01/04/2024 14:00:19

Octovalve (Heat Pump) (Remove and Replace)

Correction code 18400202 1.08 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.
  1. Open LH front door
  2. Lower LH front window
  3. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure vehicle is not charging before lifting it off the ground
  4. Open hood
  5. Remove rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips
  6. Remove cabin intake upper duct assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Older vehicles may be equipped with 4x clips
  7. Remove the close out panel from frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Grab the closeout panel from the bottom then pull it upward to release clips
  8. Remove fasteners securing the frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm, Lift up the RBN covers to access the front fasteners, Newer vehicles may not be equipped with covers
  9. Remove frunk assembly from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, Replace any clips if broken or missing, Number of clips may vary on newer vehicles
  10. Remove fresh intake duct
    Informational PurposesAn informational icon, calling your attention
    Note
    2x studs, Remove from bulkhead studs
  11. Disconnect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, Ensure the vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V
  12. Disconnect first responder loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Release locking tab
  13. Remove vent tube hose from LH side of 12V battery
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    Note
    1x hose
  14. Release terminal cover and remove positive terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut
  15. Remove bolt securing 12V battery upper tie down strap to AC compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 5 Nm
  16. Remove battery upper tie down strap
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift battery tie down strap up and remove it from the rear tie down hook strap
  17. Remove 12V battery from vehicle
  18. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  19. Remove outer fasteners from front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  20. Remove remaining nuts and remove front aero shield from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  21. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  22. Position coolant drain container underneath front of vehicle
  23. Remove coolant bottle cap
  24. Place fluid extractor in front of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Set Mityvac to evacuate
  25. Evacuate coolant from coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Place evacuation hose in bottle at left front corner to remove as much fluid as possible, pump fluid into Mityvac evacuator
  26. Disconnect the coolant bottle level sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
  27. Remove clip securing harness on top of coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  28. Disconnect the sensor for the chiller to battery hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
  29. Disconnect the sensor for the powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
  30. Disconnect chiller to battery hose from supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  31. Remove thermal sub assembly harness clip on RH side of coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  32. Remove thermal sub assembly harness clip at bottom left of coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  33. Remove screw at the rear of coolant bottle securing the coolant bottle to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 5 Nm
  34. Remove screw at the front of coolant bottle securing coolant bottle to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 5 Nm
  35. Remove coolant bottle from Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove by sliding the bottle away from the Supermanifold towards the rear of the vehicle, and rotate out the top, Verify coolant bottle o-ring is removed with coolant bottle
  36. Disconnect Octovalve connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
  37. Remove fasteners securing Octovalve to Supermanifold and remove Octovalve from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    4x screws, T25, 5 Nm
  38. Position Octovalve to Supermanifold and install fasteners securing Octovalve to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    4x screws, T25, 5 Nm, Ensure dowels on Octovalve engage the Supermanifold before installing fasteners, Octovalve must be flush with Supermanifold to properly seal
  39. Connect Octovalve connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab
  40. Position the coolant bottle onto the Supermanifold for installation
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate coolant bottle o-ring with silicone o-ring lubricant, Verify coolant bottle o-ring is properly seated on coolant bottle, Position the coolant bottle outlet pipe to the Supermanifold coolant inlet
  41. Install the screw at rear of coolant bottle securing coolant bottle to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 5 Nm
  42. Install screw at front of the coolant bottle securing the coolant bottle to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 5 Nm
  43. Install thermal sub assembly harness clip to bottom left of coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  44. Install thermal sub assembly harness clip to RH side of coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  45. Connect the chiller to battery hose to the Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  46. Connect the sensor for the powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab, Harness and coolant hose are color coded, Match harness color to coolant hose color
  47. Connect the sensor for the chiller to battery hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab, Harness and coolant hose are color coded, Match harness color to coolant hose color
  48. Install the retaining clip securing the level sensor pigtail to the coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  49. Connect the coolant bottle level sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Engage locking tab
  50. Install 12V battery into vehicle
  51. Position battery tie down strap onto the battery
    Informational PurposesAn informational icon, calling your attention
    Note
    Hook the upper tie down strap into the rear tie down hook strap and position for installation
  52. Install bolt securing upper tie down strap to the AC compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 5 Nm
  53. Install vent tube hose in 12V battery
  54. Install positive terminal and terminal cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm, 2x clips
  55. Remove coolant drain container from underneath vehicle
  56. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
  57. Position the front aero shield to vehicle and install nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 5 Nm
  58. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm
  59. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  60. Fill coolant to the proper level
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level filled to the Max line
  61. Connect first responder loop
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, Engage locking tab
  62. Connect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 6 Nm
  63. Connect to vehicle using Toolbox 3.0
    Informational PurposesAn informational icon, calling your attention
    Note
    Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle. Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)
  64. Select "Actions/Autodiag" and search for "Thermal"
  65. Select TEST-SELF_VCFRONT_X_FIVE-WAY-VALVESearch for routine in ToolboxCoolant Valve TestThermal / Coolant System - Coolant Valve Test, click Run and allow routine to complete_
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "X" at top right of window to close once complete
  66. Select "Actions/Autodiag" tab and search for "Purge"
  67. Select "TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ", click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Coolant pump speeds can be monitored in Service Mode + (see Service Mode Plus), in the CAN Viewer submenu. Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select "X" at top right of window to close once complete
  68. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line
  69. Install coolant bottle cap
  70. Select "Actions/Autodiag" and search for "Thermal"
  71. Select TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCESearch for routine in ToolboxThermal System Performance TestThermal / Actions - Test Thermal Performancehv / Front Drive Inverter Replacement - Thermal System Testhv / Rear Drive Inverter Replacement - Thermal System Testhv / Rear Left Drive Inverter Replacement - Thermal System Testhv / Rear Right Drive Inverter Replacement - Thermal System Testhv / Front Drive Unit Replacement - Thermal System Testhv / Rear Drive Unit Replacement - Thermal System Test, click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "X" at top right of window to close once complete
  72. Remove HSD cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
  73. Install fresh intake duct
    Informational PurposesAn informational icon, calling your attention
    Note
    Set clips on bulkhead studs
  74. Install frunk assembly to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips, Make sure frunk assembly is fully seated onto the clips, Number of clips may vary on newer vehicles
  75. Install fasteners securing the frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    7x bolts, 10mm, 5 Nm, Lift up the RBN cover to access the front fasteners, Newer vehicles may not be equipped with covers
  76. Install frunk close out panel
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align the 3x tabs then push downward to secure clips
  77. Install cabin intake upper duct assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, Older vehicles may be equipped with 4x clips
  78. Install rear apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, If present untuck cut loop label and make sure it is still visible after apron is installed, Later builds may not have label
  79. Close hood
  80. Raise LH front window
  81. Close LH front door