04/09/2024 13:25:29

Supermanifold - Supermanifold (Remove and Replace)

Correction code 1840114072 FRT 2.04 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.

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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.

Remove

  1. Open the LH front door and lower the LH front window.
  2. Put the vehicle in Service Mode. See Service Mode.
  3. Unlock the vehicle gateway. See Gateway (Unlock).
  4. Navigate to Refrigerant System on the vehicle touchscreen.
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    Note
    Touch Service Mode > Thermal > Refrigerant System
  5. Touch Start Thermal Fill Drain (Refrigerant only).
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    Note
    Allow routine to complete. Ensure routine is successful.
  6. Open the powered frunk.
  7. Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
  8. Disconnect MV power. See Disconnect MV Power.
  9. Raise and support the vehicle on a 2 post lift. See Raise Vehicle - 2 Post Lift.
  10. Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
  11. Remove the front aero shield.
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    Note
    x11 bolts, 10 mm, 6 Nm
  12. Place a coolant catcher below the RH front of the vehicle.
  13. Lower the vehicle until the tires are touching the ground.
  14. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
  15. Remove the frunk assembly. See Frunk Assembly (Remove and Install).
  16. Remove the bolts (x2) that attach the supermanifold to the megabeam.
    33 Nm (24.3 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm deep socket
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    Break free the bolts, and then remove by hand to avoid tool jamming.
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    Support the supermanifold from underneath. Lower supermanifold until resting on the HVAC case.
  17. Disconnect the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose from the supermanifold.
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    Note
    x3 spring clips
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    This will drain the coolant reservoir.
  18. Disconnect the radiator outlet hose from the radiator.
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    x1 spring clip.
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    Remove the hose from the vehicle.
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    Plug hoses.
  19. Disconnect the supermanifold harness electrical connector.
  20. Disconnect the chiller to battery hose, the powertrain supply hose, and the chiller to battery hose from the supermanifold.
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    x3 spring clip; x2 electrical connectors
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    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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    Pull the supermanifold forward to access the spring clips and electrical connectors.
  21. Remove the remote brake fluid reservoir.
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    x1 bolt, 10 mm, 8 Nm, x1 datum
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    Lift upwards to release datum.
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    Position aside.
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    Avoid tipping over.
  22. Disconnect the A/C compressor logic electrical connector.
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    x1 locking electrical connector. Do not push down on red tab. Pull to disengage lock, and then pull again to release the electrical connector.
  23. Release the connector lock, and then disconnect the A/C Compressor HV harness electrical connector from the A/C Compressor.
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    Pull the red locking tab away from the black lever, and then slide the black lever upwards.
  24. Remove the bolt that attaches the A/C compressor ground strap.
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
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    Note
    Release the harness edge clip once the ground is free.
  25. Remove the A/C hoses from the vehicle.
  26. Remove bolts (x3) that attach the A/C compressor to the megabeam.
    5 Nm (3.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm socket
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    Recommend assistance.
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    Support the A/C compressor while removing the fasteners.
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    Carefully remove the A/C compressor towards the front of the vehicle and under the megabeam.
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    Place fender cover on the fan housing, and then gently place the A/C compressor assembly down.
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    Avoid straining the MV or HV harnesses.
  27. 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)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
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    Remove the nuts (x2), and then remove the A/C lines from the A/C compressor.
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    Make sure that the washers do not remain on the A/C compressor.
  28. Remove the A/C compressor from the vehicle.
  29. Remove the NVH cover from the old A/C compressor.
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    x5 tabs
  30. Protect the LP and HP opening ports on the AC compressor with masking tape.
  31. Reset the A/C compressor oil level.
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    Zero scale before use.
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    Locate manufacturer label on compressor, and then note the "Dry Weight" from the label.
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    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).
  32. Install the NVH cover to the A/C compressor.
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    x5 tabs
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    Make sure that the NVH cover is secured.
  33. Install the A/C flush adapters on the A/C manifold to A/C compressor lines.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
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    Install the flush adapters onto the suction and discharge lines on the A/C compressor side.
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    Leave the seal washers on the A/C manifold line.
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    Inspect O-rings and replace them, if damaged.
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    Use 13 mm nuts from the A/C compressor to secure the flush adapters.
  34. Perform the A/C System Flush procedure.
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    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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    A/C machine will perform multiple flush cycles.
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    Allow process to complete.
  35. Remove the A/C flush adapters from the supermanifold to the compressor A/C line assembly.
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    x2 nuts, 13 mm, 22 Nm
  36. Remove the nut that attaches the Penta HVAC line assembly to the supermanifold plate.
    36 Nm (26.5 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
  37. Remove the bolt that attaches the A/C line to the supermanifold.
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    Note
    x1 bolt, 13 mm, 22 Nm; x1 bolt, 10 mm, 8 Nm
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    Remove the bolt at the supermanifold, and then mounting bracket bolt near the MV battery.
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    Remove the A/C line assembly from the supermanifold.
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    Make sure that no washers remain on the supermanifold.
  38. Remove the supermanifold from the vehicle.
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    Recommend assistance.
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    Rotate the supermanifold counterclockwise under the megabeam.
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    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. Install the supermanifold to the vehicle.
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    Recommend assistance.
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    Rotate the supermanifold counterclockwise under the megabeam.
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    Support from underneath and at reservoir.
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    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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    x3 spring clip, x2 electrical connectors.
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    Engage the locking tabs.
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    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)
    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)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm deep socket
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    Note
    Start the bolts by hand.
  6. Connect the radiator outlet hose to the radiator.
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    Note
    x1 spring clip
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    Note
    Make sure that the hose is fully engaged with a push-pull-push test.
  7. Secure the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose to the supermanifold.
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    Note
    x3 spring clips
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    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.
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    Note
    Lubricate the seal washers with RB100EV POE oil.
  10. Install the A/C manifold line assembly to the supermanifold.
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    Note
    x1 bolt, 13 mm, 22 Nm; x1 bolt, 10 mm, 8 Nm
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    Install new washer seals.
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    Install the manifold to the supermanifold, and then secure the bracket near the MV battery.
  11. Perform the A/C Vacuum and Run Leak Test. See A/C Refrigerant (Recovery and Recharge).
  12. Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
  13. Perform the A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge).
  14. Reconnect MV power. See Disconnect MV Power.
  15. Reinstall vehicle software.
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    Touch Service Mode UI > Software Reinstall > Reinstall.
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    Vehicle software installation will begin immediately.
  16. Perform the A/C performance tests. See A/C Refrigerant (Recovery and Recharge).
  17. Exit Service Mode. See Service Mode.
  18. Install the frunk. See Frunk Assembly (Remove and Install).
  19. Close the powered frunk.
  20. Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
  21. Raise the LH front window and close the LH front door.