29/05/2024 18:10:27
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
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Raise and support vehicle with wheels still touching the ground
NoteEnsure 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
Note2x bolts, 10mm, 5 Nm
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Power off vehicle from center display
NoteVia Controls > Safety & Security > Vehicle Power > Power Off
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Disconnect LV battery connector and First Responder Loop
Note2x 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
NoteSet multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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Raise vehicle fully and lower lift 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
-
Remove push clips at left and right wheel house liner to mid aero shield
Note2x clips
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Remove mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
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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_R4.pdf
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Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
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Install amp clamp to RDU HV harness
NoteVerify 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.
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Release RDU HV harness from HV battery
Note1x 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
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Verify no high voltage at RDU HV header
NoteMake 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
NoteMake 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
Note1x 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
NoteMake 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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Position the oil drain container under hydraulic control unit area
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Position protective fender cover over fan shroud and support
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Remove clips securing PT supply hose to AC compressor bracket
Note2x clips
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Release clip securing HV compressor harness to plastic connector housing
Note1x clip, Take note of original routing
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Release clip securing AC compressor logic connector to HV harness
Note1x fir tree clip
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Release AC compressor logic connector
Note1x locking connector, Pull red tab to disengage lock and pull again to release connector, Do not push down on red tab
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Remove fastener securing compressor HV harness to AC compressor
Note1x bolt, 13mm, 9 Nm
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Release HV harness connector from AC compressor
Note1x locking connector, Disengage black locking tab and release connector
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Remove AC compressor ground strap
Note1x bolt, 10mm, 7 Nm, MYSP uses T25 bolt
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Remove the clip securing the coolant hose to the AC compressor bracket
Note1x fir tree clip
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Remove AC compressor and AC compressor bracket assembly from strut tower support brace
Note2x 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
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Disconnect HCU connector
Note1x connector, Release red locking tab, Press black release tab and rotate lever upward to remove
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Release HCU connector harness
Note2x clips
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Remove 4-tube bundle brake lines from HCU
Note4x nuts, 12mm, 16 Nm
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Release 4-tube bundle brake lines from LH top spacer
Note4x clips, Do not bend pipes
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Remove master cylinder secondary pipe from HCU
Note1x nut, 12mm, 16 Nm
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Remove master cylinder primary pipe from HCU
Note1x nut, 12mm, 16 Nm
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Remove LH top spacer from master cylinder brake pipes
Note2x clips, Do not bend pipes
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Release the master cylinder brake lines from clip at rear of hydraulic control unit bracket
Note1x harness clip
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Remove the bolts securing the hydraulic control unit to frame rail
Note2x bolts, 10mm, 10 Nm
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Remove HCU and bracket assembly from vehicle
Note2x tabs, Negotiate HCU around brake lines, Take care not to damage bracket tabs
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Loosen the fasteners securing the hydraulic control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
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Pry hydraulic control unit from the bracket
Install
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Install hydraulic control unit into hydraulic control unit bracket
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Install the fasteners securing hydraulic control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
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Position HCU and bracket assembly onto vehicle
Note2x tabs, Negotiate HCU around brake lines, Align bracket tabs with body holes
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Install the bolts securing the hydraulic control unit to frame rail
Note2x bolts, 10mm, 10 Nm
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Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket
Note1x harness clip
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Install LH top spacer onto master cylinder brake pipes
Note2x clips, Do not bend pipes
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Install master cylinder primary pipe onto HCU
Note1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
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Install master cylinder secondary pipe onto HCU
Note1x nut, 12mm, 16 Nm, Start nut by hand to avoid cross threading
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Secure 4-tube bundle brake lines onto LH top spacer
Note4x clips, Do not bend pipes
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Install 4-tube bundle brake lines onto HCU
Note4x nuts, 12mm, 16 Nm, Clean lines with brake cleaner before mating as needed
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Secure HCU connector harness
Note2x clips
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Connect HCU connector
Note1x connector, Seat connection and rotate lever downward, Secure red locking tab
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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
Note2x 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
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Install the clip securing the coolant hose to the AC compressor bracket
Note1x fir tree clip
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Install AC compressor ground strap
Note1x bolt, 10mm, 7 Nm
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Install clip securing HV compressor harness to plastic connector housing
Note1x clip, Take note of original routing
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Secure HV harness connector onto AC compressor
Note1x locking connector, Secure connector and engage black locking tab, Verify fully seated
-
Install fastener securing AC compressor HV harness bracket to AC compressor
Note1x bolt, 13mm, 9 Nm
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Secure AC compressor logic connector
Note1x locking connector, secure connection and engage red locking tab
-
Install clip securing AC compressor logic connector to HV harness
Note1x fir tree clip
-
Install clips securing PT supply hose to AC compressor bracket
Note2x 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
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
-
Secure RDU HV harness onto HV battery
Note1x 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
Note11x 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
Note2x clips
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Lower vehicle fully
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Position LV battery into vehicle
NoteLower vertically LV battery into the vehicle
-
Install fasteners securing LV battery
Note3x 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
Note1x clip
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Connect first responder loop and LV battery
Note2x connectors, Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
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Connect to vehicle using Toolbox 3.0
NoteVehicle 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’
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Select ‘UPDATE_CAN-REDEPLOYSearch for routine in ToolboxService CAN Redeployhv / Drive Inverter DIRE1L Replacement - CAN Redeployhv / Drive Inverter DIRE1R Replacement - CAN Redeployhv / Drive Inverter DIRE2 Replacement - CAN Redeployhv / Front Drive Inverter Replacement - CAN Redeployhv / Rear Drive Inverter Replacement - CAN Redeployhv / Rear Left Drive Inverter Replacement - CAN Redeployhv / Rear Right Drive Inverter Replacement - CAN Redeployhv / Front Drive Unit Replacement - CAN Redeployhv / Rear Drive Unit Replacement - CAN Redeploy’, click ‘Run’, and allow routine to complete
NoteSelect ‘X’ at top right of window to close once complete
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Once firmware redeploy is complete, Verify on center display release notes are present
NoteIf the redeploy fails you may receive an error message on UI
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Fill brake bleeder reservoir to full level
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Clean area around brake fluid reservoir and remove brake reservoir cap
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Top off brake fluid reservoir
NoteTop off brake fluid as needed
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Install pressure bleeder adapter onto reservoir
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Set brake bleed reservoir pressure to 30 psi
NoteConnect 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"
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Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP
Note2x covers
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Open LH front brake caliper outer
bleeding valve then click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDSearch for routine in ToolboxFL and RR brake bleed procedureChassis / Brakes - Brake Bleed FL-RRChassis / Brakes - Brake Bleed FL-RR 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
Note2x 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
Note2x 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
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
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Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP
Note2x covers
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Open RH front brake caliper outer
bleeding valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDSearch for routine in ToolboxFR and RL brake bleed procedureChassis / Brakes - Brake Bleed FR-RLChassis / Brakes - Brake Bleed FR-RL 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
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
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Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves
Note2x 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
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
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Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP
Note1x cover
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Open RH rear brake caliper bleeding
valve then Click the play button next to PROC_ESP_FRONT-L-REAR-R-BRAKE-BLEEDSearch for routine in ToolboxFL and RR brake bleed procedureChassis / Brakes - Brake Bleed FL-RRChassis / Brakes - Brake Bleed FL-RR and select Run to start the ESP, then close
the bleeding valve once the pump stop running
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
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Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
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Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover
Note1x 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
Note1x cover
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Open LH rear brake caliper bleeding
valve then Click the play button next to PROC_ESP_FRONT-R-REAR-L-BRAKE-BLEEDSearch for routine in ToolboxFR and RL brake bleed procedureChassis / Brakes - Brake Bleed FR-RLChassis / Brakes - Brake Bleed FR-RL and select Run to start the ESP, then close
the bleeding valve once the pump stop running
Note1x 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
Note1x 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
Note1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
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Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
-
Remove pressure bleeder adapter from reservoir
-
Check fluid level
NoteTop off if necessary
-
Install brake reservoir cap
- Pump the brake pedal a few times to ensure the brake pedal feels normal
-
Using Toolbox 3:
- Remove ethernet cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
-
Raise vehicle partially and lower lift onto locks
NoteSet 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
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Install LH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Install RH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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Install RH front wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
-
Raise vehicle fully and lower lift 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
-
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
Note12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
-
Lower vehicle until tires are touching the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Torque LH front wheel
Note5x nuts, 21mm, 175 Nm
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Torque RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Torque RH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Torque LH rear wheel
Note5x nuts, 21mm, 175 Nm
-
Install LH front wheel cap
Note1x cap, Align valve stem with wheel cap cavity
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Install RH front wheel cap
Note1x cap, Align valve stem with wheel cap cavity
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Install RH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
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Install LH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
-
Install HEPA filter assembly
Note2x 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
NoteLower rack arms fully and remove from under vehicle
- Raise LH front window
- Close LH front door
-
Perform test drive
NotePer 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