06/11/2024 06:49:50

Chiller (Remove and Replace)

Correction code 184016022.20 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.

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

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
Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Open LH front door
Lower LH front window
Turn Off the AC and Blower motor
Place vehicle in service mode with touchscreen

Note
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
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 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 >HP> 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
Remove the underhood storage unit. See .
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
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 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
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
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
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
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 electronic expansion valve chiller connector

Note
1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
Release locking tab at bottom of chiller expansion valve coil and remove expansion valve coil from expansion valve

Note
1x locking tab, Pull EXV coil towards front of vehicle
Remove fasteners securing chiller to Supermanifold

Note
4x bolts, 8mm, 8 Nm
Slightly release chiller and allow excess coolant to drain

Note
Slightly release RH side of chiller and allow excess coolant to drain, Leave AC ports intact to Supermanifold while coolant drains to avoid cross contamination
Remove chiller from Supermanifold
Remove chiller gasket from Supermanifold

Note
1x gasket, Discard after removal

Install

Install chiller gasket into Supermanifold

Note
1x gasket, Install new gasket
Install chiller to Supermanifold and install fasteners hand tight

Note
Lubricate o-rings with ND-11 oil, Verify chiller is fully seated on Supermanifold before installing fasteners, Torque at later step
Torque fasteners securing chiller to Supermanifold in sequence

Note
4x bolts, 8mm, 8 Nm, Torque chiller in the following sequence, Chiller mount 1, Chiller mount 4, Chiller mount 2, Chiller mount 3
Install electronic expansion valve chiller coil

Note
Align locking tab to Supermanifold, Perform push pull test and verify coil properly seated
Connect electronic expansion valve chiller connector

Note
1x 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 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)
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 right 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
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, Putting vehicle into drive state will stop this routine, Monitor levels as required
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): TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONING

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

Chiller (Remove and Replace)

Remove

Install

Figure 1

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Figure 3