2025-08-26

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

Correction code 18401802 1.26 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 ServiceManualFeedback@tesla.com. 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: Added step to set pump type configuration to DUAL_MIX, removed/replaced several steps that use Garage.

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

Check Firmware version on the touchscreen.

Note
Firmware package installed must be 2021.36 or above for vehicle configuration update and Toolbox routine
Raise and support vehicle

Note
Prepare to raise vehicle, Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads
Place vehicle in service mode plus.
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes):
PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-COOLANT
via Toolbox: (link)via Service Mode Plus:
Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Start Fluid Fill/Drain
Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
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
Open hood

Note
Via Center Display > Controls > Frunk Open
Power off vehicle from center display

Note
Via Controls > Safety & Security > Power Off
Remove rear underhood apron

Note
8x clips
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
Remove LH underhood apron

Note
10x clips
Remove RH underhood apron

Note
10x clips
Remove front underhood apron

Note
7x clips
Remove frunk access panel

Note
3x clips, 3x hooks, 1x connector
Remove frunk carpet
Remove frunk assembly

Note
4x bolts, 10mm, 5 Nm
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
Release upper connections on the front controller

Note
2x locking connectors, Push in locking tabs and lift levers to release
Release LH middle connection on the front controller

Note
1x locking connector, Push in locking tab and lift lever to release
Release RH middle connections on the front controller

Note
2x locking connectors, Slide locking mechanism outwards to release
Release lower connections on the front controller

Note
2x locking connectors, Slide red locking tab outwards to release
Remove bolt securing front controller ground cable

Note
1x bolt, 10mm, 10 Nm
Remove bolts securing front controller

Note
3x bolts, 10mm, 10 Nm
Remove front controller from vehicle and release ground cable from multi system beam

Note
2x locating tabs, 1x ground cable
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
Place absorbent material on top of front drive unit and under coolant hoses at rear of supermanifold
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, Plug supermanifold and powertrain supply hose
Release thermal harness from Supermanifold

Note
1x fir clip, 1x clip
Release thermal harness from powertrain coolant pump and chiller coolant pump

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
Release chiller coolant pump from supermanifold

Note
4x screws, T20, 1.8 Nm
Remove chiller coolant pump from Supermanifold

Note
Make sure both o-rings (inner purple, and outer black) come off with old pump

Install

Install chiller coolant pump

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
Secure chiller coolant pump tp supermanifold

Note
4x screws, T20, 1.8 Nm
Secure thermal harness to powertrain coolant pump and chiller coolant pump

Note
2x locking electrical connectors, Route thermal bar harness between upper powertrain coolant pump and lower chiller coolant pump, Ensure connector locks fully engaged
Secure thermal harness to Supermanifold

Note
1x fir clip, 1x clip
Secure powertrain supply hose to supermanifold

Note
1x spring clip, Remove all plugs, 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 absorbent material on top of front drive unit and from under coolant hoses at rear of supermanifold
Clean area and wipe away any residual fluid
Position front controller for installation and position ground cable

Note
2x locating tabs, 1x ground cable
Install bolts securing front controller

Note
3x bolts, 10mm, 10 Nm. Start with the side bolt
Install bolt securing front controller ground cable

Note
1x bolts, 10mm, 10 Nm
Secure lower connections on the front controller

Note
2x locking connectors, Engage red locking tab
Secure RH middle connections on front controller

Note
2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage
Secure LH middle connection for front controller

Note
1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
Secure upper connections for the front controller

Note
2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
Install frunk assembly

Note
4x bolts, 10mm, 5 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
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. PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAIN
  via Toolbox: (link)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
  Note
  Select ‘X’ at top right of window to close once complete
2. 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.
3. TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATION
  via Toolbox: (link)via Service Mode:
  Thermal ➜ Actions ➜ Run Coolant Pumps Identification
  Thermal ➜ Coolant System ➜ Pump Identification
  Note
  Select ‘X’ at top right of window to close once complete, Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
4. TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE
  via Toolbox: (link)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
  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
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
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 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 fully

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
Remove vehicle from lift

Note
Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
Inspect coolant level and top off as necessary

Note
Ensure that the fluid level is at the Max line, Top off fluid as required
Install coolant bottle cap
Install rear underhood apron

Note
8x clips
Close hood

Note
Press firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
Exit Service Mode or disconnect the laptop if applicable (see 0005 - Service Modes).
Raise LH front window
Close LH front door

Model S Service Manual

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

Remove

Install

Figure 1

Figure 2

Figure 3