29/05/2024 18:11:16
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.
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Raise and support vehicle with wheels still touching the ground
NoteEnsure 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).
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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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Remove clip securing negative terminal cable to AC compressor bracket
Note1x clip
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Remove negative terminal cable from body
Note1x 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).
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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
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Remove front aero shield
Note12x bolts, 10mm, 6 Nm, 2x nuts, 15mm, 6 Nm, 2x clips, 2x hooks
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Release LH and RH front wheel liner from
HV battery
Note1x rocker bolt, 10mm, 12 Nm, 2x aero shield bolts, 10mm, 6 Nm
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Release clipping points securing compressor HV harness to front of vehicle body
Note5x 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).
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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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Release positive terminal cover
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Remove positive terminal cable from cowl
Note1x stud, E5, 8 Nm
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Release 12V positive cable clip from front controller
Note1x clip
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Disconnect the supermanifold harness from the front controller
Note1x connector
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Remove bolts securing front controller shield assembly and remove from vehicle
Note2x bolts, 10mm, 8.5 Nm
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Disconnect remaining connectors on front controller
Note5x connectors, Release locking tabs first if equipped
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Release harness guide from front controller
Note2x 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
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Remove bolts securing front controller
Note3x bolts, 10mm, 10 Nm
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Remove front controller upper ground strap from body
Note1x bolt, 10mm, 10 Nm, Located under cowl, Discard bolt after removal
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Remove front controller lower ground strap
Note1x bolt, 10mm, 10 Nm
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Remove the front controller from vehicle
NotePush 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
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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 bolt securing the steering gear assembly to intermediate shaft assembly
Note1x bolt, 13mm, 18 Nm
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Slide the electric steering column upward to remove it from the steering gear assembly
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Loosen bolts securing shock tower brace to RH shock tower
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
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Remove fasteners for LH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
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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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Release 4-tube bundle brake lines from LH bottom spacer
Note4x clips, Do not bend pipe
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Release front brake pipe A from RH jounce hose
Note1x nut, 12mm, 16 Nm
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Release front brake pipe A from clips
Note5x clips, Do not bend pipe
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Remove front brake pipe A
NoteDo 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
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Release side sill brake pipe assembly from LH front junction block
Note2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
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Remove bolt securing LH junction block to body
Note1x bolt, 10mm, 6 Nm
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Remove front brake pipe B and C bundle
Note1x 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
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Release front brake pipe D from LH jounce hose
Note1x nut, 12mm, 16 Nm
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Release front brake pipe D from clip
Note1x clip, Do not bend pipe
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Remove front brake pipe D
NoteDo not bend pipe, Remove pipe from HCU then guide through LH wheel well
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Position front brake pipe D
NoteDo not bend pipe, Guide pipe through LH wheel well then position onto HCU
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Secure front brake pipe D onto clip
Note1x clip, Do not bend pipe
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Secure front brake pipe D onto LH jounce hose
Note1x nut, 12mm, 16 Nm
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Position front brake pipe B and C bundle
Note1x 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
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Install bolt securing LH junction block to body
Note1x bolt, 10mm, 6 Nm
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Secure side sill brake pipe assembly onto LH front junction block
Note2x nuts, 12mm, 16 Nm, Front brake pipe B and C bundle does not detach from junction block
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Position front brake pipe A
NoteDo 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
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Secure front brake pipe A onto clips
Note5x clips, Do not bend pipe
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Secure front brake pipe A onto RH jounce hose
Note1x nut, 12mm, 16 Nm
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Secure 4-tube bundle brake lines onto LH bottom spacer
Note4x clips, Do not bend pipe
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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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Install fasteners for LH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
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Torque fasteners for RH side of shock tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
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Slide the intermediate shaft assembly downward to install it to the steering gear assembly
NoteEnsure the intermediate shaft is aligned and fully seated,If necessary to align the shaft to steering gear
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Install bolt securing the intermediate shaft assembly to the steering gear assembly
Note1x bolt, 13mm, 18 Nm
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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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Maneuver front controller into position
NoteSlide over temp set hook first, then into bottom bracket temp set holes
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Secure front controller
Note3x bolts, 10mm, 10 Nm
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Install front controller lower ground strap
Note1x bolt, 10mm, 10 Nm
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Install front controller upper ground strap onto body
Note1x bolt, 10mm, 10 Nm, Install new bolt
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Install harness guide to front controller
Note2x 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
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Connect front controller harness connectors
Note5x connectors, Fully seat connector, then engage locking tabs if equipped
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Install front controller protection shield
Note2x bolts, 10mm, 8.5 Nm
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Connect the supermanifold harness to the front controller
Note1x connector
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Secure 12V positive cable to front controller
Note1x clip
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Install positive terminal cable onto cowl
Note1x stud, E5, 8 Nm
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Secure positive terminal cover
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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
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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
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Install clip securing AC compressor logic connector to HV harness
Note1x fir tree clip
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Install clips securing PT supply hose to AC compressor bracket
Note2x clips
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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
- Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
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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 LV battery into vehicle
NoteLower vertically LV battery into the vehicle
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Install fasteners securing LV battery
Note3x bolts, 8mm, 6 Nm Early production vehicle may have 3x bolts, M6, 10mm, 10 Nm
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Install negative terminal cable onto body
Note1x bolt, 10mm, 10 Nm
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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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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
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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 "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
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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
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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
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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
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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
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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
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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
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Remove pressure bleeder adapter from reservoir
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Check fluid level
NoteTop off if necessary
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Install brake reservoir cap
- Pump the brake pedal a few times to ensure the brake pedal feels normal
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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 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).
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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
-
Install clipping points securing compressor HV harness to front of vehicle body
Note5x clips, Return to original routing, Verify fully secured
-
Install RH front wheel liner to HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
-
Install LH front wheel liner to HV battery
Note1x clip, 1x bolt, 10mm, 5 Nm
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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
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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
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Torque all four wheels
Note5x nuts (each wheel), 21mm, 175 Nm
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Install all four wheel caps
Note1x 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).
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Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle
- Raise the LH front window and close the LH front door
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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