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.
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
NoteEnsure vehicle is not charging before lifting it off the ground,
- Open LH front door
- Lower LH front window
-
Lock steering wheel into position
NoteProtect seat from damage
- Remove the 12V battery. See 12V/LV Battery (Remove and Replace).
-
Remove fasteners for LH side of shock
tower brace
Note2x bolts, 15mm, 67 Nm, 1x bolt, 15mm, 62 Nm
-
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
-
Shift shock tower brace assembly to gain
clearance for removal of battery bracket
NoteShift shock tower brace forward, but do not fully remove
-
Remove bolt securing the steering gear
assembly to intermediate shaft assembly
Note1x bolt, 13mm, 18 Nm
-
Slide the electric steering column
upward to remove it from the steering gear assembly
- Remove all four wheels. See Wheel Assembly (Remove and Install).
-
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
-
Remove outer fasteners from front aero
shield
Note7x bolts, 10mm, 5 Nm
-
Remove remaining nuts and remove front
aero shield from vehicle
Note2x nuts, 15mm, 5 Nm
-
Lower vehicle partially and set lift
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
-
Disconnect the hydraulic control unit
connector
Note1x connector, Disengage locking tab and pull up on connector to release
-
Position the oil drain container under
hydraulic control unit area
-
Remove the RH front brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the LH rear brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the RH rear brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the LH front brake line tube nut
from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder secondary
pipe nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder primary pipe
nut from hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Remove the master cylinder brake lines
from the 4 tube bundle
Note1x clip
-
Remove RH front brake line from front
brake line bundle clip around the LH front rail area
Note1x brake line
-
Move brake lines away from hydraulic
control unit
-
Release the master cylinder brake lines
from clip at rear of hydraulic control unit bracket
Note1x harness clip
-
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
-
Remove the bolts securing the hydraulic
control unit to frame rail
Note2x bolts, 10mm, 10 Nm
-
Remove the hydraulic control unit and
bracket from vehicle
Note2x tabs, Slide the HCU toward 12V battery area to remove
-
Loosen the fasteners securing the
hydraulic control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
-
Pry hydraulic control unit from the
bracket
-
Install hydraulic control unit into
hydraulic control unit bracket
-
Install the fasteners securing hydraulic
control unit to the hydraulic control unit bracket
Note2x nuts, 10mm, 8 Nm
-
Position the hydraulic control unit and
bracket into vehicle for installation
Note2x tabs, Align hydraulic control unit bracket datums into body
-
Install the bolts securing the hydraulic
control unit to frame rail
Note2x bolts, 10mm, 10 Nm
-
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
-
Apply Loctite 222 onto front aero shield
bolts and install outer fasteners to front aero shield
Note7x bolts, 10mm, 5 Nm
-
Position the front aero shield to
vehicle and install nuts
Note2x nuts, 15mm, 5 Nm
-
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
-
Position the master cylinder brake lines
to clip at rear of hydraulic control unit bracket
Note1x harness clip
-
Install RH front brake line to front
brake line bundle clip around the LH front rail area
Note1x brake line
-
Install the master cylinder brake lines
to 4 tube bundle clip
Note1x clip
-
Install the master cylinder primary pipe
nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the master cylinder secondary
pipe nut to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Move master cylinder lines into position
for installation
-
Install the LH front brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH rear brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the LH rear brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Install the RH front brake line tube nut
to hydraulic control unit
Note1x nut, 12mm, 16 Nm
-
Connect the hydraulic control unit
connector
Note1x connector, Gently push connector downward, Engage locking tab
-
Slide the intermediate shaft assembly
downward to install it to the steering gear assembly
NoteEnsure the intermediate shaft is aligned and fully seated, Recommend assistance if necessary to align the shaft to steering gear
-
Install bolt securing the intermediate
shaft assembly to the steering gear assembly
Note1x bolt, 13mm, 18 Nm
-
Position shock tower brace assembly back
for installation
-
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
-
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
- Install the 12V battery. See 12V/LV Battery (Remove and Replace).
-
Remove the steering wheel holder
- Connect to vehicle using Toolbox 3.0
- Select ‘Actions/Autodiag’ and search for ‘Service_Redeploy’
-
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
NoteSelect ‘X’ at top right of window to close once complete
- Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
-
Once firmware redeploy is complete,
Verify on center display release notes are present
NoteIf the redeploy fails you may receive an error message on UI
-
Fill brake bleeder reservoir to full
level
-
Clean area around brake fluid reservoir
and remove brake reservoir cap
-
Top off brake fluid reservoir
NoteTop off brake fluid as needed
-
Install pressure bleeder adapter onto
reservoir
-
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
- Connect to vehicle using Toolbox 3.0
- Select Actions/Autodiag and search for "bleed"
-
Remove bleeding valve covers and install
the fluid catching bottle to LH front brake caliper outer bleeding valve before starting
the ESP
Note2x covers
-
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
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Repeat the above step till clear fluid
and no air bubbles come out of the LH front brake caliper bleeding valve
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove the fluid catching bottle, Torque
LH front brake caliper bleeding valves then install covers
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove bleeding valve covers and install
the fluid catching bottle to RH front brake caliper outer bleeding valve before starting
the ESP
Note2x covers
-
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
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Repeat the above step till clear fluid
and no air bubbles come out of the RH front brake caliper bleeding valves
Note2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove the fluid catching bottle, Torque
RH front brake caliper bleeding valves and install covers
Note2x covers, 2x bleeding valves, 11mm, 18.5 Nm (+/- 2 Nm) Base and Plus calipers
-
Remove bleeding valve cover and install
the fluid catching bottle to RH rear brake caliper bleeding valve before starting the
ESP
Note1x cover
-
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
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Repeat the above step till clear fluid
and no air bubbles come out of the RH rear brake caliper bleeding valve
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove the fluid catching bottle, Torque
RH rear brake caliper bleeding valve and install cover
Note1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove bleeding valve cover and install
the fluid catching bottle to LH rear brake caliper bleeding valve before starting the
ESP
Note1x cover
-
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
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Repeat the above step untill clear fluid
and no air bubbles come out of the LH rear brake caliper bleeding valve
Note1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Remove the fluid catching bottle, Torque
LH rear brake caliper bleeding valve and install cover
Note1x cover, 1x bleeding valve, 11mm, 10 Nm (+/- 3 Nm) Base caliper, 14 Nm (+/- 2 Nm) Plus caliper
-
Power off brake bleed reservoir and
detach brake bleed reservoir from brake bleed adapter
-
Remove pressure bleeder adapter from
reservoir
-
Check fluid level
NoteTop off if necessary
-
Install brake reservoir cap
-
Pump the brake pedal a few times to
ensure the brake pedal feels normal
-
Using Toolbox 3:
- Install all four wheels. See Wheel Assembly (Remove and Install).
-
Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle if necessary, Remove air suspension from "Jack Mode" if equipped
- Raise LH front window
- Close LH front door
-
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