25/03/2024 17:27:55

Hose - Inverter to Heat Exchanger - Rear Drive Unit (3DU) (Remove and Replace)

Correction code 18300192 1.92 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.

2023-06-09: Added shear plate small bolts torque figure for Structural Pack vehicles.

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

Note
Ensure vehicle is not charging, Remove charging cable if it's plugged in, Note the MYSP lifting points are more narrow than the MY
Open all four doors
Lower all four windows
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)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
Select ‘Actions/Autodiag’ tab and search for ‘Fill Drain’
Select ‘Thermal Fluid Fill/DrainPROC_VCFRONT_X_THERMAL-FILL-DRAINGen3/tasks/PROC_VCFRONT_X_THERMAL-FILL-DRAIN Model3/tasks/PROC_VCFRONT_X_THERMAL-FILL-DRAINLow Voltage Controllers Low Voltage Controllers’, click ‘Run’, and allow routine to complete

Note
This will ensure the octovalve is in the Series position, Coolant pumps will also be disabled, Once run is selected routine is in progress despite the prompt with loading circle, Routine will time out after several hours and return valves to parallel position if unattended, Select 'X' at top right of window to close once complete
Remove laptop from vehicle

Note
Do not close Toolbox 3.0, we will need to resume later
Move LH front seat forward
Move RH front seat forward
Remove 2nd row seat cushion

Note
1x connector, Lift front edge of seat cushion upward to release foam from frame
Open hood
Remove rear apron

Note
14x clips
Power off vehicle from center display

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box
Disconnect 12V negative terminal and first responders loop

Note
1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge
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
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
Remove ancillary bay probe lid cover from ancillary bay cover
Verify no high voltage

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
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover

Note
Confirm no visual damage present, Replace gasket if damage is found
Install the bolts securing ancillary bay probe lid cover to ancillary bay cover

Note
2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
Remove HV insulating gloves
Remove LH rear wheel cap

Note
1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
Loosen LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Close all four doors

Note
Unlatch rear doors at later step
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
Remove LH rear wheel

Note
5x nuts, 21mm, 175 Nm
Remove clips securing RH rear wheel liner to rear fascia assembly

Note
3x push clips
Remove clips securing LH rear wheel liner to rear fascia assembly

Note
3x push clips
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 mid aero shield

Note
11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
Remove bolts securing rear diffuser to body

Note
9x bolts, 10mm, 4 Nm
Remove clips securing rear diffuser to body and remove from vehicle

Note
6x push clips
Remove LH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Remove RH rear suspension cover

Note
1x bolt, 10mm, 6 Nm, 2x tabs
Disconnect RH side 12V subframe harness connector

Note
1x connector, Release locking tab
Remove RH side 12V subframe harness clip from body

Note
1x clip
Disconnect LH side 12V subframe harness connector

Note
1x connector, Release locking tab
Remove LH side 12V subframe harness clip from body

Note
1x clip
Remove nut securing RDU ground strap to vehicle

Note
1x nut, 10mm, 10 Nm
Remove nut securing LH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from LH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
Remove nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
Remove stabilizer bar from RH rear end link

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link, Use a pry bar as needed for assistance
Position support stand to support front portion of rear subframe
Remove bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal
Lower support stand and remove stabilizer bar from vehicle
Remove support stand from under vehicle
Release clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Release LH side hose clip from rear battery skid plate

Note
2x clips, Clip quantity may vary on older vehicles
Release RH side hose clips from rear battery skid plate

Note
2x fir tree clips
Release clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Position coolant drain container underneath LH RDU area

Note
Position neck to catch all coolant loss
Disconnect RDU inverter inlet hose from fluid coupling

Note
1x spring clip, 2x plugs, Plug ends as needed
Remove coolant drain container from underneath vehicle
Release RDU inverter inlet tube from RDU HV cable harness

Note
1x fir tree clip
Remove bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Disconnect RDU HV cable from RDU

Note
1x connector, Red locking tab
Perform RDU diode test

Note
Verify RDU HV cable is disconnected from HV battery. Use a multimeter in diode mode, with the positive DMM probe to B- of the inverter and the negative probe to B+. Pin #1 on HV cables is B- and Pin #2 is B+. MOSFET acceptable diode reading:1.0 - 2.0 V. IGBT acceptable diode reading 0.45 - 2 V (if you get OL or > 2V for a reading you most likely have the probes installed the wrong way around)
Release RDU logic connection

Note
1x connector, Do not get coolant ingress into this connector, Move aside as needed
Release RDU logic connection clip

Note
1x clip
Place subframe lifting tool into position underneath rear subframe
Connect air supply to subframe lifting tool
Raise subframe lifting tool to support rear subframe

Note
3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance
Remove smaller fasteners for LH shear plate

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Remove large bolt securing LH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm
Install LH front extension bolt securing subframe to body

Note
1x bolt, 21mm, 10 Nm, During lowering and raising the sub frame, the adjusting nut and the other three nuts should be kept at the same height as possible
Remove smaller fasteners for RH shear plate

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Remove large bolt securing RH shear plate and subframe to body and remove shear plate

Note
1x bolt, 21mm, 130 Nm
Install RH front extension bolt securing subframe to body

Note
1x bolt, 21mm, 10 Nm, During lowering and raising the sub frame, the adjusting nut and the other three nuts should be kept at the same height as possible
Remove LH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm
Install LH rear extension bolt securing subframe to body

Note
1x bolt, 21mm, 10 Nm, During lowering and raising the sub frame, the adjusting nut and the other three nuts should be kept at the same height as possible
Remove RH rear bolt securing subframe to body

Note
1x bolt, 21mm, 165 Nm
Install RH rear extension bolt securing subframe to body

Note
1x bolt, 21mm, 10 Nm, During lowering and raising the sub frame, the adjusting nut and the other three nuts should be kept at the same height as possible
Partially lower the subframe and rear drive unit assembly from the vehicle

Note
Use caution while lowering subframe to avoid damage to surrounding components, The descending height is about 13cm
Release clip securing inverter to cooler hose to inverter and remove hose

Note
1x spring clip
Release clips securing inverter coolant hose

Note
4x clips
Release RDU inverter coolant hose from heat exchanger and remove hose

Note
1x spring clip
Secure inverter to cooler hose to cooler

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Secure clips holding inverter to coolant hose to RDU

Note
4x clips
Secure inverter to cooler hose to inverter

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Raise drive unit and subframe into position

Note
Use caution to not damage components while raising subframe
Remove the RH rear extension bolt from the body

Note
1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
Install RH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Torque at later step
Remove the LH rear extension bolt from the body

Note
1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
Install LH rear bolt securing rear subframe to body hand tight

Note
1x bolt, 21mm, 165 Nm, Torque at later step
Remove the LH front extension bolt from the body

Note
1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
Install bolt and shear plate to LH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Torque at later step
Install bolts securing LH rear shear plate to body hand tight

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
Remove the RH front extension bolt from the body

Note
1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
Install bolt and shear plate to RH side of rear subframe hand tight

Note
1x bolt, 21mm, 130 Nm, Torque at later step
Install bolts securing RH shear plate to HV battery hand tight

Note
2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
Torque bolts securing shear plates to vehicle

Note
4x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
Torque bolt securing subframe and LH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm, Mark bolt after torque
Torque bolt securing subframe and RH rear shear plate to body

Note
1x bolt, 21mm, 130 Nm
Torque bolt securing RH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Torque bolt securing LH rear of subframe to body

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
Install clips securing coolant hoses to RH shear plate

Note
2x fir tree clips
Install clips securing coolant hoses to LH shear plate

Note
2x fir tree clips
Lower rear subframe lifting tool from vehicle

Note
Verify yellow safety straps are removed from subframe
Disconnect air supply from subframe lifting tool
Remove subframe lifting tool from underneath vehicle
Secure RDU logic connection clip

Note
1x clip
Secure RDU logic connector

Note
1x connector, Verify there is no coolant ingress in connector
Connect RDU HV cable to RDU

Note
1x connector, Install HV connector lever lock to RDU HV cable connector, Align connector to RDU then remove HV connector lever lock before fully latch connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position
Install bolt securing RDU HV cable bracket to RDU

Note
1x bolt, 10mm, 6 Nm
Remove hose plugs and connect coolant inlet hose to rear drive unit

Note
1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
Secure RDU inverter inlet hose clip onto HV cable

Note
1x fir tree clip
Install RH side hose clips to rear battery skid plate

Note
2x fir tree clips
Install LH side hose clip to HV battery rear skid plate enclosure

Note
2x clips, Clip quantity may vary on older vehicles
Place stabilizer bar into position for installation and raise stand to support stabilizer bar
Install bolts securing stabilizer bar to subframe

Note
4x patch bolts, 11mm, 30 Nm, Install new patch bolts
Position LH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing LH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Position RH rear end link into stabilizer bar

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link
Install nut securing RH rear end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
Torque nut securing RH rear stabilizer bar end link to stabilizer bar

Note
1x nyloc nut, 15mm, 55 Nm, Mark bolt after torque
Remove support stand from under vehicle
Install the RDU ground strap to body

Note
1x bolt, 10mm, 10 Nm
Install LH side 12V subframe harness clip to body

Note
1x clip
Connect LH side 12V subframe harness connector

Note
1x connector, Engage locking tab
Install RH side 12V subframe harness clip to body

Note
1x clip
Connect RH side 12V subframe harness connector

Note
1x connector, Engage locking tab
Install rear diffuser to rear fascia assembly and secure clips to body

Note
6x clips
Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body

Note
9x bolts, 10mm, 4 Nm
Lower vehicle partially and set onto locks

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
Install LH rear wheel

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

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

Note
1x cap, Align valve stem with wheel cap cavity
Open all four doors

Note
Latch rear doors to prevent accidental closure
Remove coolant bottle cap
Inspect coolant level and top off as necessary

Note
Ensure coolant is filled using G-48 coolant
Connect first responder loop and 12V negative terminal

Note
1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
Install 2nd row seat cushion

Note
1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
Move RH front seat to original position
Move LH front seat to original position
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)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
Select ‘Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer ’, click ‘Run’, and allow routine to complete

Note
Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
Inspect coolant level and top off as necessary

Note
Ensure coolant is filled using G-48 coolant
Install coolant bottle cap
Install rear apron

Note
14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
Close hood
Raise all four windows
Close all four doors

Note
If 12V is powered up, Unlatch rear doors before closing
Remove vehicle from lift

Note
Lower rack arms fully and remove from under vehicle
Refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.