29/05/2024 18:12:30
Brake Lines - Rear - RH to Sill (Structural Pack) (Remove and Replace)
Correction code 33035312 2.76 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.
- 2024-01-26: Corrected High Voltage check sequence.
- 2023-12-08: 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.
Remove
- Remove the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove butyl patches covering LH rocker access holes
Note2x butyl patches, Clean excess butyl from area
-
Install lift pad adapters onto LH rocker
Note2x lift pad adapters
- Remove the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove butyl patches covering RH rocker access holes
Note2x butyl patches, Clean excess butyl from area
-
Install lift pad adapters onto RH rocker
Note2x lift pad adapters
-
Raise and support vehicle
NoteVerify jack locations prior to lifting vehicle, ONLY place on lifting points at front and rear of rocker panels
- Open LH front door
- Lower LH front window
- Open hood
- Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
-
Remove bolt securing frunk to washer fluid reservoir neck
Note1x bolt, 10mm, 5 Nm
-
Release washer tank neck from washer tank and set aside
Note1x O-ring, No need to remove hose from neck
-
Remove HEPA filter assembly
Note2x bolts, 10mm, 5 Nm, Pivot rearward edge up and past brake reservoir, then lift up to clear frunk assembly
-
Power off vehicle from center display
NoteVia Controls > Safety > Power Off, Select Power Off button at warning dialogue box
-
Disconnect LV battery connector and First Responder Loop
Note2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge
-
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
- Remove all four wheels. See Wheel Assembly (Remove and Install).
- Remove the LH rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
-
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 push clips at left and right wheel house liner to mid aero shield
Note2x clips
-
Remove mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will have one less bolt and one extra clip
-
Remove all items from pockets and ensure not wearing metal items
-
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
-
Put on HV insulating gloves and leather over gloves
NoteMake sure to wear Electrical Protective Gloves any time Hioki tester is used
-
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 requiredIf current < 0.5A, Ok to disconnect and check voltage at HV plug on the battery side.
-
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
-
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
-
Position coolant drain container underneath LH rear of HV battery
-
Remove clip securing RDU inverter inlet hose to RDU HV cable
Note1x clip
-
Disconnect RDU inverter inlet hose from fluid coupling
Note1x spring clip, 2x plugs, Plug ends as needed
-
Remove RDU inverter inlet hose
Note1x spring clip, 1x clip, Rotate between subframe and battery out of vehicle
-
Release RDU oil cooler outlet pipe
Note2x spring clips, 5x clips, Plug hose connections as needed
-
Remove RDU oil cooler outlet pipe
NoteRotate down over RDU and rearward around subframe
-
Remove coolant drain container from underneath vehicle
-
Remove RDU 12V harness clip
Note1x clip
-
Disconnect RDU 12V connector
Note1x connector
-
Remove bolt securing RDU HV cable bracket to RDU
Note1x bolt, 10mm, 6 Nm
-
Disconnect RDU HV cable from RDU
Note1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up
-
Remove RDU HV cable from vehicle
NoteCarefully route cable out and do damage housing or surrounding components
-
Remove smaller fasteners for LH and RH shear plates
Note4x bolts, 13mm, 47 Nm, Bolt position 8-9 and 14-15
-
Loosen large bolt securing LH shear plate and subframe to body and rotate shear plate clear of HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Loosen large bolt securing RH shear plate and subframe to body and rotate shear plate clear of HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
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
-
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
-
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
-
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
-
Position support stand to support front portion of rear subframe
-
Remove bolts securing stabilizer bar to subframe
Note4x patch bolts, 11mm, 30 Nm, Discard after removal
-
Lower support stand and remove stabilizer bar from vehicle
-
Release RH rear brake line from LH rear junction block
Note1x nut, 12mm, 16 Nm
-
Release RH rear brake line from jounce hose
Note1x nut, 12mm, 16 Nm
-
Release RH rear brake line from clips
Note8x clips, Do not bend pipe
-
Position support stand to support front portion of rear subframe
NoteRear stabilizer bar should not be installed at this point
-
Remove large fore bolts securing rear subframe to body and lower support stand
Note2x fore bolts, 21mm, 130 Nm, Lower subframe just enough for RH rear pipe to pass through
-
Remove RH rear brake line
NoteDo not bend pipe, Four-step removal, Guide LH side of pipe over subframe bushing, Guide RH side of pipe over top of subframe, Guide LH side of pipe between battery and subframe gap then rotate to RH side of vehicle, Guide RH side of pipe over subframe bushing
Install
-
Install RH rear brake line
NoteDo not bend pipe, Four-step installation, Guide RH side of pipe over subframe bushing, Rotate RH side of pipe to LH side of vehicle and guide between battery and subframe gap, Guide RH side of pipe over top of subframe, Guide LH side of pipe over subframe bushing
-
Raise support stand and install large fore bolts securing rear subframe to body hand tight
Note2x fore bolts, 21mm, 130 Nm, Make sure RH rear pipe does not get pinched between subframe and body, Torque at later step
-
Remove support stand from front portion of rear subframe
NoteRear stabilizer bar should not be installed at this point
-
Secure RH rear brake line onto clips
Note8x clips, Do not bend pipe
-
Secure RH rear brake line onto jounce hose
Note1x nut, 12mm, 16 Nm
-
Secure RH rear brake line onto LH rear junction block
Note1x nut, 12mm, 16 Nm
-
Place stabilizer bar into position for installation and raise stand to support stabilizer bar
-
Install bolts securing stabilizer bar to subframe
Note4x patch bolts, 11mm, 30 Nm, Install new patch bolts
-
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
-
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
-
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
-
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
-
Remove support stand from under vehicle
-
Loosen RH rear subframe bolt and align RH rear shear plate with HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Install bolts securing RH shear plate to HV battery hand tight
Note2x bolts, 13mm, 62 Nm, Bolt position 8-9, Torque at later step
-
Torque bolt securing subframe and RH rear shear plate to body
Note1x bolt, 21mm, 130 Nm
-
Torque small fasteners securing RH rear shear plate to body
Note2x bolts, 13mm, 62 Nm, Bolt position 8-9
-
Loosen LH rear subframe bolt and align LH rear shear plate with HV battery
Note1x bolt, 21mm, 130 Nm, Hand tighten bolt once shear plate is in position
-
Install bolts securing LH rear shear plate to body hand tight
Note2x bolts, 13mm, 62 Nm, Bolt position 14-15, Torque at later step
-
Torque bolt securing subframe and LH rear shear plate to body
Note1x bolt, 21mm, 130 Nm
-
Torque small fasteners securing LH rear shear plate to body
Note2x bolts, 13mm, 62 Nm, Bolt position 14-15
-
Position RDU HV cable into vehicle
NoteCarefully maneuver cable in and do damage housing or surrounding components
-
Connect RDU HV cable onto RDU
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
-
Install bolt securing RDU HV cable bracket to RDU
Note1x bolt, 10mm, 6 Nm
-
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
-
Install RDU 12V connector
Note1x connector
-
Install RDU 12V harness clip
Note1x clip
-
Position coolant drain container underneath LH rear of HV battery
-
Install RDU oil cooler outlet pipe
NoteRotate up over RDU and rearward around subframe to oil cooler
-
Secure RDU oil cooler outlet pipe
Note2x spring clips, 5x clips, Remove plugs as needed
-
Install RDU inverter inlet hose
Note1x spring clip, 1x clip, Rotate between subframe and battery into RDU and PCS outlet, Remove plugs as needed
-
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
-
Remove coolant drain container from underneath vehicle
-
Apply Loctite 222 onto mid aero shield bolts and install mid aero shield
Note11x bolts, 10mm, 5 Nm, Fasteners may vary, Model Y Structural Pack will one less bolt and one extra clip
-
Install push clips at left and right wheel house liner to mid aero shield
Note2x clips
-
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
-
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
-
Remove coolant bottle cap
-
Fill coolant to the proper level
NoteEnsure that the fluid level filled to the Max line
-
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
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"
-
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 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
-
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 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
-
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 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
-
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 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
-
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:
- Select ‘Actions/Autodiag’ tab and search for ‘ Purge'
-
Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / 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
-
Install coolant bottle cap
-
Inspect coolant level and top off as necessary
NoteEnsure that the fluid level is at the Max line
-
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 rear wheel arch liner. See Wheel Arch Liner - Rear - LH (Structural Pack) (Remove and Replace).
- Install all four wheels. See Wheel Assembly (Remove and Install).
-
Install HEPA filter assembly
Note2x bolts, 10mm, 5 Nm, Pivot forward edge down past frunk assembly, then carefully move rear edge past brake reservoir and into position
-
Install washer tank neck to washer tank
Note1x O-ring, Ensure washer hose is properly routed after installation
-
Secure frunk to washer fluid reservoir neck
Note1x bolt, 10mm, 5 Nm
- Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
- Close hood
-
Remove vehicle from lift
NoteLower rack arms fully and remove from under vehicle
- Raise LH front window
- Close LH front door
-
Remove lift pad adapters from LH rocker
Note2x lift pad adapters
-
Install butyl patches onto LH rocker access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the LH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).
-
Remove lift pad adapters from RH rocker
Note2x lift pad adapters
-
Install butyl patches onto RH rocker access holes
Note2x butyl patches, Apply pressure along patch to verify fully secured to body, Replace with new patch if needed, Roughly 2" x 2 1/2"
- Install the RH rocker panel carrier. See Carrier - Rocker Panel - LH (Structural Pack) (Remove and Replace).