01/04/2024 13:59:47

Hydraulic Control Unit (HCU) - Brake (Structural Pack) (Remove and Replace)

Correction code 33109532 2.58 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.

2023-12-07: Updated brake stiffness routine.

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

Raise and support vehicle with wheels still touching the ground

Note
Ensure vehicle is not charging
Open LH front door
Lower LH front window
Open hood
Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
Remove HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm
Power off vehicle from center display

Note
Via Controls > Safety & Security > Vehicle Power > Power Off
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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 push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Remove mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
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_R4.pdf
Put on HV insulating gloves and leather over gloves

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used
Install amp clamp to RDU HV harness

Note
Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction. If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required If current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
Release RDU HV harness from HV battery

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged
Verify no high voltage at RDU HV header

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering
Remove the front aero shield panel. See Panel - Aero Shield - Front (Structural Pack) (Remove and Replace).
Lower vehicle for access to underhood area

Note
Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Remove clip securing negative terminal cable to AC compressor bracket

Note
1x clip
Remove the LV battery. See 12V/LV Battery (Remove and Replace).
Remove all four wheels. See Wheel Assembly (Remove and Install).
Lower vehicle for access to underhood area

Note
Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
Position the oil drain container under hydraulic control unit area
Position protective fender cover over fan shroud and support
Remove clips securing PT supply hose to AC compressor bracket

Note
2x clips
Release clip securing HV compressor harness to plastic connector housing

Note
1x clip, Take note of original routing
Release clip securing AC compressor logic connector to HV harness

Note
1x fir tree clip
Release AC compressor logic connector

Note
1x locking connector, Pull red tab to disengage lock and pull again to release connector, Do not push down on red tab
Remove fastener securing compressor HV harness to AC compressor

Note
1x bolt, 13mm, 9 Nm
Release HV harness connector from AC compressor

Note
1x locking connector, Disengage black locking tab and release connector
Remove AC compressor ground strap

Note
1x bolt, 10mm, 7 Nm, MYSP uses T25 bolt
Remove the clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Remove AC compressor and AC compressor bracket assembly from strut tower support brace

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle, under the strut tower support brace and rest on fender cover
Disconnect HCU connector

Note
1x connector, Release red locking tab, Press black release tab and rotate lever upward to remove
Release HCU connector harness

Note
2x clips
Remove 4-tube bundle brake lines from HCU

Note
4x nuts, 12mm, 16 Nm
Release 4-tube bundle brake lines from LH top spacer

Note
4x clips, Do not bend pipes
Remove master cylinder secondary pipe from HCU

Note
1x nut, 12mm, 16 Nm
Remove master cylinder primary pipe from HCU

Note
1x nut, 12mm, 16 Nm
Remove LH top spacer from master cylinder brake pipes

Note
2x clips, Do not bend pipes
Release the master cylinder brake lines from clip at rear of hydraulic control unit bracket

Note
1x harness clip
Remove the bolts securing the hydraulic control unit to frame rail

Note
2x bolts, 10mm, 10 Nm
Remove HCU and bracket assembly from vehicle

Note
2x tabs, Negotiate HCU around brake lines, Take care not to damage bracket tabs
Loosen the fasteners securing the hydraulic control unit to the hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm
Pry hydraulic control unit from the bracket

Install

Install hydraulic control unit into hydraulic control unit bracket
Install the fasteners securing hydraulic control unit to the hydraulic control unit bracket

Note
2x nuts, 10mm, 8 Nm
Position HCU and bracket assembly onto vehicle

Note
2x tabs, Negotiate HCU around brake lines, Align bracket tabs with body holes
Install the bolts securing the hydraulic control unit to frame rail

Note
2x bolts, 10mm, 10 Nm
Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket

Note
1x harness clip
Install LH top spacer onto master cylinder brake pipes

Note
2x clips, Do not bend pipes
Install master cylinder primary pipe onto HCU

Note
1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
Install master cylinder secondary pipe onto HCU

Note
1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
Secure 4-tube bundle brake lines onto LH top spacer

Note
4x clips, Do not bend pipes
Install 4-tube bundle brake lines onto HCU

Note
4x nuts, 12mm, 16 Nm, Clean lines with brake cleaner before mating as needed
Secure HCU connector harness

Note
2x clips
Connect HCU connector

Note
1x connector, Seat connection and rotate lever downward, Secure red locking tab
Position the AC compressor and AC compressor bracket assembly into the vehicle for assembly and install the fasteners securing the AC compressor assembly to the strut tower support brace

Note
2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Carefully install the AC compressor and AC compressor bracket towards the rear of the vehicle, under the strut tower support brace
Install the clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Install AC compressor ground strap

Note
1x bolt, 10mm, 7 Nm
Install clip securing HV compressor harness to plastic connector housing

Note
1x clip, Take note of original routing
Secure HV harness connector onto AC compressor

Note
1x locking connector, Secure connector and engage black locking tab, Verify fully seated
Install fastener securing AC compressor HV harness bracket to AC compressor

Note
1x bolt, 13mm, 9 Nm
Secure AC compressor logic connector

Note
1x locking connector, secure connection and engage red locking tab
Install clip securing AC compressor logic connector to HV harness

Note
1x fir tree clip
Install clips securing PT supply hose to AC compressor bracket

Note
2x clips
Remove protective fender cover over fan shroud and support
Remove the oil drain container from underneath 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
Secure RDU HV harness onto HV battery

Note
1x connector, 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
Remove HV insulating gloves
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
Install push clips at left and right wheel house liner to mid aero shield

Note
2x clips
Lower vehicle fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Position LV battery into vehicle

Note
Lower vertically LV battery into the vehicle
Install fasteners securing LV battery

Note
3x bolts, 8mm, 6 Nm Early production vehicle may have 3x bolts, M6, 10mm, 10 Nm
Install clip securing negative terminal cable to AC compressor bracket

Note
1x clip
Connect first responder loop and LV battery

Note
2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Connect to vehicle using Toolbox 3.0

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
Select ‘Actions/Autodiag’ and search for ‘Service_Redeploy’
Select ‘UPDATE_SERVICE-REDEPLOY’, click ‘Run’, and allow routine to complete

Note
Select ‘X’ at top right of window to close once complete
Once firmware redeploy is complete, Verify on center display release notes are present

Note
If the redeploy fails you may receive an error message on UI
Fill brake bleeder reservoir to full level
Clean area around brake fluid reservoir and remove brake reservoir cap
Top off brake fluid reservoir

Note
Top off brake fluid as needed
Install pressure bleeder adapter onto reservoir
Set brake bleed reservoir pressure to 30 psi

Note
Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
Select Actions/Autodiag and search for "bleed"
Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open LH front brake caliper outer bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP

Note
2x covers
Open RH front brake caliper outer bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running, then repeat the process for inner bleeding valve, and then lastly repeat the process for outer bleeding valve again

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves

Note
2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers

Note
2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open RH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP

Note
1x cover
Open LH rear brake caliper bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L_BRAKE_BLEED and select Run to start the ESP, then close the bleeding valve once the pump stop running

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve

Note
1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover

Note
1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
Remove pressure bleeder adapter from reservoir
Check fluid level

Note
Top off if necessary
Install brake reservoir cap
Pump the brake pedal a few times to ensure the brake pedal feels normal
Using Toolbox 3:
1. Select the Actions tab and search for "Stiffness".
2. Select the ODIN routine IBST Stiffness Test - Service - BURNISHED/UNBURNISHEDTEST_BRAKE_X_STIFFNESS-TEST-SERVICEGen3/tasks/TEST_BRAKE_X_STIFFNESS-TEST-SERVICEChassisChassis / Brakes - Brake Stiffness TestService Mode Service Plus Factory Mode Developer , and then click the link of the routine.
3. If brake pads or rotors have been replaced, select UNBURNISHED under "Action_Type". In all other cases, select BURNISHED.
4. Click RUN, and allow the routine to complete.
  
  Note
  Do not press the brake pedal during the test.
Remove ethernet cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Raise vehicle partially and lower lift onto locks

Note
Set vehicle to a 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 LH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install LH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH rear wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
Install RH front wheel

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
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
Torque LH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH front wheel

Note
5x nuts, 21mm, 175 Nm
Torque RH rear wheel

Note
5x nuts, 21mm, 175 Nm
Torque LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Install LH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install RH front wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install RH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install LH rear wheel cap

Note
1x cap, Align valve stem with wheel cap cavity
Install HEPA filter assembly

Note
2x bolts, 10mm, 5 Nm, 2x datums
Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Close hood
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Raise LH front window
Close LH front door
Perform test drive

Note
Per current FRT (00040100) 0.3 hrs, If alignment was adjusted verify tracking, If DAS components were adjusted verify operation, If brakes were serviced perform burnishing