29/05/2024 18:11:58

Pump - Coolant - Battery - Supermanifold (Remove and Replace)

Correction code 18401802 1.20 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.

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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. Log into Tesla Garage
  2. Enter vehicle VIN and select "Vitals" from drop down menu
  3. Check Firmware version
    Informational PurposesAn informational icon, calling your attention
    Note
    Firmware package installed must be 2021.36 or above for vehicle configuration update and Toolbox routine
  4. Navigate to "CFG" tab on "Vitals" page
  5. Check the coolant pump GTW configuration
    Informational PurposesAn informational icon, calling your attention
    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
  6. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
  7. Open LH front door
  8. Lower LH front window
  9. Place vehicle in service mode with touchscreen
    Informational PurposesAn informational icon, calling your attention
    Note
    Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
  10. Release IP service panel
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    Note
    2x tabs, 4x datums, Release top tabs and slide rearward
  11. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3
  12. Select "Dashboards" tab, and select "Infotainment Dashboard"
  13. Select "Vehicle Configuration"
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    Note
    Configuration values should load automatically, if not select "Read Config" and "Run" to load
  14. Scroll down to "coolantPumpType" and change to "Two coolant pumps installed, mixed pole pair batches"
    Informational PurposesAn informational icon, calling your attention
    Note
    Click on current pump configuration, Select new pump configuration from drop down menu
  15. Select "Apply Changes" and select "Run" to save updated configuration
    Informational PurposesAn informational icon, calling your attention
    Note
    Center display will reboot, Toolbox connection will be lost, Select ‘X’ at top right of window to close once complete
  16. Re-establish vehicle connection to Toolbox 3
  17. Select ‘Actions/Autodiag’ and search for ‘Thermal’
  18. Select "Start Thermal Fluid Fill/Drain (Coolant only)", click Run and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete, Verify vehicle is in Series via Garage > Vitals > HP tab > Coolant loops, Thermal Fluid Fill/Drain routine has a 5 hour limit, After 5 hours routine must be performed again
  19. Open hood
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    Note
    Via Center Display > Controls > Frunk Open
  20. Power off vehicle from center display
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    Note
    Via Controls > Safety & Security > Power Off
  21. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  22. Disconnect LV battery connector and First Responder Loop
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Lift up and release green locking tab, Pull black connector lock outwards to release connection
  23. Remove LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  24. Remove RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  25. Remove front underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  26. Remove frunk access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 3x hooks, 1x connector
  27. Remove frunk carpet
  28. Remove frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm
  29. Release clip securing the supermanifold to battery pump supply hose from LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  30. Remove fasteners securing the LV battery and move aside
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    Note
    3x bolts, 10mm, 9 Nm, 2x datums, Take note of datums and carefully move assembly aside
  31. Release air quality sensor connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  32. Remove HEPA filter assembly cover
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    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
  33. Remove LV battery from vehicle
  34. Release upper connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Push in locking tabs and lift levers to release
  35. Release LH middle connection on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Push in locking tab and lift lever to release
  36. Release RH middle connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Slide locking mechanism outwards to release
  37. Release lower connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Slide red locking tab outwards to release
  38. Remove bolt securing front controller ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  39. Remove bolts securing front controller
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    Note
    3x bolts, 10mm, 10 Nm
  40. Remove front controller from vehicle and release ground cable from multi system beam
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    Note
    2x locating tabs, 1x ground cable
  41. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  42. Remove clips securing front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips
  43. Remove bolts securing front aero shield and remove from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 6 Nm
  44. Place coolant catcher below RH front of vehicle
  45. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  46. Place absorbent material on top of front drive unit and under coolant hoses at rear of supermanifold
  47. Disconnect the sensor for the powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
  48. Disconnect powertrain supply hose from supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug supermanifold and powertrain supply hose
  49. Release thermal harness from Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir clip, 1x clip
  50. Release thermal harness from powertrain coolant pump and chiller coolant pump
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking electrical connectors, Do not push down on red tab, Pull red tab to disengage lock, Pull again to release connector, Move harness away from rear of supermanifold
  51. Release chiller coolant pump from supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    4x screws, T20, 1.8 Nm
  52. Remove chiller coolant pump from Supermanifold
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    Note
    Make sure both o-rings (inner purple, and outer black) come off with old pump
  53. Install chiller coolant pump
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    Note
    1x datum, Lubricate both O-rings with silicone lubricant, Align datum in supermanifold with cutout in pump, Seat pump fully into supermanifold, Do not use screws to pull pump into supermanifold
  54. Secure chiller coolant pump tp supermanifold
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    Note
    4x screws, T20, 1.8 Nm
  55. Secure thermal harness to powertrain coolant pump and chiller coolant pump
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking electrical connectors, Route thermal bar harness between upper powertrain coolant pump and lower chiller coolant pump, Ensure connector locks fully engaged
  56. Secure thermal harness to Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir clip, 1x clip
  57. Secure powertrain supply hose to supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove all plugs, Perform push-pull-push test to make sure hose is fully seated
  58. Connect the sensor for the powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Engage locking tab
  59. Remove absorbent material on top of front drive unit and from under coolant hoses at rear of supermanifold
  60. Clean area and wipe away any residual fluid
  61. Position front controller for installation and position ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locating tabs, 1x ground cable
  62. Install bolts securing front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 10 Nm. Start with the side bolt
  63. Install bolt securing front controller ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolts, 10mm, 10 Nm
  64. Secure lower connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Engage red locking tab
  65. Secure RH middle connections on front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage
  66. Secure LH middle connection for front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
  67. Secure upper connections for the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
  68. Install frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 5 Nm
  69. Remove coolant bottle cap
  70. Place empty coolant container into front storage area
  71. Fill container with at least 15L of coolant
  72. Place filled coolant container into front storage area
  73. Install vacuum refill cap onto coolant bottle assembly
  74. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  75. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  76. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  77. Position overflow hose into empty container
  78. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  79. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
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    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  80. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  81. Once the gauge reads zero, close the coolant refill valve
  82. Remove coolant refill hose from coolant container
  83. Remove coolant overflow hose from coolant container
  84. Remove vacuum refill hose from refill cap on coolant bottle
  85. Remove vacuum refill tool cap
  86. Remove coolant refill tool from vehicle
  87. Remove both coolant containers from inside underhood area
  88. Position LV battery into vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Position LV battery to the left and allow space for HEPA cover to be installed
  89. Install HEPA filter assembly cover
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 2x datums, 2x slots, Maneuver cover down and under V-brace cross member, Fully engage seal and locking tabs
  90. Secure air quality sensor connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  91. Install fasteners securing LV battery to multi-system beam
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm, 2x datums, Shift into position and install fasteners
  92. Install clip securing the supermanifold to battery pump supply hose onto LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  93. Connect First Responder Loop and LV battery connector
    Informational PurposesAn informational icon, calling your attention
    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
  94. Re-establish vehicle connection to Toolbox 3
  95. Select ‘Actions/Autodiag’ and search for ‘Thermal’
  96. Select ‘Stop Thermal Fluid Fill/Drain’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete
  97. Select ‘Actions/Autodiag’ tab and search for ‘Purge'
  98. Select ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start ’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    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
  99. Inspect coolant level and top off as necessary
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  100. Install coolant bottle cap
  101. Select ‘Actions/Autodiag’ and search for ‘Pump’
  102. Select TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATIONSearch for routine in ToolboxCoolant Pumps IdentificationThermal / Coolant System - Pump IdentificationThermal / Actions - Run Coolant Pumps Identification, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete, Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
  103. Select ‘Actions/Autodiag’ and search for ‘Thermal’
  104. Select ‘TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCESearch for routine in ToolboxHeat Pump Thermal System Performance Test’, click ‘Run’, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top right of window to close once complete
  105. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
  106. Install IP service panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP
  107. Install frunk carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify carpet is properly seated under the seal
  108. Install frunk access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 3x hooks, 1x connector
  109. Install front underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    7x clips
  110. Install RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  111. Install LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  112. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  113. Close hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
  114. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  115. Remove coolant catcher from under vehicle
  116. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 6 Nm
  117. Install clips securing front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips
  118. Lower vehicle fully
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  119. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  120. Raise LH front window
  121. Close LH front door