23/05/2024 07:07:37

Supermanifold (Remove and Replace)

Correction code 1840010012 FRT 2.70 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.

  • 2024-04-24: Added steps of calculating the oil amount of desiccant bag and accumulator, and changed the way of removing the supermanifold from the vehicle directly to removing the supermanifold together with the shock tower brace and the compressor, and then separating the supermanifold from the assembly.
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Remove

  1. Connect the A/C machine to power, turn the power switch on, and select gas type.
  2. Place the vehicle on the 2-post lift.
    Tip: Ensure the vehicle is not charging.
  3. Open all doors and lower all windows.
  4. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
  5. While recovering, perform the vehicle HV disablement procedure. See Vehicle HV Disablement Procedure.
  6. While recovering, remove the fresh intake duct. See Fresh Air Intake - HVAC (Remove and Replace).
  7. While recovering, remove the LV battery. See LV Battery (Remove and Replace).
  8. Remove the A/C hoses from vehicle.
  9. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  10. Remove the desiccant. See Desiccant (Remove and Replace).
  11. Weigh the desiccant bag. This is considered the "wet weight."
  12. Determine the "dry weight" of the desiccant bag: Inspect the bag for a label that contains the Part Number (P), Serial Number (S), and Dry Weight (W). If the label is missing, or if the dry weight is not visible, assume the dry weight is 90.4 grams.
  13. Subtract the dry weight from the wet weight. This is the amount of oil that must be added to the system in addition to the oil that was removed during refrigerant recovery. Note this amount for later.
  14. Stick a steel ruler into the accumulator to measure the refrigerant oil level inside the accumulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Level will vary per vehicle. Keep the steel ruler vertical during measurement, and record the measurement in millimeters.
  15. Multiply the measurement by 5.6 and add 15 to convert it to grams. Record the measurement in grams.
  16. Calculate the total oil loss from AC recovery, desiccant bag, and accumulator. Record the total oil amount. This amount will be used for oil injection at later step.
  17. Remove the coolant bottle cap.
  18. Position a coolant drain container underneath the front of the HV battery.
  19. Release the clip, disconnect the front drive unit powertrain bypass hose from the supermanifold and plug the hose and the supermanifold.
  20. Release the spring clip, disconnect the radiator outlet hose from the supermanifold, and then plug the hose and supermanifold.
  21. Release the spring clip, disconnect the radiator inlet hose from the supermanifold, and then plug the hose and supermanifold.
  22. Release the spring clip, disconnect the chiller to battery hose from the supermanifold, and then plug the hose and supermanifold.
  23. Release the spring clip, disconnect the powertrain supply hose from the supermanifold, and then plug the hose and supermanifold.
  24. Release the clip, disconnect the HV battery return hose from the supermanifold, and then plug the hose and supermanifold.
  25. Disconnect the thermal sub-harness electrical connector from the front body controller module.
  26. Remove the clip that attaches the thermal sub-assembly harness to the front harness guide cover.
  27. Remove the supermanifold to compressor A/C line. See Assembly - A/C Line - Supermanifold to Compressor (Remove and Replace).
  28. Remove the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 6 in extension
    • Cordless Ratchet/Impact Driver
  29. Remove the shock tower beam together with the supermanifold and A/C compressor. See A/C Compressor (Remove and Replace) and Brace - Shock Tower (Remove and Replace).
  30. Remove the bolts (x2) that attach the supermanifold to the shock tower beam.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the supermanifold counter-clockwise under the shock tower support beam.
  31. Remove the nut that attaches the supermanifold to HVAC A/C line to the supermanifold, and then remove the supermanifold to HVAC A/C line assembly.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 6 in extension
    • Cordless Ratchet/Impact Driver
  32. Take note of the old and new part numbers and serial numbers for the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    The label is located in front of the accumulator, document part numbers and serial numbers into the repair order.

Install

  1. Position the supermanifold assembly to the shock tower brace, and install the bolts (x2) to secure it.
    31 Nm (22.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate the supermanifold counter-clockwise and install it under the shock tower support beam.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  2. Replace the seal washers (x5) on the supermanifold to HVAC A/C line on the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal washers with ND-11 oil.
  3. Replace the seal washers (x5) on the supermanifold to HVAC A/C line on the HVAC side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal washers with ND-11 oil.
  4. Hand-tighten the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
  5. Torque the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
    27 Nm (19.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
  6. Install the shock tower beam together with the supermanifold and A/C compressor. See A/C Compressor (Remove and Replace) and Brace - Shock Tower (Remove and Replace).
  7. Install the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
  8. Remove the plugs from the supermanifold and radiator inlet hose, immediately connect the radiator inlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  9. Remove the plugs from the supermanifold and radiator outlet hose, immediately connect the radiator outlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  10. Remove the plugs from the supermanifold and front drive unit powertrain bypass hose, immediately connect the front drive unit powertrain bypass hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  11. Install the clip that attaches the thermal sub-assembly harness to the front harness guide cover.
  12. Connect the thermal sub-harness electrical connector to the front body controller.
  13. Remove the plugs from the supermanifold and HV battery return hose, immediately connect the HV battery return hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  14. Remove the plugs from the supermanifold and powertrain supply hose, immediately connect the powertrain supply hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  15. Remove the plugs from the supermanifold and chiller to battery hose, immediately connect the chiller to battery hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is secure.
  16. Connect the powertrain supply hose sensor electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The harness and coolant hose are color coded, match the harness color with the coolant hose color.
  17. Connect the chiller to battery hose sensor electrical connector.
    Informational PurposesAn informational icon, calling your attention
    Note
    The harness and coolant hose are color coded, match the harness color with the coolant hose color.
  18. Install the supermanifold to compressor A/C line. See Assembly - A/C Line - Supermanifold to Compressor (Remove and Replace).
  19. Install the LV battery. See LV Battery (Remove and Replace).
  20. Connect the LV power. See LV Battery - Li-lon (Disconnect and Connect).
  21. Unlock the vehicle gateway. See Gateway Unlock.
  22. On the touchscreen, touch Service Mode > Thermal > Refrigerant System > Start Thermal Fill/Drain, click Run, and allow the routine to complete.
  23. Perform the vacuum leak test and inject oil. See Vacuum Leak Test and Oil Injection.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the procedure takes more than 5 hours, perform the procedure again.
  24. Recharge the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
  25. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  26. Reinstall the software. See Software Reinstall - Touchscreen.
  27. On the touchscreen, perform the following steps:
    1. Touch Service Mode > Thermal > Refrigerant System > Stop Thermal Fill Drain, click Run, and allow the routine to complete.
    2. Touch Service Mode > Thermal > Coolant System > Pump Identification, click Run, and allow the routine to complete.
    3. Touch Service Mode > Thermal > Coolant System > Coolant Purge Start, click Run, and allow the routine to complete.
      Informational PurposesAn informational icon, calling your attention
      Note
      • The routine will last for a while after the stop message displays. The coolant pumps are audible.
      • The test lasts for approximately 10 mins. Do not start another routine during this time.
      • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
      • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
      • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  28. Inspect the coolant level, top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
  29. On the touchscreen, touch Service Mode > Thermal > Sensors and Valves > Run Heat Pump Commissioning, click Run, and allow the routine to complete.
  30. Touch Thermal > Actions, then click the START button next to Test Thermal Performance, click Run, and allow the routine to complete.
  31. Touch the START button next to Test HVAC Performance, click Run, and then allow the routine to complete.
  32. Exit Service Mode. See Service Mode.
  33. Remove the fluid catcher from underneath the vehicle.
  34. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  35. Install the fresh intake duct. See Fresh Air Intake - HVAC (Remove and Replace).
  36. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  37. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  38. Raise all windows and close all doors.
  39. Remove the lift arms from below the vehicle.