2026-08-09

Supermanifold (Remove and Replace)

Correction code 1840114072 FRT 1.68 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above 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. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2024-10-7: Added step to add refrigerant evacuation and recharge correction codes as needed.
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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.

Remove

  1. This procedure requires refrigerant evacuation and recharge. Add the specific evacuation and recharge correction as needed.
  2. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
  3. Prepare the A/C machine.
  4. Open the LH front door and lower the LH front window.
  5. Place the vehicle into Service Mode. See Service Mode.
  6. Unlock the vehicle Gateway. See Gateway (Unlock).
  7. On the vehicle touchscreen, navigate to Service Mode > Thermal > Refrigerant System.
  8. Tap Start Thermal Fill Drain (Coolant + Refrigerant ) and allow the routine to complete.
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    Note
    Make sure the routine is successful.
  9. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Install).
  10. Disconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  11. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure (without Terrestrial Armor) (Test/Adjust).
  12. Remove the front aero shield. See Aeroshield - Front (Remove and Install).
  13. Place a coolant catcher below the RH front of the vehicle.
  14. Lower the vehicle until the tires are touching the ground.
  15. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
  16. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  17. Remove the bolts (x2) that attach the supermanifold to the megabeam.
    33 Nm (24.3 lbs-ft)
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    Note
    Break the bolts free, and then remove by hand to avoid tool jamming.
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    Note
    Support the supermanifold from underneath. Lower supermanifold until it resting on the HVAC case.
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    TIp
    Use of the following tool(s) is recommended:
    • 15 mm deep socket
  18. Release the hose clips, and then disconnect the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose from the supermanifold.
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    Note
    This will drain the coolant reservoir.
  19. Release the hose clip, disconnect the radiator outlet hose from the radiator, and then remove the hose from the vehicle.
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    Note
    Plug the radiator after removing the hose.
  20. Move radiator inlet hose aside
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    Note
    1x clip, release clip and move hose aside
  21. Disconnect the supermanifold harness electrical connector.
  22. Disconnect the chiller to battery hose, the powertrain supply hose, and the chiller to battery hose from the supermanifold.
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    Note
    x3 spring clip; x2 electrical connectors
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    Note
    Do not push down on red tab. Pull the red tab to disengage the lock, and then pull again to release the electrical connector.
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    Note
    Pull the supermanifold forward to access the spring clips and electrical connectors.
  23. Remove the bolt that attaches the remote brake fluid reservoir to the vehicle, lift the reservoir upward to release the datum, and then position the reservoir aside.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure the reservoir does not tip over while maneuvering.
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    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  24. Release the connector lock, and then disconnect the A/C compressor logic electrical connector.
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    Note
    Do not push down on red tab. Pull to disengage lock, and then pull again to release the electrical connector.
  25. Release the connector lock, and then disconnect the A/C Compressor HV harness electrical connector from the A/C Compressor.
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    Note
    Pull the red locking tab away from the black lever, and then slide the black lever upwards.
  26. Remove the bolt that attaches the A/C compressor ground strap, and then release the harness edge clip once the ground is free.
    7 Nm (5.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  27. Release AC suction/discharge line bracket from Megabeam
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    Note
    1x bolt, 10mm, 7 Nm
  28. Place a fender cover on the fan housing.
  29. With an assistant supporting the A/C compressor, remove the bolts (x3) that attach the A/C compressor to the megabeam, and then gently place the A/C compressor assembly down.
    5 Nm (3.7 lbs-ft)
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    Note
    Carefully maneuver the A/C compressor towards the front of the vehicle and under the megabeam.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Avoid straining the MV or HV harnesses.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 10 mm socket
  30. Remove the nuts (x2) that attach the refrigerant suction and discharge lines from the A/C compressor, and then remove the lines from the A/C compressor.
    22 Nm (16.2 lbs-ft)
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    Note
    Make sure that the washers do not remain on the A/C compressor.
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    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  31. Remove the A/C compressor from the vehicle.
  32. Release the tabs (x5) that attach the NVH cover to the old A/C compressor, and then remove the NVH cover from the compressor.
  33. Protect the LP and HP opening ports on the AC compressor with masking tape.
  34. Reset the A/C compressor oil level.
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    Note
    Zero scale before use.
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    Note
    Locate manufacturer label on compressor, and then note the "Dry Weight" from the label.
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    Note
    Place compressor on the scale, and then add RB100EV POE oil until the scale reads the value equal to dry weight plus 250g. For example: (Dry weight = 7000g. Add oil until scale reads 7250g).
  35. Position the NVH cover onto the A/C compressor, and then engage the tabs (x5).
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    Note
    Make sure that the NVH cover is fully secured to the compressor.
  36. Install the A/C flush adapters on the A/C manifold to A/C compressor lines.
    22 Nm (16.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
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    Note
    Install the flush adapters onto the suction and discharge lines on the A/C compressor side.
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    Note
    Leave the seal washers on the A/C manifold line.
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    Note
    Inspect O-rings and replace them, if damaged.
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    Note
    Use 13 mm nuts from the A/C compressor to secure the flush adapters.
  37. Perform the A/C System Flush procedure.
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    Note
    System flush procedure runs for approximately 90 minutes. Minimum of 3200g of refrigerant needed in the tank to run system flush procedure. On the A/C machine main menu, select > Manual > Flushing Kit. Enter 25 min vacuum time > Enter > Connect and open couplers > Enter.
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    Note
    A/C machine will perform multiple flush cycles.
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    Note
    Allow process to complete.
  38. Remove the A/C flush adapters from the supermanifold to the compressor A/C line assembly.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  39. Remove the A/C line from the supermanifold.
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    Note
    x1 bolt, 13 mm, 22 Nm; x1 bolt, 10 mm, 8 Nm
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    Note
    Remove the bolt at the supermanifold, and then mounting bracket bolt near the MV battery.
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    Note
    Remove the A/C line assembly from the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that no washers remain on the supermanifold.
  40. Remove the nut that attaches the Penta HVAC line assembly to the supermanifold plate.
    36 Nm (26.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
  41. With assistance, remove the supermanifold from the vehicle.
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    Note
    Rotate the supermanifold counterclockwise under the megabeam.
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    Note
    Support from underneath and at the reservoir.

Install

  1. Replace the seal washers (x5) to the Penta HVAC line on the A/C manifold side.
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    Note
    Lubricate the seal washers with RB100EV POE oil.
  2. With assistance, install the supermanifold to the vehicle.
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    Note
    Rotate the supermanifold counterclockwise under the megabeam.
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    Note
    Support from underneath and at reservoir.
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    Note
    Align penta HVAC line.
  3. Secure the chiller to battery hose, the powertrain supply hose, and the chiller to battery hose to the supermanifold.
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    Note
    x3 spring clip, x2 electrical connectors.
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    Note
    Engage the locking tabs.
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    Note
    Make sure that all hoses are fully engaged with a push-pull-push test.
  4. Install the nut that attaches the pentaline to the supermanifold.
    36 Nm (26.5 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm deep socket
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    Note
    Make sure that good alignment of pipes before tightening the nut.
  5. Install the bolts (x2) that attach the supermanifold to the megabeam.
    33 Nm (24.3 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm deep socket
    Informational PurposesAn informational icon, calling your attention
    Note
    Start the bolts by hand.
  6. Connect the radiator outlet hose to the radiator, and then secure the hose clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure the hose is fully engaged.
  7. Secure the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    x3 spring clips
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that all hoses are fully engaged with a push-pull-push test.
  8. Connect the supermanifold electrical connector.
  9. Replace the seal washers (x2) for the supermanifold to compressor A/C line on the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal washers with RB100EV POE oil.
  10. Install refrigerant suction and discharge lines to compressor.
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    Note
    2x nuts, 13mm, 22 Nm, Install new washer seals, Position AC lines onto studs then install nuts.
  11. Install AC compressor to Megabeam
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    Note
    3x bolts, 10mm, 5 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Start bolts by hand
  12. Secure remote brake fluid reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 8 Nm, 1x datum, Align datum and slide downwards to engage
  13. Install AC manifold line assembly to Supermanifold
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    Note
    1x bolt, 13mm, 22 Nm, 1x bolt, 10mm, 8 Nm, Install manifold to Supermanifold then secure bracket near LV battery
  14. Connect HV harness connector to AC compressor
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    Note
    1x locking electrical connector, Slide down black lock then push in red locking tab, Perform a push-pull-push test, Ensure red locking tab is fully engaged, Black tab will protrude from red locking tab when engaged correctly, Refer to images and video for clarity
  15. Install AC compressor ground strap
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    Note
    1x bolt, 10mm, 16 Nm
  16. Connect AC compressor logic connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  17. Install the front aeroshield. See Aeroshield - Front (Remove and Install).
  18. Perform the A/C Vacuum and Run Leak Test. See A/C Refrigerant (Recovery and Recharge).
    Informational PurposesAn informational icon, calling your attention
    Note
    Set the vacuum time to 20 minutes.
  19. Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
  20. Perform the A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge).
  21. Reconnect MV power. See Mid-Voltage Power (Disconnect and Connect) (Modify).
  22. Reinstall vehicle software.
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    Note
    Touch Service Mode UI > Software Reinstall > Reinstall.
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    Note
    Vehicle software installation will begin immediately.
  23. On the vehicle touchscreen, navigate to Service Mode > Thermal > Actions.
  24. Tap Start Coolant Air Purge, tap Run, and allow the routine to complete.
  25. Inspect the coolant level and top off as necessary.
  26. Perform the A/C performance tests. See A/C Refrigerant (Recovery and Recharge).
  27. Exit Service Mode. See Service Mode.
  28. Install the frunk. See Frunk Assembly (Remove and Install).
  29. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  30. Raise the LH front window and close the LH front door.