29/05/2024 18:11:37

Hydraulic Control Unit (HCU) - Brake (Non-Structural Pack) (Remove and Replace)

Correction code 33109522 2.16 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.

  • 2023-12-05: Updated brake stiffness routine.
  • 2023-07-21: Removed Jack Mode note.
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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.
  1. Raise and support vehicle
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    Note
    Ensure vehicle is not charging before lifting it off the ground,
  2. Open LH front door
  3. Lower LH front window
  4. Lock steering wheel into position
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    Note
    Protect seat from damage
  5. Remove the 12V battery. See 12V/LV Battery (Remove and Replace).
  6. Remove fasteners for LH side of shock tower brace
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
  7. Loosen bolts securing shock tower brace to RH shock tower
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, See image for torque location
  8. Shift shock tower brace assembly to gain clearance for removal of battery bracket
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    Note
    Shift shock tower brace forward, but do not fully remove
  9. Remove bolt securing the steering gear assembly to intermediate shaft assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 18 Nm
  10. Slide the electric steering column upward to remove it from the steering gear assembly
  11. Remove all four wheels. See Wheel Assembly (Remove and Install).
  12. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  13. Remove outer fasteners from front aero shield
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    Note
    7x bolts, 10mm, 5 Nm
  14. Remove remaining nuts and remove front aero shield from vehicle
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    Note
    2x nuts, 15mm, 5 Nm
  15. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  16. Disconnect the hydraulic control unit connector
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    Note
    1x connector, Disengage locking tab and pull up on connector to release
  17. Position the oil drain container under hydraulic control unit area
  18. Remove the RH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  19. Remove the LH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  20. Remove the RH rear brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  21. Remove the LH front brake line tube nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  22. Remove the master cylinder secondary pipe nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  23. Remove the master cylinder primary pipe nut from hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  24. Remove the master cylinder brake lines from the 4 tube bundle
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    Note
    1x clip
  25. Remove RH front brake line from front brake line bundle clip around the LH front rail area
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    Note
    1x brake line
  26. Move brake lines away from hydraulic control unit
  27. Release the master cylinder brake lines from clip at rear of hydraulic control unit bracket
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    Note
    1x harness clip
  28. Remove the oil drain container from underneath vehicle
  29. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  30. Remove the bolts securing the hydraulic control unit to frame rail
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  31. Remove the hydraulic control unit and bracket from vehicle
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    Note
    2x tabs, Slide the HCU toward 12V battery area to remove
  32. Loosen the fasteners securing the hydraulic control unit to the hydraulic control unit bracket
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    Note
    2x nuts, 10mm, 8 Nm
  33. Pry hydraulic control unit from the bracket
  34. Install hydraulic control unit into hydraulic control unit bracket
  35. Install the fasteners securing hydraulic control unit to the hydraulic control unit bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 8 Nm
  36. Position the hydraulic control unit and bracket into vehicle for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, Align hydraulic control unit bracket datums into body
  37. Install the bolts securing the hydraulic control unit to frame rail
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 10 Nm
  38. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  39. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  40. Position the front aero shield to vehicle and install nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  41. Lower vehicle partially and set onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  42. Position the master cylinder brake lines to clip at rear of hydraulic control unit bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x harness clip
  43. Install RH front brake line to front brake line bundle clip around the LH front rail area
    Informational PurposesAn informational icon, calling your attention
    Note
    1x brake line
  44. Install the master cylinder brake lines to 4 tube bundle clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  45. Install the master cylinder primary pipe nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  46. Install the master cylinder secondary pipe nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  47. Move master cylinder lines into position for installation
  48. Install the LH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  49. Install the RH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  50. Install the LH rear brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  51. Install the RH front brake line tube nut to hydraulic control unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 12mm, 16 Nm
  52. Connect the hydraulic control unit connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Gently push connector downward, Engage locking tab
  53. Slide the intermediate shaft assembly downward to install it to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
  54. Install bolt securing the intermediate shaft assembly to the steering gear assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 18 Nm
  55. Position shock tower brace assembly back for installation
  56. Install fasteners for LH side of shock tower brace
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
  57. Torque fasteners for RH side of shock tower brace
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm, Refer to picture proper torque position
  58. Install the 12V battery. See 12V/LV Battery (Remove and Replace).
  59. Remove the steering wheel holder
  60. Connect to vehicle using Toolbox 3.0
  61. Select ‘Actions/Autodiag’ and search for ‘Service_Redeploy’
  62. Select ‘UPDATE_CAN-REDEPLOYSearch for routine in Toolboxhv / Drive Inverter DIRE1L Replacement - CAN Redeployhv / Drive Inverter DIRE1R Replacement - CAN Redeployhv / Drive Inverter DIRE2 Replacement - CAN Redeployhv / Front Drive Inverter Replacement - CAN Redeployhv / Rear Drive Inverter Replacement - CAN Redeployhv / Rear Left Drive Inverter Replacement - CAN Redeployhv / Rear Right Drive Inverter Replacement - CAN Redeployhv / Front Drive Unit Replacement - CAN Redeployhv / Rear Drive Unit Replacement - CAN Redeploy’, click ‘Run’, and allow routine to complete
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    Note
    Select ‘X’ at top right of window to close once complete
  63. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  64. Once firmware redeploy is complete, Verify on center display release notes are present
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    Note
    If the redeploy fails you may receive an error message on UI
  65. Fill brake bleeder reservoir to full level
  66. Clean area around brake fluid reservoir and remove brake reservoir cap
  67. Top off brake fluid reservoir
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    Note
    Top off brake fluid as needed
  68. Install pressure bleeder adapter onto reservoir
  69. Set brake bleed reservoir pressure to 30 psi
    Informational PurposesAn informational icon, calling your attention
    Note
    Connect power supply to bleeder and turn on the power, Set pressure to 30 psi, Attach brake bleed reservoir to brake bleed adapter
  70. Connect to vehicle using Toolbox 3.0
  71. Select Actions/Autodiag and search for "bleed"
  72. Remove bleeding valve covers and install the fluid catching bottle to LH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  73. 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 ToolboxChassis / 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
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  74. Repeat the above step till clear fluid and no air bubbles come out of the LH front brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  75. Remove the fluid catching bottle, Torque LH front brake caliper bleeding valves then install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  76. Remove bleeding valve covers and install the fluid catching bottle to RH front brake caliper outer bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers
  77. 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 ToolboxChassis / 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
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  78. Repeat the above step till clear fluid and no air bubbles come out of the RH front brake caliper bleeding valves
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  79. Remove the fluid catching bottle, Torque RH front brake caliper bleeding valves and install covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
  80. Remove bleeding valve cover and install the fluid catching bottle to RH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  81. 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 ToolboxChassis / 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
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  82. Repeat the above step till clear fluid and no air bubbles come out of the RH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  83. Remove the fluid catching bottle, Torque RH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  84. Remove bleeding valve cover and install the fluid catching bottle to LH rear brake caliper bleeding valve before starting the ESP
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  85. 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 ToolboxChassis / 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
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  86. Repeat the above step untill clear fluid and no air bubbles come out of the LH rear brake caliper bleeding valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  87. Remove the fluid catching bottle, Torque LH rear brake caliper bleeding valve and install cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
  88. Power off brake bleed reservoir and detach brake bleed reservoir from brake bleed adapter
  89. Remove pressure bleeder adapter from reservoir
  90. Check fluid level
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    Note
    Top off if necessary
  91. Install brake reservoir cap
  92. Pump the brake pedal a few times to ensure the brake pedal feels normal
  93. Using Toolbox 3:
    1. Select the Actions tab and search for "Stiffness".
    2. Select the ODIN routine TEST_BRAKE_X_STIFFNESS-TEST-SERVICESearch for routine in ToolboxChassis / Brakes - Brake Stiffness Test, 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.
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      Note
      Do not press the brake pedal during the test.
  94. Install all four wheels. See Wheel Assembly (Remove and Install).
  95. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
  96. Raise LH front window
  97. Close LH front door
  98. Perform test drive
    Informational PurposesAn informational icon, calling your attention
    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