Correction code 18400106 2.22 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.

1. Raise and support vehicle

   

   

   

2. Open all four doors
   Note

   If vehicle is being powered down, Latch rear doors to prevent accidental closure
3. Lower all four windows
4. Set up AC machine
   Note

   Touch time only

   

5. Open hood
6. Remove rear apron
   Note

   12x clips, only store the rear apron visible face upwards

   

   

   

7. Remove cabin intake upper duct assembly
   Note

   3x clips, Older vehicles may be equipped with 4x clips

   

8. Remove the close out panel from frunk assembly
   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

   

   

9. Remove fasteners securing the frunk assembly
   Note

   7x bolts, 10mm, 5 Nm, Lift up the RBN covers to access the upper fasteners, Newer vehicles may not be equipped with covers

   

10. Remove frunk assembly from vehicle
    Note

    12x clips, Replace any clips if broken or missing, Number of clips may vary on older vehicles

    

    

    

11. Log into Tesla Garage
12. Enter vehicle VIN and select "Search"
13. Check Firmware version
    Note

    Firmware package installed must be 2021.36 or above for vehicle configuration update and Toolbox routine
14. Navigate to "CFG" tab on "Vitals" page
15. Perform inspection of the current coolant pump configuration
    Note

    If the current configuration is DUAL or DUAL_SAN_P4, it will required change to DUAL_MIX, This will be required to identify the pumps in the replacement supermanifold
16. Perform inspection of the current revision supermanifold
    Note

    Determine the part number of the equipped supermanifold, If replacing a -A to -E (v1.0) with a -F (v1.1) then a manifold configuration change and replacement of A/C pentaline will also be required

    

    

    

17. Connect to vehicle using Toolbox 3.0
    Note

    Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, Select connection status icon at top right corner, and select connect locally (icon will turn green when vehicle is connected)If RJ45 ethernet diagnostic connector present connect directly from laptop using an RJ45 Ethernet cable
18. Select "Dashboards" tab, and select "Infotainment Dashboard"
19. Select "Vehicle Configuration"
    Note

    Configuration values should load automatically, if not select "Read Config" and "Run" to load
20. Select "Read Config" and select "Run" to pull current vehicle configuration
    Note

    Select ‘X’ at top right of window to close once complete
21. Scroll down to "coolantPumpType" and change to "Two coolant pumps installed, mixed pole pair batches"
    Note

    if "Two coolant pumps installed, mixed pole pair batches" is already selected proceed to the next step
22. Scroll down to "superManifoldType" and change to "TYPE1"
23. Select "Apply Changes" and select "Run" to save updated configuration
    Note

    Center display will reboot, Toolbox connection will be lost, Select ‘X’ at top right of window to close once complete, Verify configuration changes are complete
24. Turn HVAC on, Turn AC OFF and set the Blower Speed to 10. Set the Temperature to HI and run for 10 minutes
    Note

    This will clear most of the oil out of the cabin condenser

    

25. Turn off the HVAC and let it sit for 1 minute
    Note

    Make sure both compressor and blower are off, this allows refrigerant inside cabin condenser to return to the accumulator

    

26. Turn the HVAC back on, Turn the AC on, set the Blower Speed to 10 and the Temperature to LO, run the HVAC for 10 minutes
    Note

    This step will clear most of the oil out of the evaporator

    

27. Turn Off the AC and Blower motor

    

28. Move LH front seat forward
29. Move RH front seat forward

    

30. Re-establish vehicle connection to Toolbox 3.0
31. Select ‘Actions/Autodiag’ and search for ‘Thermal’
32. Select "Thermal Fluid Fill/Drain", click Run and allow routine to complete
    Note

    Select ‘X’ at top right of window to close once complete, Thermal Fluid Fill/Drain routine has a 5 hour time limit, After 5 hours routine must be performed again, Verify all EXV's opened VIA Garage > Vitals >Thermal > Refrigerant loop EXV, Verify LCC, CC Left, Evap, CC Right, Chiller are all at ~100%. Recirc is at ~20%, LCC Solenoid is OPENED, Verify vehicle is in Series Mode VIA garage > Vitals > Thermal > Coolant loops
33. Power off vehicle from center display
    Note

    Via Controls > Safety & Security > Vehicle Power > Power Off, Confirm power off at warning dialogue box
34. Disconnect 12V negative terminal
    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

    

35. Disconnect first responder loop
    Note

    1x connector, Release locking tab

    

36. Remove 2nd row seat cushion and disconnect harness
    Note

    2x tabs, 2x connectors, Press tab toward LH side of vehicle on each side to release front edge of seat cushion

    

    

    

    

37. Remove all items from pockets and ensure not wearing metal items

    

38. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to each use, Refer to service document TN-15-92-003 R5, for information on inspecting HV gloves, https://service.tesla.com/docs/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R5.pdf

    

39. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

40. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

    

41. Remove the ancillary bay probe lid cover from the ancillary bay cover

    

42. Verify no high voltage
    Note

    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

43. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Note

    Confirm no visual damage present

    

    

44. Install bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners

    

45. Remove HV insulating gloves
46. Raise vehicle fully and lower lift onto locks
    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, Verify doors are clear of surrounding objects
47. Remove outer fasteners securing front aero shield
    Note

    9x bolts, 10mm, 5 Nm

    

48. Remove remaining nuts and remove front aero shield from vehicle
    Note

    2x nuts, 15mm, 5 Nm

    

    

49. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is
50. Remove caps from low side and high side AC ports
    Note

    2x caps

    

51. Connect hoses to vehicle and perform AC recovery
    Note

    Touch time only, Connect couplers to vehicle, Open couplers by turning clockwise, Open Machine valves, Note the amount of refrigerant and oil recovered, mark oil drain bottle oil level (use a piece of tape marking the fluid level) If drained oil level increased more than 30 mL refer to drained oil loss chart.

    

    

52. Remove fresh air intake assembly
    Note

    2x studs, Maneuver between cowl and frunk

    

    

53. Remove vent tube hose from LH side of 12V battery
    Note

    1x tube adapter

    

54. Release terminal cover and remove positive terminal
    Note

    2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut

    

    

55. Remove bolt securing 12V battery upper tie down strap to AC compressor bracket
    Note

    1x bolt, 10mm, 5 Nm

    

56. Remove battery upper tie down strap
    Note

    Lift battery tie down strap up and remove it from the rear tie down hook strap

    

    

57. Remove 12V battery from vehicle

    

58. Position fluid catcher underneath front of vehicle

    

59. Remove coolant bottle cap

    

60. Disconnect the powertrain bypass hose from the Supermanifold
    Note

    1x spring clip, This will drain the coolant reservoir

    

    

61. Disconnect radiator outlet hose from Supermanifold
    Note

    1x spring clip, Plug hose and supermanifold as needed

    

    

62. Disconnect radiator inlet hose from Supermanifold
    Note

    1x spring clip, Plug hose and supermanifold as needed

    

    

63. Install 3 male plugs into the coolant ports at the front of the Supermanifold
    Note

    3x plugs, This will avoid any cross contamination

    

64. Disconnect the sensor for the chiller to battery hose
    Note

    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector

    

65. Disconnect the sensor for the PT supply hose
    Note

    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector

    

66. Disconnect chiller to battery hose from supermanifold
    Note

    1x spring clip

    

67. Disconnect powertrain supply hose from supermanifold
    Note

    1x spring clip

    

68. Disconnect the HV battery return hose from the Supermanifold
    Note

    1x spring clip

    

69. Install 3 male plugs into the coolant ports at the rear of the Supermanifold
    Note

    3x plugs, This will avoid any cross contamination

    

70. Disconnect thermal sub-harness from front controller
    Note

    1x connector, Depress locking tab and rotate to release

    

71. Remove clip securing thermal sub assembly harness to front harness guide cover
    Note

    1x clip

    

72. Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket
    Note

    1x fir tree clip

    

73. Disconnect AC compressor logic connector
    Note

    1x locking electrical connector, Do not push down on red tab, pull to disengage lock, pull again to release connector

    

74. Overlap from AC refrigerant recovery

    

75. Remove AC hoses from vehicle

    

76. Remove nut securing low side of manifold to compressor pipe and move low side pipe out of the way
    Note

    1x nut, 13mm, 22 Nm

    

77. Remove nut securing high side of manifold to compressor pipe and move high side pipe out of the way
    Note

    1x nut, 13mm, 22 Nm

    

78. Remove bolt on supermanifold to compressor AC line assembly
    Note

    1x bolt, 13mm, 22 Nm

    

79. Remove supermanifold to compressor AC line assembly from Supermanifold and remove out of vehicle

    

    

80. Loosen nut securing supermanifold to HVAC AC line assembly to supermanifold
    Note

    1x nut, 13mm, 27 Nm, Loosen nut but do not remove, Remove nut at later step

    

81. Remove bolts securing supermanifold to HVAC AC line assembly to HVAC assembly
    Note

    2x bolts, 13mm, 22 Nm

    

82. Remove bolts securing supermanifold to shock tower beam and remove supermanifold from vehicle
    Note

    2x bolts, 15 mm, 31 Nm, Recommend assistance, Rotate the Supermanifold counter clockwise under the shock tower support beam

    

    

    

83. Remove nut securing supermanifold to HVAC AC line assembly to supermanifold and remove supermanifold to HVAC AC line assembly
    Note

    1x nut, 13mm, 27 Nm

    

    

84. Document old and new part numbers and serial numbers for Supermanifold
    Note

    Label is located in front of accumulator, document part numbers and serial numbers into the repair order

    

85. Transfer plastic bracket from old to new Supermanifold to HVAC AC line
    Note

    1x tab, Engage tab and release bracket, Transfer bracket onto new A/C line

    

    

86. Secure Supermanifold to HVAC AC line assembly to supermanifold and install nut hand tight
    Note

    1x nut, 13mm, 27 Nm, Torque at later step. Lubricate the lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

    

    

87. Install the Supermanifold into the vehicle and install the bolts securing the Supermanifold to the Shock tower beam
    Note

    2x bolts, 15mm, 31 Nm, Recommend assistance, Rotate the Supermanifold counter clockwise and install under the shock tower support beam, Hand start bolts to Supermanifold

    

    

88. Torque nut securing supermanifold to HVAC AC line assembly to supermanifold
    Note

    1x nut, 13mm, 27 Nm

    

89. Install supermanifold to HVAC AC line assembly to HVAC assembly
    Note

    2x bolts, 13 mm, 22 Nm

    

90. Install radiator inlet hose to Supermanifold
    Note

    1x spring clip, Remove any plugs from both ends of coolant connections, Perform push-pull-push test to make sure hose is fully seated

    

91. Install radiator outlet hose to Supermanifold
    Note

    1x spring clip, Remove any plugs from both ends of the coolant connection, Perform push-pull-push test to make sure hose is fully seated

    

92. Install the powertrain bypass hose to the Supermanifold
    Note

    1x spring clip, Remove any plugs from both ends of the coolant connection, Perform push-pull-push test to make sure hose is fully seated

    

93. Install clip securing thermal sub assembly harness to front harness guide cover
    Note

    1x clip

    

94. Connect thermal sub-harness to front controller
    Note

    1x connector, Rotate fully to secure locking tab

    

95. Connect the HV battery return hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seated

    

96. Connect the powertrain supply hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seated

    

97. Connect the chiller to battery hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seated

    

98. Connect the sensor for the PT supply hose
    Note

    1x locking connector, Engage locking tab, Harness and coolant hose are color coded, Match harness color to coolant hose color

    

99. Connect the sensor for the chiller to battery hose
    Note

    1x locking connector, Engage locking tab, Harness and coolant hose are color coded, Match harness color to coolant hose color

    

100. Remove the clips securing the coolant hose to AC compressor bracket
     Note

     2x clips

     

101. Remove rear battery tie down strap
     Note

     Rotate forward to disengage

     

102. Release 12v battery vent tube from battery bracket
     Note

     1x fir tree clip

     

103. Remove fastener securing AC compressor HV harness bracket to AC compressor
     Note

     1x bolt, 13mm, 9 Nm

     

104. Remove AC compressor ground strap
     Note

     1x bolt, T25, 7 Nm

     

105. Remove the clip securing the coolant hose to the AC compressor bracket
     Note

     1x fir tree clip

     

106. Disconnect HV harness connector from AC compressor
     Note

     1x locking electrical connector, 3 stage locking connector, See photos for connector positions, Move black locking tab away form the AC compressor, position 1, then using a 45 degree pick, push down on position 2 of the locking connector while prying up on position 3 and disconnect

     

     

     

107. Remove AC compressor HV harness from the AC compressor and set aside
     Note

     Move AC compressor HV harness bracket toward the front of the vehicle, lift the bracket up to clear the upper bracket mount and carefully set harness and bracket aside

     

     

     

108. Remove the fasteners securing the AC compressor bracket to the strut tower support brace and remove the AC compressor and AC compressor bracket assembly
     Note

     2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle, under the strut tower support brace

     

     

     

109. Remove the AC compressor bracket from the AC compressor
     Note

     3x bolts, 10mm, 9 Nm

     

110. Remove NVH acoustic cover from AC compressor
     Note

     NVH acoustic cover must be removed to properly weigh compressor

     

111. Remove NVH cover material from compressor
     Note

     Remove as much material of the NVH acoustic cover as possible, Excessive material left on AC compressor will cause an inaccurate weight measurement

     

112. Weigh the compressor and reset the amount of compressor oil.
     Note

     The compressor weight is to be measured in grams. Take note of the compressor weight. Add the appropriate A/C oil through the suction port of the compressor until it weighs 7193 grams (Denso compressor) or 7809 grams (Sanden compressor). See Fluids and Capacities for A/C oil specifications.

     

113. Install NVH acoustic onto AC compressor
     Note

     Install new NVH blanket or re-use old one if new one is not available, and adhesive is in good working condition. Remove adhesive backing, Lay NVH acoustic cover down with adhesive side facing up, Align cut outs of NVH acoustic cover to suction port on AC compressor, Install NVH acoustic cover around suction port on AC compressor then continue to wrap NVH acoustic cover around compressor

     

     

     

     

     

114. Install the AC compressor bracket to the AC compressor
     Note

     3x bolts, 10mm, 9 Nm

     

115. Position the AC compressor and AC compressor bracket assembly to the strut tower support brace and secure
     Note

     2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Carefully install the AC compressor and AC compressor bracket towards the rear of the vehicle, under the strut tower support brace, Keep AC compressor caps on the compressor until manifold lines are installed, Hand start bolts

     

     

     

116. Position the AC compressor HV harness onto the AC compressor for installation
     Note

     Ensure the HV harness bracket engages the upper bracket mount on the AC compressor

     

117. Connect HV harness connector to AC compressor
     Note

     1x locking electrical connector, 3 stage locking connector, After fully seating the connector onto the AC compressor engage the black locking tab by pushing toward the AC compressor, Perform push-pull-push test to ensure proper seating

     

118. Install fastener securing AC compressor HV harness bracket to AC compressor
     Note

     1x bolt, 13mm, 9 Nm

     

119. Install the clip securing the coolant hose to the AC compressor bracket
     Note

     1x fir tree clip

     

120. Install AC compressor ground strap
     Note

     1x bolt, T25, 7 Nm

     

121. Install retaining clip securing AC compressor logic harness to AC compressor HV harness bracket
     Note

     1x fir tree clip

     

122. Connect the AC compressor logic connector
     Note

     1x locking electrical connector, Engage locking tab

     

123. Install the clips securing the coolant hoses to the AC compressor bracket
     Note

     2x clips

     

124. Install rear battery tie down strap
     Note

     Insert assembly into bracket and rotate to 90 degrees

     

125. Install 12V battery vent tube to battery bracket

     

126. Install 12V battery into vehicle

     

127. Position battery tie down strap onto the battery
     Note

     Hook the upper tie down strap into the rear tie down hook strap and position for installation

     

128. Install bolt securing upper tie down strap to the AC compressor bracket
     Note

     1x bolt, 10mm, 5 Nm

     

129. Install vent tube hose in 12V battery

     

130. Install positive terminal and terminal cover
     Note

     1x nut, 10mm, 6 Nm, 2x clips

     

     

131. Replace seal washers for supermanifold to compressor AC line assembly on supermanifold side
     Note

     2x seal washers, Lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

132. Replace seal washer on supermanifold to compressor AC line assembly on compressor discharge line
     Note

     1x seal washer, Lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

133. Replace seal washer on supermanifold to compressor AC line assembly on compressor suction line
     Note

     1x seal washer, Lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

134. Install supermanifold to compressor AC line assembly onto Supermanifold
     Note

     1x bolt, 13mm, 22 Nm, Hand start bolt to prevent stripped threads

     

     

135. Install supermanifold to compressor discharge line to compressor
     Note

     1x nut, 13mm, 22 Nm

     

136. Install supermanifold to compressor suction line to compressor
     Note

     1x nut, 13mm, 22 Nm

     

137. Place empty coolant container into front storage area

     

138. Fill container with at least 15L of coolant

     

139. Place filled coolant container into front storage area

     

140. Place refill hose inside filled coolant container
     Note

     Make sure hose end is fully submerged into coolant

     

     

141. Install refill tool cap onto coolant bottle assembly

     

142. Setup vacuum refill tool
     Note

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

143. Install vacuum refill hose into refill cap on coolant bottle
     Note

     Perform push-pull-push test to verify hose is fully engaged

     

144. Position overflow hose into empty container

     

145. Place refill hose inside filled coolant container
     Note

     Make sure hose end is fully submerged into coolant

     

     

146. Connect shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

147. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Note

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

148. Slowly open the coolant refill valve to allow coolant to be drawn into the coolant refill hose, Close the valve when the hose is full of coolant
     Note

     This purges trapped air from the hose

     

     

149. Monitor gauge for 30 seconds to verify a vacuum is maintained in the cooling system

     

150. Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve

     

     

151. Slowly open the refill valve to allow coolant to be drawn into the system
     Note

     Make sure hose end of refill hose is fully submerged during entire process

     

152. Once the gauge reads zero, close the refill valve

     

     

153. Disconnect shop air supply from coolant refill tool

     

154. Remove coolant refill hose from coolant container

     

155. Remove coolant overflow hose from coolant container

     

156. Remove vacuum refill hose from refill cap on coolant bottle

     

157. Remove coolant refill tool from vehicle

     

     

158. Remove both coolant containers from inside underhood area

     

159. Remove fluid catcher from underneath vehicle

     

160. Raise vehicle fully and lower lift onto locks
     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
161. Position front aero shield to vehicle and install nuts
     Note

     2x nuts, 15mm, 5 Nm

     

     

162. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
     Note

     9x bolts, 10mm, 5 Nm

     

163. Lower vehicle fully
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
164. Connect first responder loop
     Note

     1x connector, Engage locking tab, Connect FRL before connecting 12V to avoid damage to car computer

     

165. Connect 12V negative terminal
     Note

     1x nut, 10mm, 6 Nm

     

166. Re-establish vehicle connection to Toolbox 3.0
167. Select ‘Actions/Autodiag’ and search for ‘Thermal’
168. Select TEST-SELF_VCFRONT_X_FIVE-WAY-VALVEvia Toolbox: (link)via Service Mode: Thermal ➜ Coolant System ➜ Coolant Valve Test, click Run and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete
169. Select "Thermal Fluid Fill/Drain", click Run and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete, Thermal Fluid Fill/Drain routine has a 5 hour time limit, After 5 hours routine must be performed again, Verify all EXV's opened VIA Garage > Vitals >Thermal > Refrigerant loop EXV, Verify LCC, CC Left, Evap, CC Right, Chiller are all at ~100%. Recirc is at ~20%, LCC Solenoid is OPENED, Verify vehicle is in Series Mode VIA garage > Vitals > Thermal > Coolant loops
170. Reconnect AC hoses to vehicle

     

171. Perform AC vacuum test
     Note

     2 minute vacuum leak test, 15 minute vacuum

     

172. Perform AC refrigerant refill
     Note

     Recharge refrigerant to 1.02 kg (1020g), For Robinair AC machines press ESC to NOT ACCEPT the step to clear out residual oil, Once complete press next to start End of Charge process

     

     

     

173. Perform step 1 for End of Charge process
     Note

     Close high and low machine valves, Press next to continue

     

     

174. Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete
175. Select "Actions/Autodiag" and search for "commissioning"
176. Select TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Toolbox: (link)via Service Mode: Thermal ➜ Refrigerant System ➜ Run Heat Pump Commissioningvia Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioning, click Run and allow routine to complete
     Note

     If this routine is not run after exiting Thermal Drain/Fill mode, the AC compressor operation will be blocked, Select ‘X’ at top right of window to close once complete
177. Proceed with steps 2-4 for End of Charge process and follow instructions displayed on AC Machine
     Note

     Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 3, Verify Discharge pressure does not exceed 26 bar and Suction pressure is not below 1.15 bar, Turn AC OFF, allow pressures to stabilize and remove high side hose

     

     

     

     

178. Proceed with steps 5-6 for End of Charge process and follow instructions displayed on AC Machine
     Note

     Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 3, Turn machine valves to OPEN, Allow pressures to stabilize, Remove low side hose from vehicle, Continue with AC machine instructions and clear AC hoses

     

     

     

179. Install caps onto AC ports
     Note

     2x caps

     

180. Select ‘Actions/Autodiag’ tab and search for ‘Purge'
181. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
     • Thermal ➜ Coolant System ➜ Coolant Purge Start
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
     ’, click ‘Run’, and allow routine to complete
     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, Speeds can be monitored in garage under PT Thermal tab, 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
182. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line

     

183. Install coolant bottle cap

     

184. Select ‘Actions/Autodiag’ and search for ‘Pump’
185. Select ‘TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATIONvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Run Coolant Pumps Identification
     • Thermal ➜ Coolant System ➜ Pump Identification
     ’, click ‘Run’, and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete, Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
186. Select ‘Actions/Autodiag’ and search for ‘Thermal’
187. Select ‘TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
     ’, click ‘Run’, and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete.
188. Search for HVAC Performance in Actions and select HVAC System Performance Test "ODIN - TEST-SELF_VCRIGHT_X_HVAC-PERFORMANCEvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Test HVAC Performance
     • Thermal ➜ Actions ➜ Test HVAC Performance
     "
189. Select RUN to start HVAC System Performance Test
190. Remove HSD or RJ45 cable from Ethernet port to disconnect Toolbox 3.0 from vehicle
191. Install fresh air intake assembly
     Note

     2x studs, Maneuver between cowl and frunk

     

     

192. Install frunk assembly to vehicle
     Note

     12x clips, Make sure frunk assembly is fully seated onto the clips, Number of clips may vary on older vehicles

     

     

193. Install fasteners securing the frunk assembly
     Note

     7x bolts, 10mm, 5 Nm, Lower the RBN covers after installing upper fasteners, Newer vehicles may not be equipped with covers

     

194. Install frunk close out panel
     Note

     4x clips, 1x connector, Frunk safety switch, 3x guide tabs, Align the 3x tabs then push downward to secure clips

     

195. Install cabin intake upper duct assembly
     Note

     3x clips, Older vehicles may be equipped with 4x clips

     

196. Install rear apron
     Note

     12x clips

     

     

197. Close hood
198. Connect 2nd row seat cushion harness and install 2nd row seat cushion
     Note

     2x connectors, 2x clips, Insert the seat belt buckles through the holes, Slide rear cushion inward then align front guide tabs to locking tabs, Make sure cushion is fully seated with push & pull test near clips

     

     

     

     

199. Move RH front seat to original position
200. Move LH front seat to original position
201. Raise all windows
202. Close all four doors
     Note

     Unlatch rear doors before closing