11/11/2024 06:51:05

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. 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.

2023-04-13: 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. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
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
Remove the underhood storage unit. See .
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
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
Connect A/C machine to power and switch on

Note
Touch time only, Machine will run various background tasks, Wait until Main Menu comes up before continuing
Skip the following panels when prompted

Note
Use selections indicated in pictures
Perform hose flush

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
Turn Off the AC and Blower motor
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN

Note
Select ‘X’ at top left of window to close once complete, Verify indicator displays green for both Coolant and Refrigerant readiness, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again
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
Verify operation of multimeter

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing LV battery, Touch lightly and do not damage terminals
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
Remove clips securing mid aero shield

Note
4x push clips
Remove bolts securing mid aero shield and remove from vehicle

Note
16x bolts, 10mm, 6 Nm
Install amp clamp to LH RDU HV harness

Note
Verify meter is zeroed out before performing measurement, Measure single cable. Verify ammeter is installed in correct direction._x000A__x000A_ If current > 0.5A do not proceed with disconnecting HV connector. In this case, start vehicle electrical isolation again to make sure that all was properly shut down. Escalate for assistance as required_x000A__x000A_If current < 0.5A, OK to disconnect and check voltage at HV plug on the battery side.
Remove all items from pockets and ensure not wearing metal items
Inspect HV insulating gloves

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
Put on HV insulating gloves and leather over gloves
Release LH RDU HV harness from HV battery

Note
1x connector, Hold down red locking tab and disengage the release lever, Do not force the release lever up
Verify no high voltage at LH rear RDU HV header

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Verify test equipment is rated CATIII or higher, 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
Secure LH RDU HV harness to battery pack

Note
1x connector, Verify lever is in the upright and open position, Carefully seat connector and allow lever to engage, Fully secure lever and verify red tab is locked, Do not damage any pins
Remove the leather glove protectors and HV insulating gloves
Apply Loctite 222 onto mid aero shield bolts and install fasteners securing mid aero shield to vehicle

Note
16x bolts, 10mm, 6 Nm
Install clips securing mid aero shield

Note
4x push clips
Remove clips securing front aero shield

Note
5x push clips
Remove bolts securing front aero shield and remove from vehicle

Note
9x bolts, 10mm, 6 Nm
Place coolant catcher below RH front of vehicle
Lower vehicle until tires are touching the ground

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Release clip securing the supermanifold to battery pump supply hose from LV battery

Note
1x clip
Remove fasteners securing the LV battery and move aside

Note
3x bolts, 10mm, 9 Nm, 2x datums, Take note of datums and carefully move assembly aside
Release air quality sensor connection

Note
1x connector
Remove HEPA filter assembly cover

Note
2x tabs, 2x datums, 2x slots, , Be cautious and do not damage the mounting clips, Maneuver cover forward and up in front of V-brace cross member
Remove LV battery from vehicle
Remove caps from low side and high side AC ports

Note
2x caps
Connect hoses to vehicle and perform A/C recovery

Note
Connect couplers to vehicle, Note the amount of refrigerant and oil recovered, mark oil drain bottle oil level (use a piece of tape marking the fluid level), 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
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 AC hoses from vehicle
Remove nut securing supermanifold to compressor suction line to compressor and remove line

Note
1x nut, 13mm, 22 Nm
Remove nut securing supermanifold to compressor discharge line to compressor and remove line

Note
1x nut, 13mm, 22 Nm
Install AC flush adapters onto AC manifold to compressor line

Note
2x nuts, 13mm, 22 Nm, Install flush adapters onto suction and discharge lines on compressor side, Leave seal washers on AC manifold line, Inspect o-rings and replace if damaged, Use 13mm nuts from compressor to secure flush adapters
Connect AC machine hoses to AC flush adapters and run System Flush procedure

Note
Touch time only, System flush procedure runs for approximately 90 minutes, Must use Robinair 34988ni machine (R134a) to run system flush procedure, Minimum of 13lb of refrigerant needed in tank to run system flush procedure, On AC machine main menu click next, Click menu, Scroll down to system flush, Enter 30 min run time
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 the AC compressor bracket from the AC compressor

Note
3x bolts, 10mm, 9 Nm
Protect the LP and HP opening ports on the AC compressor

Note
Need to be fully covered when cleaning the AC compressor in next step
Remove NVH acoustic cover from AC compressor

Note
NVH acoustic cover must be removed to properly weigh compressor
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
Weigh compressor and reset compressor oil amount

Note
Weight measured in grams, Take note of the compressor weight, Add ND-11 oil through suction port of compressor until it weighs 7193 grams
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._x000A_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
Install the AC compressor bracket to the AC compressor

Note
3x bolts, 10mm, 9 Nm
Disconnect AC machine hoses from AC flush adapters
Remove AC flush adapters from supermanifold to compressor AC line assembly

Note
2x nuts, 13mm, 22 Nm
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 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 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

Install

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 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
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect the HV battery return hose from the Supermanifold

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect powertrain supply hose from supermanifold

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
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
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect the radiator outlet hose from the Supermanifold

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect the powertrain bypass hose from the Supermanifold

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
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
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
Reconnect AC hoses to vehicle
Perform AC vacuum and run leak test

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
Select "refrigerant charge" on AC machine

Note
Select the arrows under "refrigerant charge", Enter refrigerant amount of 1.02 kg (1020 g)
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): PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAIN

Note
Select ‘X’ at top left of window to close once complete
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE

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
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): UPDATE_CAN-REDEPLOY

Note
Select ‘X’ at top right of window to close once complete, Routine will state pass but update will continue to run in the background, UI will indicate status of update
Log into Tesla Garage

Note
https://garage.vn.teslamotors.com/vehicles
Enter vehicle VIN and select "Vitals" from drop down menu
Check Firmware version

Note
Firmware package installed must be 2021.36 or above for vehicle configuration update and Toolbox routine
Navigate to "CFG" tab on "Vitals" page
Check the coolant pump GTW configuration

Note
If the config is DUAL or DUAL_SAN_P4, change the config to DUAL_MIX – This is critical, since the Coolant Pump Identification will apply to this new config, If gateway configuration is already DUAL_MIX no further action required
Release IP service panel

Note
2x tabs, 4x datums, Release top tabs and slide rearward
Establish vehicle connection to Toolbox 3

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)
Select "Dashboards" tab, and select "Infotainment Dashboard"
Select "Vehicle Configuration"

Note
Configuration values should load automatically, if not select "Read Config" and "Run" to load
Scroll down to "coolantPumpType" and change to "Two coolant pumps installed, mixed pole pair batches"

Note
Click on current pump configuration, Select new pump configuration from drop down menu
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
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_COOLANT-PUMPS-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
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONING, click Run and allow routine to complete

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
Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine

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,
Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine

Note
Remove low side coupler from vehicle, Turn vehicle off, Verify Hose Equalize settings, Machine will chime once process is complete
Install caps onto AC ports

Note
2x caps
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE

Note
Select ‘X’ at top right of window to close once complete
Exit Service Mode

Note
Controls>Software select Exit Service Mode button
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

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Install the underhood storage unit. See .
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"

Model S Service Manual

Supermanifold (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3