01/04/2024 13:56:47

Brake Lines - Front Bundle (Structural Pack) (Remove and Replace)

Correction code 33035012 3.60 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.

2023-12-06: 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.

Raise and support vehicle with wheels still touching the ground

Note
Ensure vehicle is not charging
Open the LH front door and lower the LH front window.
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 the HEPA filter. See Assembly - Filter - HEPA (Remove and Replace).
Remove the HEPA duct. See Duct - HEPA (Remove and Replace)
Disconnect LV power. See 12V/LV Power (Disconnect and Connect).
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
Remove clip securing negative terminal cable to AC compressor bracket

Note
1x clip
Remove negative terminal cable from body

Note
1x bolt, 10mm, 10 Nm
Remove the LV battery. See 12V/LV Battery (Remove and Replace).
Remove all four wheels. See Wheel Assembly (Remove and Install).
Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
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 front aero shield

Note
12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
Release LH and RH front wheel liner from HV battery

Note
1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
Release clipping points securing compressor HV harness to front of vehicle body

Note
5x clips, Take note of original routing
Remove the LH and RH front wheel arch liners. See Wheel Arch Liner - Front - LH (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
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
Release positive terminal cover
Remove positive terminal cable from cowl

Note
1x stud, E5, 8 Nm
Release 12V positive cable clip from front controller

Note
1x clip
Disconnect the supermanifold harness from the front controller

Note
1x connector
Remove bolts securing front controller shield assembly and remove from vehicle

Note
2x bolts, 10mm, 8.5 Nm
Disconnect remaining connectors on front controller

Note
5x connectors, Release locking tabs first if equipped
Release harness guide from front controller

Note
2x patch bolts, 8mm, 6 Nm, 1x temp set clip, Discard bolts after removal, Remove bolts first, then pivot harness guide slightly forward and up to remove temp set clip from front harness
Remove bolts securing front controller

Note
3x bolts, 10mm, 10 Nm
Remove front controller upper ground strap from body

Note
1x bolt, 10mm, 10 Nm, Located under cowl, Discard bolt after removal
Remove front controller lower ground strap

Note
1x bolt, 10mm, 10 Nm
Remove the front controller from vehicle

Note
Push harness connectors down to provide space, Gently pry bottom of controller out of BIW temp set holes, Then swing controller forward and up to release from top temp set
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 bolt securing the steering gear assembly to intermediate shaft assembly

Note
1x bolt, 13mm, 18 Nm
Slide the electric steering column upward to remove it from the steering gear assembly
Loosen bolts securing shock tower brace to RH shock tower

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
Remove fasteners for LH side of shock tower brace

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
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
Release 4-tube bundle brake lines from LH bottom spacer

Note
4x clips, Do not bend pipe
Release front brake pipe A from RH jounce hose

Note
1x nut, 12mm, 16 Nm
Release front brake pipe A from clips

Note
5x clips, Do not bend pipe
Remove front brake pipe A

Note
Do not bend pipe, Four-step removal, Remove pipe from HCU and negotiate around steering column, Guide pipe through RH wheel well, Lift LH side of thermal bar and guide pipe over body, Negotiate pipe around RH side of FDU and around HVAC line
Release side sill brake pipe assembly from LH front junction block

Note
2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
Remove bolt securing LH junction block to body

Note
1x bolt, 10mm, 6 Nm
Remove front brake pipe B and C bundle

Note
1x stud, Do not bend pipe, Three-step removal, Release junction block from rear brake pipes and body stud simultaneously, Remove bundle from HCU, Guide bundle toward front of vehicle
Release front brake pipe D from LH jounce hose

Note
1x nut, 12mm, 16 Nm
Release front brake pipe D from clip

Note
1x clip, Do not bend pipe
Remove front brake pipe D

Note
Do not bend pipe, Remove pipe from HCU then guide through LH wheel well
Position front brake pipe D

Note
Do not bend pipe, Guide pipe through LH wheel well then position onto HCU
Secure front brake pipe D onto clip

Note
1x clip, Do not bend pipe
Secure front brake pipe D onto LH jounce hose

Note
1x nut, 12mm, 16 Nm
Position front brake pipe B and C bundle

Note
1x stud, Do not bend pipe, Three-step installation, Guide bundle toward rear of vehicle, Position bundle onto HCU, Secure junction block onto rear brake pipes and body stud simultaneously
Install bolt securing LH junction block to body

Note
1x bolt, 10mm, 6 Nm
Secure side sill brake pipe assembly onto LH front junction block

Note
2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
Position front brake pipe A

Note
Do not bend pipe, Four-step installation, Negotiate pipe around HVAC line and around RH side of FDU, Lift LH side of thermal bar and guide pipe under bar, Guide pipe through RH wheel well, Negotiate around steering column and position pipe onto HCU
Secure front brake pipe A onto clips

Note
5x clips, Do not bend pipe
Secure front brake pipe A onto RH jounce hose

Note
1x nut, 12mm, 16 Nm
Secure 4-tube bundle brake lines onto LH bottom spacer

Note
4x clips, Do not bend pipe
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
Install fasteners for LH side of shock tower brace

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
Torque fasteners for RH side of shock tower brace

Note
2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
Slide the intermediate shaft assembly downward to install it to the steering gear assembly

Note
Ensure the intermediate shaft is aligned and fully seated,If necessary to align the shaft to steering gear
Install bolt securing the intermediate shaft assembly to the steering gear assembly

Note
1x bolt, 13mm, 18 Nm
Secure HCU connector harness

Note
2x clips
Connect HCU connector

Note
1x connector, Seat connection and rotate lever downward, Secure red locking tab
Maneuver front controller into position

Note
Slide over temp set hook first, then into bottom bracket temp set holes
Secure front controller

Note
3x bolts, 10mm, 10 Nm
Install front controller lower ground strap

Note
1x bolt, 10mm, 10 Nm
Install front controller upper ground strap onto body

Note
1x bolt, 10mm, 10 Nm, Install new bolt
Install harness guide to front controller

Note
2x patch bolts, 8mm, 6 Nm, 1x temp set clip, Install new bolts, Pivot harness guide upwards and back to install temp set clip to front harness, then install bolts
Connect front controller harness connectors

Note
5x connectors, Fully seat connector, then engage locking tabs if equipped
Install front controller protection shield

Note
2x bolts, 10mm, 8.5 Nm
Connect the supermanifold harness to the front controller

Note
1x connector
Secure 12V positive cable to front controller

Note
1x clip
Install positive terminal cable onto cowl

Note
1x stud, E5, 8 Nm
Secure positive terminal cover
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
Install the mid aero shield panel. See Panel - Aero Shield - Mid (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
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 negative terminal cable onto body

Note
1x bolt, 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
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
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 "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 the LH and RH front wheel arch liners. See Wheel Arch Liner - Front - LH (Structural Pack) (Remove and Replace).
Install all 4 wheels. See Wheel Assembly (Remove and Install).
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
Install clipping points securing compressor HV harness to front of vehicle body

Note
5x clips, Return to original routing, Verify fully secured
Install RH front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
Install LH front wheel liner to HV battery

Note
1x clip, 1x bolt, 10mm, 5 Nm
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 all four wheels

Note
5x nuts (each wheel), 21mm, 175 Nm
Install all four wheel caps

Note
1x cap, Align valve stem with wheel cap cavity
Install the HEPA duct. See Duct - HEPA (Remove and Replace)
Install the HEPA filter. See Assembly - Filter - HEPA (Remove and Replace).
Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Raise the LH front window and close the 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