07/11/2024 13:22:02

Supermanifold - Supermanifold (Remove and Replace)

Correction code 1840114072 FRT 1.26 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.

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

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

This procedure requires refrigerant evacuation and recharge. Add the specific evacuation and recharge correction as needed.
Prepare the A/C machine.
Open the LH front door and lower the LH front window.
Place the vehicle into Service Mode. See Service Mode.
Unlock the vehicle Gateway. See Gateway (Unlock).
On the vehicle touchscreen, navigate to Service Mode > Thermal > Refrigerant System.
Tap Start Thermal Fill Drain (Coolant + Refrigerant ) and allow the routine to complete.

Note
Make sure the routine is successful.
Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
Disconnect MV power. See Disconnect MV Power.
Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
Perform Vehicle HV Disablement procedure. See Vehicle HV Disablement Procedure.
Remove the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
Place a coolant catcher below the RH front of the vehicle.
Lower the vehicle until the tires are touching the ground.
Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
Remove the frunk assembly. See Frunk Assembly (Remove and Install).
Remove the bolts (x2) that attach the supermanifold to the megabeam.
33 Nm (24.3 lbs-ft)
Note
Break the bolts free, and then remove by hand to avoid tool jamming.

Note
Support the supermanifold from underneath. Lower supermanifold until it resting on the HVAC case.
Tip: Use of the following tool(s) is recommended:
- 15 mm deep socket
Release the hose clips, and then disconnect the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose from the supermanifold.

Note
This will drain the coolant reservoir.
Release the hose clip, disconnect the radiator outlet hose from the radiator, and then remove the hose from the vehicle.

Note
Plug the radiator after removing the hose.
Disconnect the supermanifold harness electrical connector.
Disconnect the chiller to battery hose, the powertrain supply hose, and the chiller to battery hose from the supermanifold.

Note
x3 spring clip; x2 electrical connectors

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.

Note
Pull the supermanifold forward to access the spring clips and electrical connectors.
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.
CAUTION
Make sure the reservoir does not tip over while maneuvering.
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Release the connector lock, and then disconnect the A/C compressor logic electrical connector.

Note
Do not push down on red tab. Pull to disengage lock, and then pull again to release the electrical connector.
Release the connector lock, and then disconnect the A/C Compressor HV harness electrical connector from the A/C Compressor.

Note
Pull the red locking tab away from the black lever, and then slide the black lever upwards.
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)
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
Place a fender cover on the fan housing.
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)
Note
Carefully maneuver the A/C compressor towards the front of the vehicle and under the megabeam.

CAUTION
Avoid straining the MV or HV harnesses.
Tip: Use of the following tool(s) is recommended:
- 10 mm socket
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)
Note
Make sure that the washers do not remain on the A/C compressor.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
Remove the A/C compressor from the vehicle.
Release the tabs (x5) that attach the NVH cover to the old A/C compressor, and then remove the NVH cover from the compressor.
Protect the LP and HP opening ports on the AC compressor with masking tape.
Reset the A/C compressor oil level.

Note
Zero scale before use.

Note
Locate manufacturer label on compressor, and then note the "Dry Weight" from the label.

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).
Position the NVH cover onto the A/C compressor, and then engage the tabs (x5).

Note
Make sure that the NVH cover is fully secured to the compressor.
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
Note
Install the flush adapters onto the suction and discharge lines on the A/C compressor side.

Note
Leave the seal washers on the A/C manifold line.

Note
Inspect O-rings and replace them, if damaged.

Note
Use 13 mm nuts from the A/C compressor to secure the flush adapters.
Perform the A/C System Flush procedure.

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.

Note
A/C machine will perform multiple flush cycles.

Note
Allow process to complete.
Remove the A/C flush adapters from the supermanifold to the compressor A/C line assembly.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
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
Remove the A/C line from the supermanifold.

Note
x1 bolt, 13 mm, 22 Nm; x1 bolt, 10 mm, 8 Nm

Note
Remove the bolt at the supermanifold, and then mounting bracket bolt near the MV battery.

Note
Remove the A/C line assembly from the supermanifold.

Note
Make sure that no washers remain on the supermanifold.
With assistance, remove the supermanifold from the vehicle.

Note
Rotate the supermanifold counterclockwise under the megabeam.

Note
Support from underneath and at the reservoir.

Install

Replace the seal washers (x5) to the Penta HVAC line on the A/C manifold side.

Note
Lubricate the seal washers with RB100EV POE oil.
With assistance, install the supermanifold to the vehicle.

Note
Rotate the supermanifold counterclockwise under the megabeam.

Note
Support from underneath and at reservoir.

Note
Align penta HVAC line.
Secure the chiller to battery hose, the powertrain supply hose, and the chiller to battery hose to the supermanifold.

Note
x3 spring clip, x2 electrical connectors.

Note
Engage the locking tabs.

Note
Make sure that all hoses are fully engaged with a push-pull-push test.
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
Note
Make sure that good alignment of pipes before tightening the nut.
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
Note
Start the bolts by hand.
Connect the radiator outlet hose to the radiator, and then secure the hose clip.

Note
Perform a push-pull-push test to make sure the hose is fully engaged.
Secure the powertrain bypass hose, the radiator outlet hose, and the radiator inlet hose to the supermanifold.

Note
x3 spring clips

Note
Make sure that all hoses are fully engaged with a push-pull-push test.
Connect the supermanifold electrical connector.
Replace the seal washers (x2) for the supermanifold to compressor A/C line on the supermanifold side.

Note
Lubricate the seal washers with RB100EV POE oil.
Install the A/C manifold line assembly to the supermanifold.

Note
x1 bolt, 13 mm, 22 Nm; x1 bolt, 10 mm, 8 Nm

Note
Install new washer seals.

Note
Install the manifold to the supermanifold, and then secure the bracket near the MV battery.
Perform the A/C Vacuum and Run Leak Test. See A/C Refrigerant (Recovery and Recharge).

Note
Set the vacuum time to 20 minutes.
Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
Perform the A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge).
Reconnect MV power. See Disconnect MV Power.
Reinstall vehicle software.

Note
Touch Service Mode UI > Software Reinstall > Reinstall.

Note
Vehicle software installation will begin immediately.
On the vehicle touchscreen, navigate to Service Mode > Thermal > Actions.
Tap Start Coolant Air Purge, tap Run, and allow the routine to complete.
Inspect the coolant level and top off as necessary.
Perform the A/C performance tests. See A/C Refrigerant (Recovery and Recharge).
Exit Service Mode. See Service Mode.
Install the frunk. See Frunk Assembly (Remove and Install).
Remove the vehicle from the lift. See Raise Vehicle - 2 Post Lift.
Raise the LH front window and close the LH front door.