23/05/2024 09:17:43

A/C Line - Supermanifold to HVAC (Remove and Replace)

Correction code 18201702 1.74 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 proper PPE is worn when performing the below procedure.

  • 2023-06-22: Added link to vehicle electrical isolation 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. Connect A/C machine to power and switch on
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    Note
    Touch time only, Machine will run various background tasks, Wait until Main Menu comes up before continuing
  2. Skip the following panels when prompted
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    Note
    Use selections indicated in pictures
  3. Perform hose flush
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    Note
    Touch time only, Connect couplers to machine, Open couplers by turning clockwise, Using Main Menu > Next > Menu > Flush hoses > Verify hose connection, Machine will chime once process is complete
  4. Open LH front door
  5. Lower LH front window
  6. Raise and support vehicle
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    Note
    Set air suspension to "Jack Mode" if equipped
  7. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3
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    Note
    Open Toolbox 3 website and establish connection to the vehicle, https://toolbox.teslamotors.com, For local connection issues with Toolbox 3 refer to article #43695, Media converter box is powered by laptop using USB, Ethernet connection will provide communication
  8. Select ‘Actions’ tab and search for ‘Refrigerant’
  9. Select "PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTSearch for routine in ToolboxStart Thermal Fluid Fill/Drain (Refrigerant only)Thermal / Refrigerant System - Start Refrigerant Fill/DrainThermal / Actions - Start Refrigerant Fill/Drain ", click "Run", and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "x" at the top right of the window to close once complete, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again, Verify EXV positions are open via Garage > Vitals > HP > Refrigerant Loop EXV, Verify LCC, CC Left, Evap, CC Right, Chiller are all at ~100%. Recirc is at ~20%, LCC Solenoid is OPENED
  10. Open hood
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    Note
    Using center display touchscreen > Quick Controls > Frunk Open
  11. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Power Off
  12. Remove rear underhood apron
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    Note
    8x clips
  13. Remove LH underhood apron
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    Note
    10x clips
  14. Remove RH underhood apron
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    Note
    10x clips
  15. Remove front underhood apron
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    Note
    7x clips
  16. Remove frunk access panel
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    Note
    3x clips, 3x hooks, 1x connector
  17. Remove frunk carpet
  18. Remove frunk assembly
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    Note
    4x bolts, 10mm, 5 Nm
  19. Disconnect LV battery connector and First Responder Loop
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    Note
    2x connectors, Lift up and release gray locking tab, Pull black connector lock outwards to release connection
  20. Verify operation of multimeter
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    Note
    Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
  21. Raise vehicle fully and lower lift onto locks
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    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
  22. Remove clips securing mid aero shield
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    Note
    4x push clips
  23. Remove bolts securing mid aero shield and remove from vehicle
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    Note
    16x bolts, 10mm, 6 Nm
  24. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  25. Remove the leather glove protectors and HV insulating gloves
  26. Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle
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    Note
    16x bolts, 10mm, 6 Nm
  27. Install clips securing mid aero shield
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    Note
    4x push clips
  28. Lower vehicle until tires are touching the ground
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    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  29. Remove caps from low side and high side AC ports
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    Note
    2x caps
  30. Connect hoses to vehicle and perform A/C recovery
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    Note
    Connect couplers to vehicle, Open couplers by turning clockwise, Using Main Menu > Recover > Verify hose connection, Machine will chime once process is complete, Vehicle may be left unattended, Note or print the amount of refrigerant and oil recovered, Refrigerant recovered should be ~2.24 lb (1.02 kg), Oil recovered should be ~0.3 oz (8.87 mL), If drained oil level increased more than 1.01 oz (30 mL) refer to drained oil loss chart https://toolbox.teslamotors.com/articles/353700
  31. Disconnect AC compressor logic connector
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    Note
    1x locking electrical connector, Do not push down on red tab, Pull to disengage lock, Pull again to release connector
  32. Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket
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    Note
    1x fir tree clip
  33. Remove fastener securing AC compressor HV harness bracket to AC compressor
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    Note
    1x bolt, 13mm, 9 Nm
  34. Disconnect HV harness connector from AC compressor
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    Note
    1x locking electrical connector, Move black locking tab away form the AC compressor, Push down on locking connector to release and pull straight out of socket
  35. Remove AC compressor ground strap
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    Note
    1x bolt, T25, 7 Nm
  36. Remove the clip securing the coolant hose to the AC compressor bracket
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    Note
    1x fir tree clip
  37. Remove coolant pump from AC compressor bracket
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    Note
    Slide pump assembly away from compressor off lower bracket
  38. Release the HV heat pump bracket from the compressor eyelet
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    Note
    1x tab, Release bracket tab and rotate rearward and up to clear compressor eyelet
  39. Set HV heat pump bracket aside
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    Note
    Negotiate underneath high pressure pipe
  40. Release compressor bracket from multi-system beam
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    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 and under the multi-system beam, Be cautious around the coolant hose and supermanifold harness, Place fender cover on fan housing and gently place AC compressor assembly down
  41. Remove nut securing Penta HVAC line assembly to the Supermanifold plate
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    Note
    1x nut, 13mm, 27 Nm, Located under multi-system beam
  42. Remove Penta HVAC line from the Supermanifold plate
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    Note
    Located under multi-system beam, Move line rearward until Penta HVAC line stud clears Supermanifold plate, Place rag underneath line
  43. Remove Penta HVAC line from HVAC assembly
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    Note
    2x bolts, 13mm, 22 Nm
  44. Remove Penta HVAC line from vehicle
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    Note
    Negotiate line around coolant reservoir
  45. Position Penta HVAC line into vehicle
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    Note
    Negotiate around coolant reservoir
  46. Install Penta HVAC line from HVAC assembly
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    Note
    2x bolts, 13mm, 22 Nm
  47. Install Penta HVAC line to the Supermanifold plate
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    Note
    Located under multi-system beam, Ensure Penta HVAC line stud clears Supermanifold plate before engaging pipes
  48. Install Penta HVAC line assembly nut to the Supermanifold plate
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    Note
    1x nut, 13mm, 27 Nm, Located under multi-system beam
  49. Position AC compressor bracket assembly into vehicle and secure AC compressor assembly to multi-system beam
    Informational PurposesAn informational icon, calling your attention
    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 and under the multi-system beam, Negotiate bracket around coolant hose and supermanifold harness, Hand start bolts
  50. Torque AC compressor bracket bolts to multi-system beam
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    Note
    2x bolts, 15mm, 31 Nm
  51. Position HV heat pump bracket
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    Note
    Negotiate underneath high pressure pipe
  52. Secure HV heat pump bracket to AC compressor eyelet
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    Note
    Ensure locking tab engages eyelet
  53. Connect HV harness connector to AC compressor
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    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
  54. Install fastener securing AC compressor HV harness bracket to AC compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 9 Nm
  55. Install AC compressor ground strap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 7 Nm
  56. Install coolant pump onto AC compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide pump assembly onto compressor lower bracket
  57. Install the clip securing the coolant hose to the AC compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  58. Perform AC vacuum and run leak test
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    Note
    Set vacuum time to 15 minutes and leak test to ON, Machine will chime once process is complete, Vehicle may be left unattended, Verify leak test passed before continuing
  59. Perform AC recharge
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    Note
    Enter refrigerant and oil amount noted at AC recovery, Settings should match notes, Select Both Sides for charge, Select ND-11 MSX using bottle icon, Machine will chime once process is complete, Vehicle may be left unattended, If desired use the Dye Inject option to inject leak detection dye
  60. Connect First Responder Loop and LV battery connector
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    Note
    2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage gray locking tab when fully seated
  61. Re-establish vehicle connection to Toolbox 3
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    Note
    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)
  62. Select "Actions/Autodiag" and search for "Stop Thermal"
  63. Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete
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    Note
    Select ‘X’ at top right of window to close once complete
  64. Select "Actions/Autodiag" and search for "Commissioning"
  65. Select TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGSearch for routine in ToolboxHeat Pump Thermal System CommissioningThermal / Refrigerant System - Run Heat Pump Commissioninghv / Front Drive Inverter Replacement - Heatpump commissioning, click Run and allow routine to complete
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    Note
    If this routine is not run after entering Thermal Drain/Fill mode, the AC compressor operation will be blocked, Select ‘X’ at top right of window to close once complete
  66. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
  67. Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine
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    Note
    Disconnect high side coupler from vehicle, Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 10, Verify Hose Equalize settings, Verify discharge pressure does not exceed 26 bar and suction pressure is not below 1.15 bar,
  68. Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine
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    Note
    Remove low side coupler from vehicle, Turn vehicle off, Verify Hose Equalize settings, Machine will chime once process is complete
  69. Install caps onto AC ports
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    Note
    2x caps
  70. Install frunk assembly
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    Note
    4x bolts, 10mm, 5 Nm
  71. Install frunk carpet
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    Note
    Verify carpet is properly seated under the seal
  72. Install frunk access panel
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    Note
    3x clips, 3x hooks, 1x connector
  73. Install front underhood apron
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    Note
    7x clips
  74. Install RH underhood apron
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    Note
    10x clips
  75. Install LH underhood apron
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    Note
    10x clips
  76. Install rear underhood apron
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    Note
    8x clips
  77. Close hood
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    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  78. Remove vehicle from lift
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    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  79. Raise LH front window
  80. Close LH front door