20/09/2024 02:18:54

Supermanifold (Remove and Replace)

Correction code 184001021.50 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.

  • 2024-09-20: Added note on adding correction code for refrigerant recovery/recharge 18200102 as a separate activity to the service visit.
  • 2024-06-12: Added caution for Schrader valves.
  • 2023-04-04: Updated A/C oil type to be used with reference to Fluids and Capacities for A/C oil specifications.
  • 2023-08-02: Updated incorrect procedure reference.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Informational PurposesAn informational icon, calling your attention
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.
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Warning
The video(s) included in this procedure are meant as an overview for supplemental purposes only. Follow all of the steps listed in the procedure to avoid damage to components and/or personal injury.

Remove

  1. Make sure vehicle firmware version is 2021.36 or later before continuing. See Software Update.
  2. Set up A/C machine
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only
  3. Position the vehicle on a 2-post lift.
  4. Open LH front door and lower the window.
  5. Connect to the vehicle using Toolbox 3.0, and then perform the following:
    1. Select the Dashboards tab, and select Infotainment dashboard.
    2. Select the Vehicle Configuration tab, select Read Config and then click Run to pull the current vehicle configuration.
    3. Scroll down to coolantPumpType and change to Two coolant pumps installed, mixed pole pair batches.
    4. Select Apply Changes and click Run to save the updated configuration.
      Informational PurposesAn informational icon, calling your attention
      Note
      The center display will reboot, Toolbox connection will be lost. Verify configuration changes are complete.
  6. Remove the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  7. Remove the cabin intake duct. See Duct - Cabin Intake (Remove and Replace).
  8. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  9. Recover the refrigerant from the vehicle. See A/C Refrigerant (Recovery and Recharge).
  10. Remove the 12V/LV battery. See 12V/LV Battery (Remove and Replace).
  11. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  12. Position a fluid catcher underneath front of vehicle.
  13. Remove the coolant bottle cap.
  14. Disconnect the powertrain bypass hose from the Supermanifold.
  15. Disconnect radiator outlet hose from Supermanifold.
  16. Disconnect radiator inlet hose from Supermanifold.
  17. Install three male plugs into the coolant ports at the front of the Supermanifold.
  18. Disconnect the sensor for the chiller to battery hose.
  19. Disconnect the sensor for the PT supply hose.
  20. Disconnect the chiller to battery hose from the supermanifold.
  21. Disconnect the powertrain supply hose from the supermanifold.
  22. Disconnect the HV battery return hose from the Supermanifold.
  23. Install three male plugs into the coolant ports at the rear of the Supermanifold.
  24. Disconnect the thermal sub-harness from the front controller.
  25. Remove the clip that attaches the thermal sub assembly harness to the front harness guide cover.
  26. Remove the retaining clip that attaches the A/C compressor logic harness to A/C compressor HV harness bracket.
  27. Disconnect the A/C compressor logic connector.
  28. Remove A/C hoses from vehicle
  29. Carefully depress the Schrader valves (x2) to release the vacuum from the A/C lines.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure to depress both Schrader valves. Failure to do so may result in injury
  30. Remove the desiccant bag from the supermanifold to determine the amount of oil that must be added later in this procedure. See Desiccant (Heat Pump) (Remove and Replace).
  31. Measure the refrigerant oil level inside the accumulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Level will vary per vehicle. Do not rely on picture. Keep steel ruler vertical during measurement. Record measurement in millimeters.
  32. Convert the accumulator oil level measurement to grams.
    Informational PurposesAn informational icon, calling your attention
    Note
    Multiply measurement by 5.6 and add 15. Record measurement in grams.
  33. Calculate the total oil loss from A/C recovery, desiccant bag, and accumulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add all measurements and record total in grams. Measurement will be used for oil injection at a later step.
  34. Remove the nut that attaches the low side of the manifold to compressor pipe and move the low side pipe out of the way.
  35. Remove the nut that attaches the high side of the manifold to compressor pipe and move the high side pipe out of the way.
  36. Remove the bolt that attaches the supermanifold to compressor A/C line assembly.
  37. Remove the supermanifold to compressor A/C line assembly from the supermanifold and remove it from the vehicle.
  38. Loosen the nut that attaches the supermanifold to the HVAC A/C line assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Loosen the nut but do not remove it. Removal is done at a later step.
  39. Remove the bolts (x2) that attaches the supermanifold to the HVAC A/C line assembly to HVAC assembly.
  40. Remove the clips (x2) that attaches the coolant hose to the A/C compressor bracket.
  41. Remove the rear battery tie down strap.
  42. Release the clip that attaches the 12V battery vent tube from the battery bracket.
  43. Remove the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
  44. Remove the bolt that attaches the A/C compressor ground strap.
  45. Remove the clip that attaches the coolant hose to the A/C compressor bracket.
  46. Disconnect the HV harness connector from the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move black locking tab away form the A/C 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.
  47. Remove the A/C compressor HV harness from the A/C compressor and put it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move A/C compressor HV harness bracket toward the front of the vehicle, lift the bracket up to clear the upper bracket mount, and then carefully set the harness and bracket aside.
  48. Remove the retaining clips (x4) that attach the A/C compressor HV harness to the shock tower support brace.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull upward on clip to assist with removal, do not pull on HV cable.
  49. Remove the bolts (x3) that attach the shock tower brace to the LH shock tower.
  50. Remove the bolts (x3) that attach the RH side of shock tower brace to the shock tower.
  51. Remove the shock tower brace together with the supermanifold and compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    2 technicians are required for this step. Mind the connectors and A/C lines, slowly lift the brace, and then put it on a cardboard pad.
  52. Remove the bolts (x2) that attach the supermanifold to the shock tower beam, and then remove the supermanifold.
  53. Remove the nut that attaches the supermanifold to the HVAC A/C line assembly to supermanifold, and then remove the supermanifold to HVAC A/C line assembly.

Install

  1. Document 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 in the repair order.
  2. Position the supermanifold assembly to the brace and attach it with the two bolts (toque 31 Nm.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start bolts to Supermanifold
  3. Replace the seal washers (x5) on the supermanifold to HVAC A/C line assembly on supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  4. Replace the seal washers (x5) on the supermanifold to HVAC A/C line assembly at the HVAC side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  5. Install the nut that attaches the supermanifold to HVAC A/C line assembly to the supermanifold (torque 27 Nm).
  6. Install the shock tower brace to the vehicle.
  7. Install the bolts (x3) that attach the shock tower brace to LH shock tower.
    Informational PurposesAn informational icon, calling your attention
    Note
    See image for torque figures by location.
  8. Install the bolts (x3) that attach the shock tower brace to RH shock tower.
    Informational PurposesAn informational icon, calling your attention
    Note
    See image for torque figures by location.
  9. Install the bolts that attach the supermanifold to HVAC A/C line assembly to the HVAC assembly (torque 22 Nm).
  10. Install the retaining clips (x4) that attach the A/C compressor HV harness to the shock tower brace.
  11. Position the A/C compressor HV harness onto the A/C compressor.
  12. Connect the HV harness connector to the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, 3 stage locking connector. After fully seating the connector onto the A/C compressor, engage the black locking tab by pushing it towards the A/C compressor. Perform a push-pull-push test to ensure proper seating.
  13. Install the bolt (torque 9 Nm) that attaches the A/C compressor HV harness bracket to the A/C compressor.
  14. Install the clip that attaches the coolant hose to the A/C compressor bracket.
  15. Install the bolt (torque 7 Nm) that attaches the A/C compressor ground strap.
  16. Install the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  17. Connect the A/C compressor logic connector.
  18. Install the radiator inlet hose to supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  19. Install the radiator outlet hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  20. Install the powertrain bypass hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  21. Install the clip that attaches the thermal sub assembly harness to the front harness guide cover.
  22. Connect the thermal sub-harness to the front controller module.
    Informational PurposesAn informational icon, calling your attention
    Note
    Rotate fully to secure the locking tab.
  23. Connect the HV battery return hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  24. Connect the powertrain supply hose to the supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  25. Connect the chiller to battery hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  26. Connect the sensor for the PT supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness and coolant hose are color coded. Match the harness color to the coolant hose color.
  27. Connect the sensor for the chiller to battery hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness and coolant hose are color coded. Match harness color to the coolant hose color.
  28. Install the clips (x2) that attach the coolant hoses to the A/C compressor bracket.
  29. Install the rear battery tie down strap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Insert assembly into bracket and rotate 90 degrees.
  30. Install the 12V battery vent tube to the battery bracket.
  31. Install the 12V/LV battery into the vehicle. See 12V/LV Battery (Remove and Replace).
  32. Install new seal washers (x2) for the supermanifold to compressor A/C line assembly at the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  33. Install a new seal washer on the supermanifold to compressor A/C line assembly at the compressor discharge line.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washer with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  34. Install a new seal washer on the supermanifold to compressor A/C line assembly at the compressor suction line.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washer with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  35. Install the bolt (torque 22 Nm) that attaches the supermanifold to compressor A/C line assembly onto the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start bolt to prevent stripped threads.
  36. Install the nut that attaches the supermanifold to compressor discharge line to the compressor (torque 22 Nm).
  37. Install the nut that attaches the supermanifold to compressor suction line to the compressor (torque 22 Nm).
  38. Perform a coolant vacuum refill. See Cooling System (Vacuum Refill).
  39. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace).
  40. Connect 12V power. See 12V/LV Power (Disconnect and Connect)
  41. Re-establish vehicle connection with Toolbox 3.0, and then perform the following:
    1. Select the Actions tab and search for ‘Thermal’.
    2. Select the ODIN routine TEST-SELF_VCFRONT_X_FIVE-WAY-VALVESearch for routine in ToolboxThermal / Coolant System - Coolant Valve Test, click Run and allow routine to complete.
    3. Select the ODIN routine PROC_VCFRONT_X_THERMAL-FILL-DRAINSearch for routine in Toolbox, click Run and allow routine to complete.
      Informational PurposesAn informational icon, calling your attention
      Note
      The Thermal Fluid Fill/Drain routine has a 5 hour time limit. After 5 hours routine must be performed again. Make sure that 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.
  42. Recharge the refrigerant system. See A/C Refrigerant (Recovery and Recharge).
  43. In Toolbox 3, perform the following:
    1. Select the ODIN routine PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINSearch for routine in ToolboxThermal / Refrigerant System - Stop Thermal Fill/DrainThermal / Coolant System - Stop Thermal Fill/Drainhv / Front Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Left Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Rear Right Drive Inverter Replacement - Stop Fluid Fill/Drainhv / Front Drive Unit Replacement - Stop Coolant Fill/Drainhv / Rear Drive Unit Replacement - Stop Coolant Fill/DrainThermal / Actions - Stop Thermal Fill/Drain, click Run and allow the routine to complete.
    2. Select the Actions tab and search for "Commissioning".
    3. Select the ODIN routine TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGSearch for routine in ToolboxThermal / Refrigerant System - Run Heat Pump Commissioninghv / Front Drive Inverter Replacement - Heatpump commissioning, click Run and allow the routine to complete.
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      Note
      If this routine is not run after exiting the Thermal Drain/Fill mode, the A/C compressor operation will be blocked.
  44. Proceed with steps 2-4 for End of Charge process and follow the instructions displayed on A/C Machine
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    Note
    Turn A/C 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 A/C OFF and allow pressures to stabilize and remove high side hose.
  45. Proceed with steps 5-6 for the End of Charge process and follow the instructions displayed on the A/C Machine.
    Informational PurposesAn informational icon, calling your attention
    Note
    Turn A/C 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 A/C machine instructions and clear A/C hoses
  46. Install caps onto the A/C ports.
  47. Perform a coolant air purge. See Cooling System (Partial Refill and Bleed).
  48. Using Toolbox 3, perform the following:
    1. Select the Actions tab and search for ‘Pump’.
    2. Select the ODIN routine TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATIONSearch for routine in ToolboxThermal / Coolant System - Pump IdentificationThermal / Actions - Run Coolant Pumps Identification, click Run, and allow the routine to complete.
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      Note
      Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
    3. Select the Actions tab and search for ‘Thermal’.
    4. Select the ODIN routine TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCESearch for routine in ToolboxThermal / 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 the routine to complete.
    5. Select the Actions tab and search for ‘HVAC performance’.
    6. Select the ODIN routine TEST-SELF_VCRIGHT_X_HEAT-PUMP-HVAC-PERFORMANCESearch for routine in Toolbox, click Run, and allow the routine to complete.
  49. Remove the laptop from the vehicle.
  50. Install the fresh air intake assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x studs, Maneuver between cowl and frunk.
  51. Install the front underhood storage. See Underhood Storage Unit (Remove and Replace).
  52. Install the cabin intake upper duct assembly.
  53. Install the rear underhood apron. SeeUnderhood Apron - Rear (Remove and Replace).
  54. Install the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).