2025-03-12

Heat Exchanger - 3DU (Remove and Replace)

Correction code 3901020902 FRT 1.05 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 wearing proper PPE when performing the below procedure.

Torque Specifications

Table 1. Torque Specifications: Heat Exchanger - 3DU (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolts (x2) that attach the heat exchanger to the front drive unit
5 Nm (3.7 lbs-ft) + 30 degrees
  • Socket 3/8 in Dr EP10
  • Torque wrench with angle measurement
 Reuse

Remove

  1. Remove the HEPA filter assembly. See Service Kit - Hepa And Carbon Filters (Remove and Replace).
  2. Disconnect the LV battery. See LV Power (Disconnect and Connect).
  3. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  4. Position a coolant drain container underneath the front drive unit.
  5. Release the spring clip, and then disconnect the front drive unit inverter hose from the front drive unit heat exchanger, and then plug the ends of both fittings as soon as possible to avoid coolant loss (1135762-00-A).
  6. Release the clip, and then disconnect the powertrain return tube from the front drive unit heat exchanger. Plug both hose ends with plugs (x2).
  7. Remove the bolts (x2) that attach the heat exchanger to the front drive unit, and then remove the heat exchanger from the front drive unit.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Gently wiggle the heat exchanger to free it from the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 3/8 in Dr EP10
    • Torque wrench with angle measurement

Install

  1. Position the front drive unit heat exchanger to the vehicle, and then install the bolts (x2) that attach the heat exchanger to the front drive unit.
    5 Nm (3.7 lbs-ft) + 30 degrees
    Informational PurposesAn informational icon, calling your attention
    Note

    Lightly coat the O-rings with clean KAF 1 gearbox fluid.

    Do not pinch or deform the O-rings during installation.

    Do not allow the coolant to enter oil passages of the drive unit to avoid cross-contamination.

    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Socket 3/8 in Dr EP10
    • Torque wrench with angle measurement
  2. Remove the plugs on the ends of fittings, and then install the spring clip to connect the front drive unit powertrain return hose to the front drive unit heat exchanger.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully secured.
    Informational PurposesAn informational icon, calling your attention
    Note
    Installing the side of hose first will eliminate the coolant loss when connecting to the supermanifold.
  3. Remove the plugs on the ends of fittings, and then install the spring clip to connect the front drive unit inverter hose to the front drive unit heat exchanger.
  4. Remove the coolant drain container from underneath the vehicle.
  5. Drain and refill the front drive unit gearbox fluid. See Gearbox Fluid - Front Drive Unit (Drain and Refill).
  6. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  7. Connect the LV battery power. See LV Power (Disconnect and Connect).
  8. Locally connect a laptop with Toolbox 3 to the vehicle. See Toolbox 3 (Connect and Disconnect).
  9. Click the Actions tab, and then enter "Oil Pump Low Pressure Test - Front Drive Unit" in the search field.
  10. Click TEST-SELF_DIF_X_OIL-PUMP-PRESSUREvia Toolbox: (link), and then click Run and allow the routine to complete.
  11. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Coolant Purge Start > Run and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  12. Disconnect the laptop.
  13. Exit Service Mode. See Service Mode.
  14. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  15. Install the HEPA filter assembly. See Service Kit - Hepa And Carbon Filters (Remove and Replace).
  16. Raise the LH front window and close the LH front door.
  17. Remove the lift arms from below the vehicle.