2026-04-16

Supermanifold (Remove and Replace)

Correction code 18400102 2.04 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. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

2025-08-14: Added steps of configuring the coolant pump type.
2025-07-28: Replaced several routines using Garage by Toolbox or touchscreen routines.
2023-04-13: Revised procedure.

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.

Remove

Raise and support vehicle.

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads.
Enable Service Mode. See Service Mode (Enable and Disable).
Unlock gateway. See Gateway (Unlock).
Select Thermal > Refrigerant System > Start Thermal Fill Drain, click Run to start the routine, close once it is completed.
Perform HV disablement procedures. See Vehicle HV Disablement Procedure.
Perform A/C refrigerant Recovery. See A/C Refrigerant (Recovery and Recharge).
Remove LV battery. See Battery - LV (Remove and Replace).
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
Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket

Note
1x fir tree clip
Remove fastener securing AC compressor HV harness bracket to AC compressor

Note
1x bolt, 13mm, 9 Nm
Disconnect HV harness connector from AC compressor

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
Remove AC compressor ground strap

Note
1x bolt, T25, 7 Nm
Release clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Remove PT coolant pump from AC compressor bracket

Note
Slide pump assembly away from compressor off lower bracket
Remove coolant bottle cap.
Disconnect the powertrain bypass hose from the Supermanifold

Note
1x spring clip, This will drain the coolant reservoir
Disconnect the radiator outlet hose from the Supermanifold

Note
1x spring clip
Disconnect the radiator inlet hose from the Supermanifold

Note
1x spring clip
Install 3 male plugs into the coolant ports at the front of the Supermanifold and 3 female plugs at the removed hoses

Note
3x male plugs, 3x female plugs, This will avoid any cross contamination
Disconnect the sensor for the powertrain 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
Disconnect powertrain supply hose from supermanifold

Note
1x spring clip, Spring is accessible from the front of the supermanifold
Disconnect the HV battery return hose from the Supermanifold

Note
1x spring clip
Disconnect chiller to battery hose from supermanifold

Note
1x spring clip
Install 3 male plugs into the coolant ports at the rear of the Supermanifold

Note
3x plugs, This will avoid any cross contamination
Disconnect the supermanifold harness from the front controller

Note
1x connector
Remove AC hoses from vehicle
Remove nut securing supermanifold to compressor suction line to compressor and remove line

Note
1x nut, 13mm, 22 Nm
Remove desiccant cartridge from accumulator. See Desiccant (Remove and Replace).
Weigh old desiccant cartridge.
Calculated oil loss is the difference between desiccant dry weight and wet weight, If equipped view dry weight printed on desiccant cartridge, If weight is not printed assume dry weight equals 90.4 grams, Calculate difference between dry desiccant weight and wet desiccant weight recorded, Add to calculated oil loss found during recovery.
Measure refrigerant oil level inside accumulator.

Note
Level will vary per vehicle, Do not rely on picture, Keep steel ruler vertical during measurement, Record measurement in millimeters.
Convert accumulator oil level measurement to grams.

Note
Multiply measurement by 5.6 and add 15, Record measurement in grams.
Calculate total oil loss from AC recovery, desiccant bag, and accumulator.

Note
Add all measurements and record total in grams, Measurement will be used for oil injection at later step.
Remove suction line from compressor.
Remove nut securing supermanifold to compressor discharge line to compressor and remove line

Note
1x nut, 13mm, 22 Nm
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, Carefully set harness and bracket aside
Remove the fasteners securing the AC compressor bracket to the multi-system beam 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 and under the multi-system beam, Be cautious around the coolant hose and supermanifold harness
Remove bolt on supermanifold to compressor AC line from supermanifold

Note
1x bolt, 13mm, 22 Nm
Remove AC manifold line from Supermanifold and remove AC manifold line assembly out of the vehicle
Remove Penta HVAC line from HVAC assembly

Note
2x bolts, 13mm, 22 Nm
Remove nut securing Penta HVAC line assembly to the Supermanifold plate

Note
1x nut, 13mm, 27 Nm, Located under multi-system beam
Remove Penta HVAC line from the Supermanifold plate

Note
Located under multi-system beam, Move line rearward until Penta HVAC line stud clears Supermanifold plate, Place rag underneath line
Remove Penta HVAC line from vehicle

Note
Negotiate line around coolant reservoir
Remove the bolts securing the supermanifold to the multi-system beam and remove the Supermanifold from the vehicle

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Rotate the Supermanifold counter clockwise under the multi-system beam, Support from underneath and at reservoir
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

Install

Install the Supermanifold into the vehicle and install the bolts securing the Supermanifold to the multi-system beam

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Rotate the Supermanifold clockwise under the multi-system beam, Support from underneath and at reservoir, Hand start bolts to Supermanifold
Connect the supermanifold harness from the front controller

Note
1x connector
Connect chiller to battery hose from supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect the HV battery return hose from the Supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect powertrain supply hose from supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect the sensor for the powertrain supply hose

Note
1x locking electrical connector, Engage locking tab
Remove 3 female plugs at the inlet, outlet, & bypass hoses

Note
3x female plugs
Connect the radiator inlet hose from the Supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect the radiator outlet hose from the Supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Connect the powertrain bypass hose from the Supermanifold

Note
Perform a push-pull-push test to make sure the hose is fully seated. Do not wiggle the hose at the connection.
Replace the seal washers to the Penta HVAC line on the AC manifold side

Note
5x seal washers, Lube seal washers with ND-11 oil
Replace the seal washers to the Penta HVAC line on the HVAC side

Note
5x seal washers, Lube seal washers with ND-11 oil
Position Penta HVAC line into vehicle

Note
Negotiate around coolant reservoir
Install Penta HVAC line from HVAC assembly

Note
2x bolts, 13mm, 22 Nm
Install Penta HVAC line to the Supermanifold plate

Note
Located under multi-system beam, Ensure Penta HVAC line stud clears Supermanifold plate before engaging pipes
Install Penta HVAC line assembly nut to the Supermanifold plate

Note
1x nut, 13mm, 27 Nm, Located under multi-system beam
Position AC compressor bracket assembly into vehicle and secure AC compressor assembly to multi-system beam

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
Torque AC compressor bracket bolts to multi-system beam

Note
2x bolts, 15mm, 31 Nm
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
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
Install fastener securing AC compressor HV harness bracket to AC compressor

Note
1x bolt, 13mm, 9 Nm
Install AC compressor ground strap

Note
1x bolt, T25, 7 Nm
Secure PT coolant pump onto AC compressor bracket

Note
Slide pump assembly onto compressor lower bracket
Install clip securing the coolant hose to the AC compressor bracket

Note
1x fir tree clip
Replace seal washers for supermanifold to compressor AC line on supermanifold side

Note
2x seal washers, Lube seal washers with ND-11 oil
Install supermanifold to compressor AC line onto supermanifold

Note
1x bolt, 13mm, 22 Nm, Hand start bolt to prevent stripped threads
Replace seal washer on supermanifold to compressor AC line assembly on compressor discharge line

Note
1x seal washer, Lube seal washers with ND-11 oil
Replace seal washer on supermanifold to compressor AC line assembly on compressor suction line

Note
1x seal washer, Lube seal washers with ND-11 oil
Install supermanifold to compressor discharge line to compressor

Note
1x nut, 13mm, 22 Nm
Install supermanifold to compressor suction line to compressor

Note
1x nut, 13mm, 22 Nm
Position LV battery into vehicle

Note
Position LV battery to the left and allow space for HEPA cover to be installed
Install HEPA filter assembly cover

Note
2x tabs, 2x datums, 2x slots, Maneuver cover down and under V-brace cross member, Fully engage seal and locking tabs
Secure air quality sensor connection

Note
1x connector
Install fasteners securing LV battery to multi-system beam

Note
3x bolts, 10mm, 9 Nm, 2x datums, Shift into position and install fasteners
Install clip securing the supermanifold to battery pump supply hose onto LV battery

Note
1x clip
Connect First Responder Loop and LV battery connector

Note
2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
1. Unlock the gateway. See Gateway (Unlock).
2. On the touchscreen, tap Thermal > Actions, ensure that the indicators are green and read Ready for Fill/Drain.
Power off vehicle from center display

Note
Via Controls > Safety & Security > Power Off
Disconnect LV battery connector and First Responder Loop

Note
2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
Reconnect AC hoses to vehicle
Perform system vacuum and refrigerant refill

Note
Select 20 mins of Vacuum, Recharge refrigerant to car's specs, add oil quantity as needed, select both HP and LP for charging
Remove AC hoses from vehicle
Use oil injector to add measured amount of oil back to the system

Note
Use calculated oil lost measurement and add new ND-11 oil into the system, If more than 30 mL drained out during recovery refer to drained oil loss chart, Some machines come with oil injection unit integrated
Install caps onto AC ports

Note
2x caps
Remove coolant bottle cap
Place empty coolant container into front storage area
Fill container with at least 15L of coolant
Place filled coolant container into front storage area
Install vacuum refill cap onto coolant bottle assembly
Setup coolant refill tool

Note
Verify all valves on refill tool are in the closed position, See image for clarity
Install vacuum refill hose into refill cap on coolant bottle

Note
Perform push-pull-push test to verify hose is fully installed
Place refill hose inside filled coolant container

Note
Make sure hose end is fully submerged into coolant
Position overflow hose into empty container
Connect shop air supply to coolant refill tool

Note
If not already done, Verify refill valve is set to off
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
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
Once the gauge reads zero, close the coolant refill valve
Remove coolant refill hose from coolant container
Remove coolant overflow hose from coolant container
Remove vacuum refill hose from refill cap on coolant bottle
Remove vacuum refill tool cap
Remove coolant refill tool from vehicle
Remove both coolant containers from inside underhood area
Connect First Responder Loop and LV battery connector

Note
2x connectors Secure FRL first, Seat LV battery connection and push black connector lock inwards to secure, Engage green locking tab when fully seated
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
1. UPDATE_CAN-REDEPLOY
  via Service Mode Plus:
  Drive Inverter Replacement ➜ Drive Inverter DIRE1L Replacement ➜ CAN Redeploy
  Drive Inverter Replacement ➜ Drive Inverter DIRE1R Replacement ➜ CAN Redeploy
  Drive Inverter Replacement ➜ Drive Inverter DIRE2 Replacement ➜ CAN Redeploy
  Drive Inverter ➜ Front Drive Inverter Replacement ➜ CAN Redeploy
  Drive Inverter ➜ Rear Drive Inverter Replacement ➜ CAN Redeploy
  Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ CAN Redeploy
  Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ CAN Redeploy
  Drive Unit ➜ Front Drive Unit Replacement ➜ CAN Redeploy
  Drive Unit ➜ Rear Drive Unit Replacement ➜ CAN Redeploy
  Thermal ➜ HVAC ➜ CAN Redeploy
  chassis ➜ DPB Post Replacement ➜ CAN Redeploy
  chassis ➜ ESP Post Replacement ➜ CAN Redeploy
  chassis ➜ IDB Post Replacement ➜ CAN Redeploy
  chassis ➜ RCU Post Replacement ➜ CAN Redeploy
  chassis ➜ ESP Replacement Panel ➜ CAN Redeploy
  chassis ➜ IBST Replacement Panel ➜ CAN Redeploy
  via Toolbox:(link)
2. PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAIN
  via Service Mode:
  Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
  Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
  Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
  via Service Mode Plus:
  Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
  Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
  Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
  Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
  Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
  Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
  via Toolbox:(link)
3. Tap Thermal > Actions > Thermal Configurations > coolantPumpType to inspect the current coolant pump configuration. If the configuration is not DUAL_MIX, change it to DUAL_MIX.
4. TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATION
  via Service Mode:
  Thermal ➜ Actions ➜ Run Coolant Pumps Identification
  Thermal ➜ Coolant System ➜ Pump Identification
  via Toolbox:(link)
  Note
  Select ‘X’ at top right of window to close once complete, Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
5. TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
  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
  via Toolbox:(link)
  Note
  Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required, Select ‘X’ at top left of window to close once complete
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
Blow off any residual coolant
Remove coolant catcher from under vehicle
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle

Note
9x bolts, 10mm, 6 Nm
Install clips securing front aero shield

Note
5x push clips
Lower vehicle until tires are touching the ground
Install frunk assembly

Note
4x bolts, 10mm, 5 Nm
Install frunk carpet

Note
Verify carpet is properly seated under the seal
Install frunk access panel

Note
3x clips, 3x hooks, 1x connector
Install front underhood apron

Note
7x clips
Install RH underhood apron

Note
10x clips
Install LH underhood apron

Note
10x clips
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line
Install coolant bottle cap
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
1. TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Service Mode:Thermal ➜ Refrigerant System ➜ Commission Heat Pumpvia Service Mode Plus:Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioningvia Toolbox:(link)
2. TEST-SELF_VCRIGHT_X_HVAC-PERFORMANCE-FACTORY-HRLvia Toolbox:(link)
3. TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Service Mode:Thermal ➜ Actions ➜ Test Thermal Performance
  via 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
  via Toolbox:(link)
Exit Service Mode or disconnect the laptop if applicable (see 0005 - Service Modes).
Install rear underhood apron

Note
8x clips
Close hood
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Raise LH front window
Close LH front door

2021+ Model S Service Manual

Supermanifold (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3