29/09/2024 23:55:10
A/C Compressor, Supermanifold and A/C Lines (Heat Pump) (Remove & Replace)
Correction code 18204012 3.42 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.
- 2024-07-10: Added details to identify the type of A/C line to be used in "refrigACLineType" configuration.
- 2024-06-17: Added the step of updating coolant pump configuration.
- 2024-05-29: Updated the procedure per the latest validation.
- 2024-03-28: Fixed bad flush link.
- 2024-03-06: Updated the routines.
- 2024-02-05: Added steps to hand-tighten the bolts that attach the supermanifold and the compressor to the shock tower brace.
Note
This procedure requires the A/C
Refrigerant (Recovery and Recharge) procedure to be performed. If not already
automatically added to the Service Visit, add correction code 18200102 as a
separate activity to the Service Visit.
Remove
- Set up the A/C machine.
- Raise and support the vehicle.
-
Open all four doors and lower the
windows.
NoteLatch rear doors to prevent accidental closing when 12V/LV power is disconnected.
- Place the vehicle in Service Mode. See Service Mode.
- On the touchscreen, touch Run to start the "Start Thermal Fill Drain (Coolant & Refrigerant)" routine. and select
- Move the front seats forward.
- Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
- Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
- Recover the refrigerant from the vehicle. See A/C Refrigerant (Recovery and Recharge).
- Remove the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
-
Disconnect the powertrain bypass hose
from the Supermanifold.
NoteThis will drain the coolant reservoir.
- Disconnect the radiator outlet hose from the Supermanifold.
- Disconnect the radiator inlet hose from the Supermanifold.
- Install three male plugs into the coolant ports at the front of the Supermanifold.
-
Before performing the next two steps,
inspect the coolant hose temperature sensors and connectors.
NoteIf the vehicle is equipped with an earlier model temperature sensor (left image), the new super manifold connectors may not fit. In this case the electrical connector cover must be swapped from the old supermanifold to the new supermanifold. Perform Rework Connectors before installation.
- Disconnect the sensor for the chiller to battery hose.
- Disconnect the sensor for the powertrain supply hose.
- Disconnect the chiller to battery hose from the supermanifold.
- Disconnect the powertrain supply hose from the supermanifold.
- Disconnect the HV battery return hose from the Supermanifold.
- Install three male plugs into the coolant ports at the rear of the Supermanifold.
- Disconnect the supermanifold harness connector from the front controller.
- Remove the clip that attaches the thermal sub assembly harness to the front harness guide cover.
- Remove the 12V/LV battery. See 12V/LV Battery (Remove and Replace).
- Release the clips (x2) that attach the coolant hose to the A/C compressor bracket.
- Remove the clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
-
Release the connector locking tab, and
then disconnect the low voltage electrical connector from the A/C compressor.
CAUTIONDO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
-
Remove the bolt that attaches the HV
harness bracket to the A/C compressor.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
-
Remove the bolt that attaches the
ground strap to the A/C compressor, and then set the ground strap aside.
Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- Release the clip that attaches the coolant hose to the A/C compressor bracket, near the ground strap attachment point.
- Pull the A/C compressor HV connector black locking tab away from the A/C compressor.
- Using a 45-degree pick, simultaneously push on the central locking tab while pulling on the outer locking tab, and remove the HV connector from the A/C compressor.
- Disconnect the HVIL electrical connector.
- After A/C recovery is completed, remove the A/C hoses from the vehicle.
-
Remove the nut that attaches the
supermanifold to compressor suction line to the compressor.
NoteUse of the following tool(s) is recommended:
- 13 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Remove the nut that attaches the
supermanifold to compressor discharge line to the compressor.
NoteUse of the following tool(s) is recommended:
- 13 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Remove the bolt on the A/C manifold to
compressor line from the Supermanifold, and then remove the A/C manifold line from the
vehicle.
Tip: Use of the following tool(s) is recommended:
- 13 mm socket
- 6 in extension
- Flex head ratchet/flex head torque wrench
-
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
- Flex head ratchet/flex head torque wrench
-
Remove the rear battery tie down strap
from the 12V/LV battery bracket.
NoteThe 12V/LV battery bracket also functions as the A/C compressor bracket.
- Release the clip that attaches the 12V/LV battery vent tube to the battery bracket.
- Release the clip that attaches the A/C compressor low voltage harness to the A/C compressor HV harness bracket.
- Move the HV harness bracket forward and up to release the bracket from the A/C compressor, and then carefully set the bracket aside.
-
Remove the retaining clips that attach
the A/C compressor HV harness to the shock tower support brace.
NotePull upward on clip to assist with removal, Do not pull on HV cable.
-
Remove the LH and RH bolts that attach
the shock tower brace to the body.Tip: Use of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
-
Remove the LH and RH outer bolts that
attach the shock tower brace to the body, and then remove the shock tower brace from the
vehicle.Tip: Use of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
-
With assistance, remove the shock
tower brace along with Supermanifold and compressor from the vehicle.
NoteMind the connectors and A/C lines, then slowly lift the brace. Put it on a cardboard pad.
-
Remove the nut that attaches the
supermanifold to HVAC A/C line assembly to the supermanifold, and remove the
supermanifold to HVAC A/C line assembly.
Tip: Use of the following tool(s) is recommended:
- 15 mm socket
- Cordless Ratchet/Impact Driver
- Flex head ratchet/flex head torque wrench
-
Install the bolts (x2) that attach the
old 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
- Flex head ratchet/flex head torque wrench
- Flush the HVAC system. See A/C Refrigerant (Unknown Oil Quantity) (Heat Pump) (Recovery, Flush, and Recharge).
-
Document the old and new part numbers
and serial numbers.
NoteLabel is located in front of accumulator.
-
Remove the bolts (x2) that attach the
supermanifold to the shock tower brace, and then remove the supermanifold.
Tip: Use of the following tool(s) is recommended:
- 15 mm socket
- Cordless Ratchet/Impact Driver
- Flex head ratchet/flex head torque wrench
-
When the flush is completed, 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
- Flex head ratchet/flex head torque wrench
-
Remove the bolts (x2) that attach the
A/C compressor bracket to the shock tower brace, and then remove the A/C compressor and
A/C compressor bracket assembly.
NoteUse of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
-
Remove A/C compressor bracket from the
A/C compressor.
NoteUse of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
- Document the part numbers of the new and old compressors to update the configuration in a later step.
Install
- Remove the A/C line plugs from the new supermanifold and compressor.
-
Install the NVH acoustic cover onto
the new compressor.
NoteInstall a new cover or reuse the old cover if the adhesive is in usable condition and a new cover is not available.NoteRemove the adhesive backing, and then lay the cover down with the adhesive side facing up. Align the cutouts to the suction port on the compressor, install the cover around the suction port, and then continue to wrap the cover around the compressor.
-
Position the A/C compressor bracket on
the A/C compressor, and then install the bolts that attach the bracket to the
compressor.NoteUse of the following tool(s) is recommended:
- 10 mm deep socket
- Flex head ratchet/flex head torque wrench
- Position the A/C compressor and A/C compressor bracket assembly to the strut shock tower brace, and then hand-tighten the bolts (x2) to secure.
- After flush is complete, disconnect the HVAC case flush adapter from the A/C machine, and then remove the adapter from the vehicle.
- Remove the A/C manifold to HVAC line from the HVAC assembly.
-
Replace the seal washers on the
supermanifold to HVAC A/C line assembly on the supermanifold side.
Note5x seal washers. Install new seal washers. Lubricate seal washers with ND-11 oil.
-
Replace the seal washers on
supermanifold to HVAC A/C line assembly on the HVAC side.
Note5x seal washers, Install new seal washers, Lube seal washers with ND-11 oil
- Hand-tighten the nut that attach the supermanifold to HVAC A/C line assembly to the supermanifold.
-
Torque the nut that attach the
supermanifold to HVAC A/C line assembly to the supermanifold.NoteUse of the following tool(s) is recommended:
- 13 mm socket
- Flex head ratchet/flex head torque wrench
- 6 in extension
- Position the supermanifold assembly to the shock tower brace, and then hand-tighten the bolts that attach the supermanifold assembly to the brace.
-
Tighten the bolts that attach the
supermanifold assembly to the shock tower brace.NoteUse of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
- 6 in extension
-
Tighten the bolts (x2) that attach the
compressor to the strut shock tower brace.NoteUse of the following tool(s) is recommended:
- 15 mm deep socket
- Flex head ratchet/flex head torque wrench
-
With assistance, install the
supermanifold and compressor along with shock tower brace to the vehicle.
Note2 technicians are required for this step, Mind the connectors and A/C lines, slowly lift the brace.
-
Install the LH and RH bolts that
attach the shock tower brace to the body.NoteUse of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
-
Install the LH and RH outer bolts that
attach the shock tower brace to the body.NoteUse of the following tool(s) is recommended:
- 15 mm socket
- Flex head ratchet/flex head torque wrench
-
Install 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
- Flex head ratchet/flex head torque wrench
-
Install the radiator inlet hose to the
Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Install the radiator outlet hose to
the Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Install the powertrain bypass hose to
the Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Connect the HV battery return hose to
the Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Connect the powertrain supply hose to
the Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Connect the chiller to battery hose to
the Supermanifold.
NotePerform push-pull-push test to make sure hose is fully seated.
-
Connect the sensor for the powertrain
supply hose.
NoteHarness and coolant hose are color coded. Match harness color to coolant hose color.
-
Connect the sensor for the chiller to
battery hose.
NoteHarness and coolant hose are color coded. Match harness color to coolant hose color.
- Install the clip that secures the thermal sub assembly harness to the front harness guide cover.
- Connect the thermal sub-harness connector to the front controller.
-
Position the A/C compressor HV harness
bracket on the A/C compressor.
NoteMake sure the HV harness bracket engages with the harness mount on the top of the A/C compressor.
-
Install the bolt that attaches the HV
harness bracket to the A/C compressor.Tip: Use of the following tool(s) is recommended:
- 13 mm deep socket
- Ratchet/torque wrench
Tip: - Connect the HVIL electrical connector.
-
Fully seat the A/C compressor HV
connector on the A/C compressor, and then engage the locking tab by pushing it toward
the A/C compressor.
NotePerform a push-pull test to verify that the connector is fully attached.
- Install the retaining clips that secure the A/C compressor HV harness to the shock tower brace.
- Install the clip that attaches the coolant hose to the A/C compressor bracket, near the ground strap attachment point.
-
Position the ground strap on the A/C
compressor, and then install the bolt that attaches the ground strap to the A/C
compressor.NoteThis bolt is self-tapping. It is not necessary to tap the compressor bolt hole.Tip: Use of the following tool(s) is recommended:
- Torx T25 socket
- Cordless Ratchet/Impact Driver
- Ratchet/torque wrench
- Install the clip that attaches the A/C compressor low voltage harness to the A/C compressor HV harness bracket.
-
Connect the low voltage electrical
connector to the A/C compressor, and then engage the locking tab.
CAUTIONPush the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
- Remove transportation plugs from the new A/C compressor.
-
Replace the o-rings on the high
pressure and low pressure supermanifold to A/C compressor hose fittings, and then
lubricate the O-rings with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
-
Position the supermanifold to A/C
compressor high pressure fitting on the A/C compressor, and then install the nut that
attaches the fitting to the A/C compressor.Tip: Use of the following tool(s) is recommended:
- 13 mm deep socket
- Flex head ratchet/flex head torque wrench
-
Position the supermanifold to A/C
compressor low pressure fitting on the A/C compressor, and then install the nut that
attaches the fitting to the A/C compressor.Tip: Use of the following tool(s) is recommended:
- 13 mm deep socket
- Flex head ratchet/flex head torque wrench
- Install the clips (x2) that attach the coolant hose to the A/C compressor bracket.
- Install the rear battery tie down strap on the 12V battery bracket.
- Install the clip that attaches the 12V battery vent tube to the 12V battery bracket.
- Install the 12V/LV auxiliary battery. See 12V/LV Battery (Remove and Replace).
- On the touchscreen, touch Run to start the "Start Thermal Fill Drain (Coolant & Refrigerant)" routine. and select
- Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
- Perform A/C vacuum leak test. See A/C Refrigerant (Recovery and Recharge).
- Perform A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge).
- Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
- Connect the first responder loop and leave the LV battery disconnected.
- Connect a LV maintainer. See LV Maintainer (Connect and Disconnect).
-
Update the compressor
configuration:
- Reinstall the firmware. See Software Reinstall - Touchscreen.
- On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap , and allow the routine to complete.
- Tap , and close once the routine is passed.
- Tap , and close once the routine is passed.
- Tap , and close once the routine is passed.
- Tap , and close once the routine is passed.
- Install the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Install the 2nd row lower seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
- Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
- Inspect the coolant level and make sure the fluid level is at the Max line.
- Tap , and close once the routine is passed.
- Tap , and close once the routine is passed.
- Exit Service Mode. See Service Mode.
- Disconnect the LV maintainer. See LV Maintainer (Connect and Disconnect).
- Connect LV power. See 12V/LV Power (Disconnect and Connect).