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.
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Raise and support vehicle
NoteEnsure 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
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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)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
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Select ‘Actions/Autodiag’ tab and search for ‘Fill Drain’
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Select ‘PROC_VCFRONT_X_THERMAL-FILL-DRAINSearch for routine in Toolbox’, click ‘Run’, and allow routine to complete
NoteThis 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
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Remove laptop from vehicle
NoteDo not close Toolbox 3.0, we will need to resume later
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Move LH front seat forward
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Move RH front seat forward
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Remove 2nd row seat cushion
Note1x connector, Lift front edge of seat cushion upward to release foam from frame
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Open hood
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Remove rear apron
Note14x clips
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Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
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Disconnect 12V negative terminal and first responders loop
Note1x 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
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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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Remove bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal
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Remove ancillary bay probe lid cover from ancillary bay cover
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Verify no high voltage
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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Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
NoteConfirm no visual damage present, Replace gasket if damage is found
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Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
Note2x bolts, EP10 5-Lobe, 6 Nm, Install new fasteners
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Remove HV insulating gloves
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Remove LH rear wheel cap
Note1x cap, Use both hands to gently pull the wheel cap to release the clips, Wheels may be equipped with center caps
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Loosen LH rear wheel
Note5x nuts, 21mm, 175 Nm
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Close all four doors
NoteUnlatch rear doors at later step
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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
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Remove LH rear wheel
Note5x nuts, 21mm, 175 Nm
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Remove clips securing RH rear wheel liner to rear fascia assembly
Note3x push clips
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Remove clips securing LH rear wheel liner to rear fascia assembly
Note3x push clips
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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
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Remove mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, MYSP will have one less bolt and an extra clip
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Remove bolts securing rear diffuser to body
Note9x bolts, 10mm, 4 Nm
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Remove clips securing rear diffuser to body and remove from vehicle
Note6x push clips
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Remove LH rear suspension cover
Note1x bolt, 10mm, 6 Nm, 2x tabs
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Remove RH rear suspension cover
Note1x bolt, 10mm, 6 Nm, 2x tabs
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Disconnect RH side 12V subframe harness connector
Note1x connector, Release locking tab
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Remove RH side 12V subframe harness clip from body
Note1x clip
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Disconnect LH side 12V subframe harness connector
Note1x connector, Release locking tab
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Remove LH side 12V subframe harness clip from body
Note1x clip
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Remove nut securing RDU ground strap to vehicle
Note1x nut, 10mm, 10 Nm
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Remove nut securing LH rear stabilizer bar end link to stabilizer bar
Note1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
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Remove stabilizer bar from LH rear end link
NoteMay 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
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Remove nut securing RH rear stabilizer bar end link to stabilizer bar
Note1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal
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Remove stabilizer bar from RH rear end link
NoteMay 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
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Position support stand to support front portion of rear subframe
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Remove bolts securing stabilizer bar to subframe
Note4x patch bolts, 11mm, 30 Nm, Discard after removal
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Lower support stand and remove stabilizer bar from vehicle
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Remove support stand from under vehicle
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Release clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Release LH side hose clip from rear battery skid plate
Note2x clips, Clip quantity may vary on older vehicles
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Release RH side hose clips from rear battery skid plate
Note2x fir tree clips
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Release clips securing coolant hoses to RH shear plate
Note2x fir tree clips
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Position coolant drain container underneath LH RDU area
NotePosition neck to catch all coolant loss
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Disconnect RDU inverter inlet hose from fluid coupling
Note1x spring clip, 2x plugs, Plug ends as needed
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Remove coolant drain container from underneath vehicle
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Release RDU inverter inlet tube from RDU HV cable harness
Note1x fir tree clip
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Remove bolt securing RDU HV cable bracket to RDU
Note1x bolt, 10mm, 6 Nm
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Disconnect RDU HV cable from RDU
Note1x connector, Red locking tab
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Perform RDU diode test
NoteVerify 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)
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Release RDU logic connection
Note1x connector, Do not get coolant ingress into this connector, Move aside as needed
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Release RDU logic connection clip
Note1x clip
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Place subframe lifting tool into position underneath rear subframe
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Connect air supply to subframe lifting tool
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Raise subframe lifting tool to support rear subframe
Note3x 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
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Remove smaller fasteners for LH shear plate
Note2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
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Remove large bolt securing LH shear plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 130 Nm
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Install LH front extension bolt securing subframe to body
Note1x 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
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Remove smaller fasteners for RH shear plate
Note2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
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Remove large bolt securing RH shear plate and subframe to body and remove shear plate
Note1x bolt, 21mm, 130 Nm
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Install RH front extension bolt securing subframe to body
Note1x 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
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Remove LH rear bolt securing subframe to body
Note1x bolt, 21mm, 165 Nm
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Install LH rear extension bolt securing subframe to body
Note1x 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
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Remove RH rear bolt securing subframe to body
Note1x bolt, 21mm, 165 Nm
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Install RH rear extension bolt securing subframe to body
Note1x 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
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Partially lower the subframe and rear drive unit assembly from the vehicle
NoteUse caution while lowering subframe to avoid damage to surrounding components, The descending height is about 13cm
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Release clip securing inverter to cooler hose to inverter and remove hose
Note1x spring clip
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Release clips securing inverter coolant hose
Note4x clips
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Release RDU inverter coolant hose from heat exchanger and remove hose
Note1x spring clip
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Secure inverter to cooler hose to cooler
Note1x spring clip, Perform push-pull-push test to make sure hose is fully seated
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Secure clips holding inverter to coolant hose to RDU
Note4x clips
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Secure inverter to cooler hose to inverter
Note1x spring clip, Perform push-pull-push test to make sure hose is fully seated
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Raise drive unit and subframe into position
NoteUse caution to not damage components while raising subframe
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Remove the RH rear extension bolt from the body
Note1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
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Install RH rear bolt securing rear subframe to body hand tight
Note1x bolt, 21mm, 165 Nm, Torque at later step
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Remove the LH rear extension bolt from the body
Note1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
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Install LH rear bolt securing rear subframe to body hand tight
Note1x bolt, 21mm, 165 Nm, Torque at later step
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Remove the LH front extension bolt from the body
Note1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
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Install bolt and shear plate to LH side of rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Torque at later step
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Install bolts securing LH rear shear plate to body hand tight
Note2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
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Remove the RH front extension bolt from the body
Note1x bolt, 21mm, 10 Nm, Remove with ratchet wrench
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Install bolt and shear plate to RH side of rear subframe hand tight
Note1x bolt, 21mm, 130 Nm, Torque at later step
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Install bolts securing RH shear plate to HV battery hand tight
Note2x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles. Torque at later step.
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Torque bolts securing shear plates to vehicle
Note4x bolts, 13mm, 35 Nm for non-Structural Pack vehicles, 62 Nm for Structural Pack vehicles.
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Torque bolt securing subframe and LH rear shear plate to body
Note1x bolt, 21mm, 130 Nm, Mark bolt after torque
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Torque bolt securing subframe and RH rear shear plate to body
Note1x bolt, 21mm, 130 Nm
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Torque bolt securing RH rear of subframe to body
Note1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
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Torque bolt securing LH rear of subframe to body
Note1x rear bolt, 21mm, 165 Nm, Mark bolt after torque
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Install clips securing coolant hoses to RH shear plate
Note2x fir tree clips
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Install clips securing coolant hoses to LH shear plate
Note2x fir tree clips
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Lower rear subframe lifting tool from vehicle
NoteVerify yellow safety straps are removed from subframe
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Disconnect air supply from subframe lifting tool
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Remove subframe lifting tool from underneath vehicle
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Secure RDU logic connection clip
Note1x clip
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Secure RDU logic connector
Note1x connector, Verify there is no coolant ingress in connector
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Connect RDU HV cable to RDU
Note1x 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
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Install bolt securing RDU HV cable bracket to RDU
Note1x bolt, 10mm, 6 Nm
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Remove hose plugs and connect coolant inlet hose to rear drive unit
Note1x spring clip, Let coolant drain from hose before install, Perform push-pull-push test to make sure hose is fully seated
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Secure RDU inverter inlet hose clip onto HV cable
Note1x fir tree clip
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Install RH side hose clips to rear battery skid plate
Note2x fir tree clips
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Install LH side hose clip to HV battery rear skid plate enclosure
Note2x clips, Clip quantity may vary on older vehicles
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Place stabilizer bar into position for installation and raise stand to support stabilizer bar
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Install bolts securing stabilizer bar to subframe
Note4x patch bolts, 11mm, 30 Nm, Install new patch bolts
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Position LH rear end link into stabilizer bar
NoteAdjust 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
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Install nut securing LH rear end link to stabilizer bar
Note1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
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Position RH rear end link into stabilizer bar
NoteAdjust 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
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Install nut securing RH rear end link to stabilizer bar
Note1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque
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Torque nut securing RH rear stabilizer bar end link to stabilizer bar
Note1x nyloc nut, 15mm, 55 Nm, Mark bolt after torque
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Remove support stand from under vehicle
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Install the RDU ground strap to body
Note1x bolt, 10mm, 10 Nm
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Install LH side 12V subframe harness clip to body
Note1x clip
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Connect LH side 12V subframe harness connector
Note1x connector, Engage locking tab
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Install RH side 12V subframe harness clip to body
Note1x clip
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Connect RH side 12V subframe harness connector
Note1x connector, Engage locking tab
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Install rear diffuser to rear fascia assembly and secure clips to body
Note6x clips
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Apply Loctite 222 onto rear diffuser bolts and install bolts securing rear diffuser to body
Note9x bolts, 10mm, 4 Nm
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Lower vehicle partially and set onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
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Install LH rear wheel
Note5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool
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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 LH rear wheel
Note5x nuts, 21mm, 175 Nm
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Install LH rear wheel cap
Note1x cap, Align valve stem with wheel cap cavity
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Open all four doors
NoteLatch rear doors to prevent accidental closure
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Remove coolant bottle cap
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Inspect coolant level and top off as necessary
NoteEnsure coolant is filled using G-48 coolant
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Connect first responder loop and 12V negative terminal
Note1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer
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Install 2nd row seat cushion
Note1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test
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Move RH front seat to original position
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Move LH front seat to original position
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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)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
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Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
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Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
NoteMake 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
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Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
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Inspect coolant level and top off as necessary
NoteEnsure coolant is filled using G-48 coolant
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Install coolant bottle cap
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Install rear apron
Note14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips
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Close hood
- Raise all four windows
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Close all four doors
NoteIf 12V is powered up, Unlatch rear doors before closing
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Remove vehicle from lift
NoteLower 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.