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Home >> Tesla >> 2017 >> Model 3 Base >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Front Drive Unit -- Model 3 >> Front Drive Inverter >> Inverter - Front Drive Unit - Remove and Replace >> Install

Inverter - Front Drive Unit - Remove and Replace: Install

  1. Secure ESD strap to new inverter housing
    G14750130Courtesy of TESLA, INC.
  2. Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria:
    • New and undamaged condition.
    • Fully covers the discharge resistor array and no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
    G14750131Courtesy of TESLA, INC.
  3. Use an IPA wipe to clean the HV mating surfaces of the front drive unit motor and front drive unit inverter 3-phase terminals.
    G14750132Courtesy of TESLA, INC.
    G14750133Courtesy of TESLA, INC.
  4. Install a new front drive unit inverter gasket onto the inverter.
    G14750134Courtesy of TESLA, INC.
  5. Carefully align the front drive unit inverter to the 2 pins in the front drive unit, and then install the inverter onto the drive unit. Make sure that the 3-phase terminals align during installation.
    CAUTION: Avoid damage to the printed circuit board of the inverter.
    G14750135Courtesy of TESLA, INC.
  6. Install and hand-tighten new bolts (x12) to attach the front drive unit inverter to the front drive unit gearbox.
    G14750136Courtesy of TESLA, INC.
  7. Torque the bolts (x12) in the sequence shown.

    12.5 N.m (9.2 ft-lbs) 

    Fig 1: Front Drive Unit Inverter To Front Drive Unit Gearbox Bolts With Tightening Sequence
    G14750137Courtesy of TESLA, INC.
  8. Install and hand-tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.
    G14750138Courtesy of TESLA, INC.
  9. Tighten the bolts (x3) that attach the front drive unit motor 3-phase terminals to the front drive unit inverter 3-phase terminals.

    11.5 N.m (8.5 ft-lbs) 

    CAUTION: If any bolts are dropped into the gearbox housing, they must be retrieved.
    NOTE: If installing a new bolt, tighten to 12.5 N.m/9.2 ft-lbs, back off 180 degrees, then torque to 5 N.m/3.7 ft-lbs +40 degrees.
    G14750139Courtesy of TESLA, INC.
  10. Lightly lubricate the front drive unit gearbox phase out cover bores with EDF2 fluid, and if a new phase out cover is to be installed, lightly lubricate the O-rings of the cover.
    G00623607Courtesy of TESLA, INC.
  11. Install the phase out cover into the front drive unit gearbox, and then install the bolts (x2) that attach the cover to the gearbox.

    14 N.m (10.3 ft-lbs) 

    G14750141Courtesy of TESLA, INC.
  12. Apply a new front drive unit inverter phase out cover label.
    G14750142Courtesy of TESLA, INC.
  13. Attach the ESD wrist strap to the old inverter, place the old inverter into the ESD return box, and then remove the ESD wrist strap from the old inverter.
    NOTE: Replace the service plugs with the factory shipping plugs from the new inverter.
  14. Perform an inverter air leak test. See INVERTER AIR LEAK TEST .
  15. Install the LH motor mount to the front drive unit, and then install and hand-tighten the bolts (x3) that attach the mount to the drive unit.
    G14750143Courtesy of TESLA, INC.
  16. Torque the bolts (x3) in the sequence shown.

    35 N.m (25.8 ft-lbs) +55 deg 

    Fig 2: LH Motor Mount To Front Drive Unit Bolts With Tightening Sequence
    G14750144Courtesy of TESLA, INC.
  17. Fasten the clips (x2) that attach the subframe electrical harness to the front drive unit inverter.
    G14750145Courtesy of TESLA, INC.
  18. Connect the subframe electrical harness to the front drive unit inverter logic connector, raise the handle upward, and then fasten the locking tab.
    G14750146Courtesy of TESLA, INC.
  19. Install the front drive unit inverter inlet hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.
    G14750147Courtesy of TESLA, INC.
  20. Connect the front drive unit inverter inlet hose to the front drive unit inverter inlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.
    G14750148Courtesy of TESLA, INC.
  21. Install the front drive unit inverter to heat exchanger hose to the front drive unit, and then fasten the clips (x2) that attach the hose to the drive unit.

    Heat Pump Model 3

    G14750149Courtesy of TESLA, INC.

    Model 3

    G14750150Courtesy of TESLA, INC.
  22. Connect the front drive unit inverter to heat exchanger hose to the front drive unit heat exchanger, fasten the clip, and then perform a Push-Pull-Push check of the fitting.

    Heat Pump Model 3

    G14750151Courtesy of TESLA, INC.

    Model 3

    G14750152Courtesy of TESLA, INC.
  23. Connect the front drive unit inverter to heat exchanger hose to the front drive unit inverter outlet, fasten the clip, and then perform a Push-Pull-Push check of the fitting.

    Heat Pump Model 3

    G14750153Courtesy of TESLA, INC.

    Model 3

    G14750154Courtesy of TESLA, INC.
  24. Install the front subframe. See SUBFRAME ASSEMBLY - FRONT (DUAL MOTOR) (REMOVE AND INSTALL) .
  25. Install the front fascia. See FASCIA - FRONT (REMOVE AND INSTALL) .
  26. Install the front aero shield panel. See PANEL - AERO SHIELD - FRONT (REMOVE AND REPLACE) .
  27. Model 3 -  Connect the electrical harness to the LV logic connectors (x2) at the steering gear, and then push the grey tabs to lock the connectors.
    G14750155Courtesy of TESLA, INC.
  28. Connect the electrical harness to the steering gear power connectors (x2), and then slide the red tab to lock the connectors.
    G14750156Courtesy of TESLA, INC.
  29. Model 3 -  Connect the electrical harness to the front subframe electrical harness.
    G14750157Courtesy of TESLA, INC.
  30. Slide the intermediate shaft down onto the steering gear, and then install the bolt that attaches the intermediate shaft to the steering gear.

    18 N.m (13.3 ft-lbs) 

    Heat Pump Model 3

    G14750158Courtesy of TESLA, INC.
    G14750159Courtesy of TESLA, INC.

    Model 3

    G14750160Courtesy of TESLA, INC.
    G14750161Courtesy of TESLA, INC.
  31. Install the underhood storage unit. See UNDERHOOD STORAGE UNIT (REMOVE AND REPLACE) .
  32. Perform a cooling system vacuum refill. See COOLING SYSTEM (VACUUM REFILL) .
  33. Connect LV power. See 12V/LV POWER (DISCONNECT AND CONNECT) .
  34. Remove the steering wheel lock from the steering wheel.
    G14750162Courtesy of TESLA, INC.
  35. Connect the laptop with Toolbox 3.
  36. From the AFTER INVERTER SWAP Action List, click Stop Thermal Fluid Fill/Drain  , click Run  , click Submit  , and then allow the routine to complete.
  37. From the AFTER INVERTER SWAP Action List, click Restore FRONT Drive INVERTER Bootloader Data after Replacement and Usage ID Configuration  , click Run  , and then allow the routine to complete.
  38. From the AFTER INVERTER SWAP Action List, click Service CAN Redeploy  , click Run  , and then allow the routine to complete.
  39. From the AFTER INVERTER SWAP Action List, click Restore Drive Inverter Slave Application Data after Replacement  , click Run  , click Submit  , and then allow the routine to complete.
  40. From the AFTER INVERTER SWAP Action List, click Coolant Air Purge  , click RUN  , and then allow the routine to complete.
  41. From the AFTER INVERTER SWAP Action List, click Thermal System Performance Test  , click Run  , and then allow the routine to complete.
  42. Inspect the coolant level and top up if necessary. See COOLING SYSTEM - PARTIAL REFILL AND BLEED .
  43. Manually engage the hood latch.
    NOTE: If the hood is open, or if the hood latch is not manually engaged, the vehicle speed will be limited and the resolver learn routine will fail.
    G00623608Courtesy of TESLA, INC.
  44. Touch the brake pedal to ensure the drive rails are on, and then click NEXT  .
  45. From the RESOLVER LEARN Action List, click Inverter Resolver Error Learning  , click Run  , and follow the displayed instructions.
  46. Disconnect the laptop with Toolbox 3 from the vehicle.
  47. Install the front LH and RH wheels. See WHEEL (REMOVE AND INSTALL)
  48. Remove the stanchions from the rear of the vehicle.
    G00623609Courtesy of TESLA, INC.
  49. On the vehicle touchscreen, open the hood to disengage the hood latch.
  50. Install the rear underhood apron. See UNDERHOOD APRON - REAR (REMOVE AND REPLACE) .
  51. Remove the vehicle from the 2 post lift. See RAISE VEHICLE - 2 POST LIFT .
  52. Perform a validation test drive at road and highway speeds to determine if an alignment check is necessary.
    • If the test drive shows the vehicle to track poorly or pull to the side, or if steering is sloppy or off center, then perform a four wheel alignment check. See Four Wheel Alignment Check , and add this service to the SV.
    • If the test drive shows the vehicle to steer and handle as expected, then an alignment check is not necessary.
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