30/08/2024 10:45:33
Cabin HVAC - Wet Side HVAC (Remove and Install)
Correction code 1810021041 FRT 3.30 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.
- 2024-05-29: Updated locking cover torque value from 4 Nm to 6 Nm.
- 2024-05-22: Updated connector images and instructions for disconnect/connect.
- 2024-05-14: Added disconnect/connect videos for MV controller.
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
- Open the LH front door and lower the LH front window.
- Move the LH front seat fully rearward.
- 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
Stop Thermal Fill Drain, and allow the routine to
complete.
NoteMake sure the routine is successful.
- Remove the rear underhood apron. See Underhood Trim - Rear Apron Assembly (Remove and Install).
- Remove the frunk assembly. See Frunk Assembly (Remove and Install).
- Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
- Open the RH front door and lower the RH front window.
- Move the RH front seat fully rearward.
- Remove the RH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
- Remove the RH lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
- Remove the RH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
-
Fold back the RH carpet.
- Remove the LH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
- Remove the LH lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
- Remove the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
- Remove the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
- Remove the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
- Remove the accelerator pedal. See Accelerator Pedal (Remove and Install).
-
Fold back the LH front cabin
carpet.
- Remove the center console front panel. See Center Console - Front Panel Assembly (Remove and Install).
- Remove the center floor trim. See Passenger Compartment Carpet - Center Floor Trim (Remove and Install).
- Remove the center floor upper bracket. See Passenger Compartment Carpet - Center Floor Upper Bracket (Remove and Install).
- Remove the instrument panel mid panel assembly. See Dash Panel - IP Mid Panel Assembly (Remove and Install).
- Disconnect MV power. See Disconnect MV Power.
- Remove the instrument panel lower panel assembly. See Dash Panel - Instrument Panel Lower Assembly (Remove and Install).
- Remove the glovebox assembly. See Dash Panel - IP Glovebox Assembly (Remove and Install).
- Remove the RH panel duct. See Passenger Ducting and Vents - Panel Duct, RH (Remove and Install).
-
Slowly loosen the bolt that secures
the locking cover to the RH controller, making sure that the cover separates from the
controller squarely, and does not bind.
Tip: Use of the following tool(s) is recommended:
- 8 mm socket
NoteDo not remove locking cover. Loosen until the bolt spins freely.NoteMake sure the bolt and locking cover are fully released before attempting to release the connectors.NoteIf the cover binds, tighten the bolt until the locking cover is square again, then loosen the bolt while holding the cover square to the controller.NoteUse a power tool to loosen the bolt. -
Release the Megavac electrical
connector housing, and then disconnect the electrical connector from the RH
controller.
NotePress the tabs on the connector housing to release the housing from the locking frame.
-
Release the grommet and harness clip
that attach the Megavac harness to the bulkhead, and then feed the harness through the
bulkhead opening.
-
Remove the interior wet side HVAC
fasteners (x6).Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- Raise and support the vehicle. See Raise Vehicle - 2 Post Lift.
- Perform vehicle electric isolation procedure. See Vehicle HV Disablement Procedure.
- Remove the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
-
Remove the bolts (x6) that attach the
lower valance to the body, and then remove the valance from the vehicle.NoteRelease the covers to expose the bolts.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Disconnect the LH and RH CFM
electrical connectors (x2) and release the harness clips.
-
With assistance, remove the bolts (x2)
that attach the fore crossmember to the front subframe, and then remove the crossmember
from the subframe.Tip: Push up on the CFM. Use a hammer, if needed.Tip: Use of the following tool(s) is recommended:
- 18 mm socket
- Put a coolant catcher below the RH front of the vehicle.
- Lower the vehicle until tires are touching the ground.
- Remove the center applique assembly. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
- Remove the front fascia assembly. See Front Bumper Fascia - Front Fascia (Remove and Install).
- Remove the cooling fan module. See Fan and Radiator - Cooling Fan Module (Remove and Install).
-
Remove the bolts (x2) that attach the
Supermanifold to the vehicle, and then lower the Supermanifold until it is resting on
the HVAC case.NoteSupport the manifold while removing the fasteners.NoteBreak the fasteners free, and then remove by hand to avoid tool jamming.Tip: Use of the following tool(s) is recommended:
- 15 mm socket
-
Release the spring clips, and then
disconnect the powertrain bypass hose, the radiator outlet hose, and the radiator inlet
hose from the Supermanifold.
NoteThis will drain the coolant reservoir.NotePlug all the fittings.
-
Release the spring clip, disconnect
the radiator outlet hose from the radiator, and then remove the hose from the
vehicle.
NotePlug the fittings.
-
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, and then disconnect the electrical connectors (x2).
NoteRelease the spring clips to disconnect the hoses.CAUTIONDo not push down on red tab. Pull the red tab to disengage the lock, and then pull again to release the electrical connector.NotePull the Supermanifold forward to access the spring clips and electrical connectors.
-
Remove the bolt that attaches the
remote fluid reservoir to the vehicle, lift the reservoir upward to release the datum,
and then move the reservoir aside.CAUTIONMake sure the reservoir does not tip over.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.
CAUTIONDo not push down on red tab. Pull to disengage lock, and then pull again to release the connector.
-
Release the connector lock, and then
disconnect the A/C Compressor HV harness electrical connector from the A/C
Compressor.
NotePull 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 to the A/C compressor, and then release the harness edge
clip.NoteRelease the harness edge clip once the ground strap is free.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Overlap from A/C Recovery.
-
Remove the A/C hoses from the
vehicle.
-
With assistance, remove the bolts (x3)
that attach the A/C compressor to the Megabeam, and then carefully remove the compressor
towards the front of the vehicle and under the Megabeam.CAUTIONSupport the AC compressor while removing the fasteners.CAUTIONPlace a fender cover on the fan housing and gently place the AC compressor assembly down.CAUTIONAvoid straining the MV or HV harnesses.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the compressor from the
vehicle.
NoteLeave the refrigerant lines attached to the compressor.
-
Remove the nut that attaches the Penta
HVAC line assembly to the Supermanifold plate.Tip: Use of the following tool(s) is recommended:
- 13 mm deep socket
-
Remove the bolt that attaches the A/C
line to the Supermanifold.NoteMake sure that no washers remain on the Supermanifold.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
-
Remove the bolt that attaches the A/C line bracket to the vehicle near the MV
battery, and then remove the A/C line from the Supermanifold.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
With assistance, remove the
Supermanifold from the vehicle.
NoteRotate the Supermanifold counterclockwise under the megabeam for clearance.NoteSupport the assembly from underneath and at the reservoir during removal.
-
Release the clips (x2) that attach the
RH frunk harness to the vehicle, and then disconnect the frunk harness electrical
connectors (x2).
-
Release the clips (x2) and hose
connections (x2) that attach the windshield washer reservoir to the vehicle.
-
Remove the fasteners (x3) that attach
the windshield washer reservoir to the vehicle, and then remove the reservoir from the
vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Release the connector lock and
disconnect the electrical connectors (x2), release the harness clips (x2), and then
release the RH frunk harness from the Megabeam.
-
Release the clips (x4) and remove the
fastener that attach the LH frunk harness to the Megabeam.Tip: Use of the following tool(s) is recommended:
- External Torx E5
-
Remove the bolts (x2) that attach the
MV battery, and then slide forward to remove the MV battery from the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Remove the bolts (x8) that attach the
Megabeam to the vehicle.
NoteBreak the fasteners free by hand before using power tools.Tip: Use of the following tool(s) is recommended:
- EP 14 socket
- 21 mm socket
-
Remove the Megabeam from the
vehicle.
CAUTIONMake sure the harness is not caught or pinched during removal.
-
Remove the bolts (x5) that attach the
wet side HVAC assembly to the vehicle, and then maneuver the assembly around the coolant
hoses to remove it from the vehicle.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- 10 mm socket
Install
-
Position the wet side HVAC assembly
into the vehicle, and then install the bolts (x5) that attach the assembly to the
vehicle.NoteTorque the 13 mm bolts (x2) to 15 Nm, and the 10 mm bolts (x3) to 7 Nm.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- 10 mm socket
-
Position the Megabeam into the
vehicle.
NoteMake sure the harness is on inboard side of cowl mounting tabs.CAUTIONMake sure the harness is not caught or pinched during installation.
-
Position the MV battery into the
vehicle, and then install the bolts (x2) that attach the battery to the vehicle.NoteSlide the MV battery rearwards into position.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the bolts (x8) that attach the
Megabeam to the vehicle.NoteThe EP14 bolts are torqued to 18 Nm and the 21 mm bolts are torqued to 165 Nm.NoteStart the fasteners by hand before using power tools.Tip: Use of the following tool(s) is recommended:
- EP 14 socket
- 21 mm socket
-
Secure the clips (x4) and install the
fastener that attach the LH frunk harness to the Megabeam.Tip: Use of the following tool(s) is recommended:
- External Torx E5
- Connect the RH frunk harness connectors (x2) and secure the locking tab, and then secure the clips (x2) that attach the harness to the Megabeam.
-
Position the windshield washer
reservoir into the vehicle, and then install the fasteners (x3) that attach the
reservoir to the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Secure the clips (x2) and hose connections (x2) that attach the windshield washer reservoir to the vehicle.
- Secure the clips (x2) that attach the RH frunk harness to the vehicle, and then connect the frunk harness electrical connectors (x2).
-
Replace the seal washers (x5) to the
Penta HVAC line on the A/C manifold side.
NoteLubricate the seal washers with RB100EV POE oil.
-
With assistance, position the
Supermanifold to the vehicle.
NoteRotate the Supermanifold counterclockwise under the megabeam.NoteSupport from underneath and at reservoir.NoteAlign penta HVAC line.
-
Secure the chiller to battery hose,
the powertrain supply hose, and the chiller to battery hose to the Supermanifold, and
then connect the electrical connectors (x2).
NoteSecure the spring clips after the hoses are fully engaged.NoteEngage the locking tabs on the electrical connectors.NotePerform a push-pull-push test to ensure the hoses are fully engaged.
-
Install the nut that attaches the
pentaline to the Supermanifold.NoteMake sure that good alignment of pipes before tightening the nut.Tip: Use of the following tool(s) is recommended:
- 13 mm deep socket
-
Install the bolts (x2) that attach the
Supermanifold to the megabeam.Tip: Use of the following tool(s) is recommended:
- 15 mm deep socket
NoteStart the bolts by hand. -
Connect the radiator outlet hose to
the radiator, and then secure the spring clip.
NotePerform a push-pull-push test to ensure the hose is fully engaged.
-
Secure powertrain bypass hose,
radiator outlet hose, and radiator inlet hose to Supermanifold, and then secure the
spring clips.
NotePerform a push-pull-push test to ensure the hose is fully engaged.
- Connect the Supermanifold harness electrical connector.
-
Replace the seal washers for
Supermanifold to compressor AC line on Supermanifold side.
NoteLube the seal washers with RB100EV POE oil.
-
Position the A/C line assembly into the vehicle, and then install the bolt that
attaches the A/C line bracket to the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Install the bolt that attaches the A/C
line to the Supermanifold.Tip: Use of the following tool(s) is recommended:
- 13 mm socket
-
With assistance, position the AC
compressor to the Megabeam, and then install the bolts (x3) that attach compressor to
the Megabeam.CAUTIONSupport the AC compressor while installing the fasteners.CAUTIONAvoid straining the MV or HV harnesses.NoteStart the fasteners by hand.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Move the remote fluid reservoir into
position, and then install the bolt that attaches reservoir to the vehicle.CAUTIONAlign the datum, and then slide the reservoir downwards.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
-
Connect the AC Compressor HV harness to the AC Compressor, and then secure the
connector lock.
NoteSlide the black lever down, and then push the red lock inwards.CAUTIONMake sure the red locking tab is pushed all the way in. The red locking tab should sit flush with the black lever.
-
Install the bolt that attaches the A/C
compressor ground strap to the compressor.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Connect the A/C compressor logic electrical connector, and then engage the connector lock.
- Reconnect the A/C hoses to the vehicle.
- Perform the A/C Vacuum and Run Leak Test. See A/C Refrigerant (Recovery and Recharge).
- Install the cooling fan module. See Fan and Radiator - Cooling Fan Module (Remove and Install).
- Install the front fascia assembly. See Front Bumper Fascia - Front Fascia (Remove and Install).
- Install the center applique assembly. See Front Grille and Applique - Front Center Applique Assembly (Remove and Install).
- Raise the vehicle fully.
-
Position the fore crossmember to the
front subframe, and then install the bolts (x2) that attach the crossmember to the
subframe.NoteLift the CFM away from the beam to aid in clearance.NoteInstall the beam by sliding it rewards.Tip: Use of the following tool(s) is recommended:
- 18 mm socket
- Install the front aero shield. See Undertray - Front Aeroshield (Remove and Install).
-
Position the lower valence onto the
vehicle, and then install the bolts (x6) that attach the valance to the vehicle.Tip: Use of the following tool(s) is recommended:
- 10 mm socket
- Lower the vehicle to a comfortable working height.
- Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
- Overlap time from A/C leak test.
-
Perform the A/C recharge.
NoteEnter refrigerant and oil amount noted at AC recovery. Settings should match notes. Select Both Sides for charge. Select ND-11 MSX using bottle icon.NoteMachine will chime once the process is completed.NoteVehicle may be left unattended.NoteIf desired, use the Dye Inject option to inject leak detection dye.
-
Install the interior wet side HVAC
fasteners (x6).Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- Feed the Megavac harness through the bulkhead, pull the harness inward to seat the grommet, and then install the harness clip.
- Connect the Megavac electrical connector to the RH controller, and then secure the connector housing.
-
Slowly tighten the bolt that secures
the locking cover to the upper RH MV controller, making sure that the cover is square to
the controller, and does not bind.Tip: Use of the following tool(s) is recommended:
- 8 mm socket
NoteIf the cover binds, loosen the bolt until the locking cover is square again, then tighten the bolt while holding the cover square to the controller.Tip: While tightening the bolt, press the connector into the controller to keep it square.Figure 10. Rear MV controller shown; other MV controllers similar - Install the RH panel duct. See Passenger Ducting and Vents - Panel Duct, RH (Remove and Install).
- Install the glovebox assembly. See Dash Panel - IP Glovebox Assembly (Remove and Install).
- Install the instrument panel lower panel assembly. See Dash Panel - Instrument Panel Lower Assembly (Remove and Install).
- Install the instrument panel mid panel assembly. See Dash Panel - IP Mid Panel Assembly (Remove and Install).
- Reconnect MV power. See Disconnect MV Power.
- On the vehicle touchscreen, navigate to Service mode > Thermal > Actions, and then tap Start Coolant Air Purge.
- Install the center floor upper bracket. See Passenger Compartment Carpet - Center Floor Upper Bracket (Remove and Install).
- Install the center floor trim. See Passenger Compartment Carpet - Center Floor Trim (Remove and Install).
- Unfold the RH front cabin carpet into position.
- Install the RH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
- Install the RH lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
- Install the RH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
- Unfold the LH front cabin carpet into position.
- Install the accelerator pedal. See Accelerator Pedal (Remove and Install).
- Install the accelerator pedal side trim. See Passenger Compartment Carpet - Pedal - Side Trim (Remove and Install).
- Install the LH center floor rail. See Passenger Compartment Carpet - Center Floor Rail - LH (Remove and Install).
- Install the LH lower A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Lower Trim - LH (Remove and Install).
- Install the LH mid A-pillar trim. See A-B-C Post Interior Trim - A-Pillar Mid Trim - LH (Remove and Install).
- Secure the LH side lower A-pillar primary seal.
- Install the footwell cover. See Dash Support Frame - Footwell Cover (Remove and Install).
- Restore the RH front seat back to its original position.
- Raise the RH front window and close the RH front door.
- Restore the LH front seat back to its original position.
-
Inspect coolant the level and top off
as necessary.
NoteEnsure the fluid level is at the Max line.
- Install the coolant bottle cap.
- Continue with A/C recharge. See A/C Refrigerant (Recovery and Recharge).
- Perform Thermal Performance. See A/C Refrigerant (Recovery and Recharge).
- Exit Service Mode. See Service Mode.
- Install the frunk assembly. 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.