricate the seals of the oil pump before installation, Align bolt holes with housing
Install the fasteners securing the oil pump to the FDU

Note
2x bolts, EP10, 5 Nm + 20 degrees
Set up fill kit

Note
Set fluid level to 2000 mL in measuring container
Install fluid transfer pump

Note
Trim both input and output hoses to 26", Insert output hose into fill hole until fully seated then pull back 5mm
Set up fill process

Note
Place measured fluid container in drain basket, fully submerge input hose, prime pump with ATF fluid
Connect the 12V power supply to oil pump

Note
1x connector
Pump ATF fluid into Raven front drive unit

Note
Assistant 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
Install fill plug into the FDU

Note
1x plug, 8mm Allen, 15 Nm
Disconnect 12V power supply tool from oil pump

Note
1x electrical connector
Connect the front drive unit oil pump connector

Note
1x electrical connector
Spray area with brake cleaner and wipe residual fluid off with towel
Remove oil drain from under vehicle
Install skid plate between battery pack and subframe
Install bolts that secure skid plate to subframe

Note
2x bolts, 10mm, 10 Nm
Install front bolts for HV battery with battery powered drill

Note
4x patch bolts, 13mm, 30 Nm, Install new patch bolts, Do not over tighten bolts, Torque at later step
Torque the front bolts for HV battery

Note
4x bolts, 13mm, 30 Nm
Install 21mm bolts at front of HV battery with battery powered drill

Note
2x bolts, 21mm, 115 Nm, Install new bolts, Do not over tighten bolts, Torque at later step
Torque bolts securing front of HV battery to vehicle

Note
2x bolts, 21mm, 115 Nm
Install front bash plate extrusion

Note
2x bolts, T30, 16 Nm
Install front aero shield

Note
6x bolts, 10mm, 3 Nm, 14x clips
Lower vehicle fully
Close small access door

Note
2x tabs
Install charger access panel

Note
11x patch bolts, T20, 2 Nm, Install new patch bolts
Clean area around charger access panel prior to installation of new warranty label

Note
Allow IPA to dry for at least 1 minute
Install new warranty label

Note
Clean area with IPA alcohol wipes and allow area to dry before placing new warranty label
Install A/C compressor

Note
3x bolts, E10, 10 Nm
Install discharge A/C line to compressor

Note
1x nuts, 10mm, 10 Nm, Replace the O-rings
Connect the A/C compressor harness

Note
2x electrical connectors, 2x fir clips
Secure the ground connection at the A/C compressor mount bracket

Note
1x bolt, T25, 7 Nm
Install the fir tree clips securing the A/C compressor HV harness to the front drive unit

Note
2x fir tree clips
Connect A/C compressor harness to FJB

Note
1x connector
Connect coolant hose to reservoir and remove hose clamp

Note
1x coolant hose
Connect coolant reservoir level sensor

Note
1x connector
Install fasteners securing coolant reservoir to shock tower cross member

Note
4x bolts, 10mm, 6 Nm
Install HEPA filter duct

Note
1x clip
Remove wiper cowl screen panel

Note
5x push clips, 1x windshield washer hose, 1x drain hose clamp
Connect cowl drain hose onto cowl trim

Note
1x clamp
Conenct cowl screen washer supply hose

Note
1x one way valve
Install RH wiper arm

Note
2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
Install LH wiper arm

Note
1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield, connect washer hose at cowl
Connect wiper arm hoses to cowl

Note
2x washer hoses
Install LH outer hood hinge cover

Note
2x clips
Install RH outer hood hinge cover

Note
2x clips
Connect first responder loop and then 12V negative terminal

Note
1x connector, 1x nut, 10mm, 5 Nm
Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2

Note
2x 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
Perform coolant purge

Note
Click Panels > Thermal > ''Coolant Air Purge'' and press PlayPer current FRT (18300000) 0.15 hrs, Monitor and top off fluid as required
Remove cubby under MCU and connect laptop to vehicle with a tethered Ethernet connection via Toolbox 2

Note
2x 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
In toolbox, run the refrigerant drain and fill routine to enable A/C filling

Note
Click Panels > Thermal > ''Fluid Drain and Fill'' > Select > Refrigerant Fill > Select > ''Start Fluid Drain and Fill'' and press Play
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
Inject oil into the system

Note
Refill with the amount removed during recovery
Perform A/C refrigerant refill

Note
Run time, per fluid capacity spec
Install HEPA filter housing
Install underhood storage unit

Note
10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
Install frunk carpet

Note
2x connectors
Remove A/C lines from vehicle

Note
Press clear lines once lines have been removed
Install dust caps onto vehicle high and low side service ports

Note
2x threaded caps
Install under hood aprons

Note
4x aprons
Close hood
Perform A/C hose flush

Note
Touch time only. No overlap from this since the machine is disconnected from the vehicle.
Test A/C functions in vehicle to ensure cabin cooling functions as designed
Disconnect laptop from vehicle and install storage cubby

Note
1x connector, 2x clips, Ensure diagnostic cables are tucked into the appropriate position then engage cubby
Calibrate falcon doors via UI

Note
Via Controls > Calibrate, Required after 12V and FRL disconnect
Remove vehicle from lift

Note
Lower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode", Via Controls > Service > Jack Mode
Reinstall LH rear charger duct

Note
Secure to plastic ducts at top and bottom
Reinstall LH trunk trim bracket and loosely install fastener

Note
1x bolt, T30, 2.5 Nm, 1x push clip
Fold LH 3rd row seat up

Note
Press button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
Loosely install bolt securing front edge of LH trunk trim bracket

Note
1x bolt, T30, 2.5 Nm
Install LH minion bracket

Note
3x clips
Tighten fasteners securing LH trunk trim bracket

Note
2x bolts, T30, 2.5 Nm, 1x push clip
Fold LH 3rd row seat down
Install LH mid zone C-pillar bracket and install fasteners

Note
2x screws, T20, 2.5 Nm, 3x push clips, Secure 2x edge clips for charge port release cables
Install LH trunk side carpet panel

Note
2x connectors, Reconnect trunk light and 12V outlet connectors before positioning panel, Use caution not to pinch rear PTC harness, See image for details
Reposition vent cover back bracket, then install vent cover to LH trunk side carpet

Note
8x clips
Install clips securing LH rear trunk side carpet panel to bracket

Note
5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
Verify charge port mechanical release cable is in proper position in trunk side carpet panel
Install LH trunk side load floor support

Note
3x tabs, 1x clip
Install rear load floor support

Note
4x push clips, 2x clips
Reinstall front lower carpet trim panel

Note
Secure 3rd row seat wiring harnesses to panel
Install trunk board
Install rear trunk sill trim

Note
4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
Install RH trunk sill side trim

Note
4x clips
Install LH lower C-pillar and secure clips along front edge

Note
9x clips, 1x magnet
Install screws securing C-pillar lower panel to LH parcel shelf support

Note
2x screws, T20, 2 Nm
Install trunk side nub to lower C-pillar

Note
3x tabs, 1x clip
Install bolt securing front of LH lower C-pillar

Note
1x patch bolt, T25, 2.5 Nm
Remove tape from LH racetrack trim
Install LH welcome plate

Note
8x clips
Install LH upper C-pillar trim panel

Note
6x clips
Install fasteners securing LH upper C-pillar

Note
1x patch bolt, T25, 3 Nm, 3x screws, T20, 2 Nm, Install new patched bolt
Install screw securing LH rear C-pillar mid trim

Note
1x screw, T20, 2 Nm
Install LH trunk sill side trim

Note
4x clips
Install rear load floor
Fold LH 3rd row seat up

Note
Press button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
Close liftgate
Move LH and RH 2nd row seat from the easy entry position to the regular upright seating position

Note
Slide seat track backwards by pushing towards rear of vehicle, Fold upper seat backwards until locked in an upright position
Close LH Falcon door
Close LH front door