2025-12-18

A/C Compressor and Supermanifold (Remove and Replace)

Correction code 18203012 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 wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2025-12-18: Released new procedure.
Informational PurposesAn informational icon, calling your attention
Note
This is the preferable procedure to replace the supermanifold and compressor after a mechanical failure of the compressor which lead to debris in the A/C system. This procedure uses the Heat Pump HVAC Debris Flush Adapter 1838504-00-B to flush both A/C lines and the HVAC assembly so that the HVAC assembly and the A/C lines can be reused. If only the Debris Flush Adapter 1838504-XX-A is available, use the procedure described in Compressor, Supermanifold, and A/C Lines (Remove and Replace).
Informational PurposesAn informational icon, calling your attention
Note
This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate activity to the Service Visit.

Remove

  1. Set up the A/C machine.
  2. Raise and support the vehicle.
  3. Open all four doors and lower the windows.
  4. Enable Service Mode. See Service Mode (Enable and Disable).
  5. On the touchscreen, tap Service Mode > Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant + Refrigerant) and tap Run to start the "Start Thermal Fill Drain (Coolant & Refrigerant)" routine.
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  7. Disconnect LV power. See LV Power (Disconnect and Connect).
  8. Perform the vehicle HV disablement procedure. See GUID-A5616D0C-FC37-45A5-BC7A-6A03120EB2D4.html.
  9. Place coolant catcher below the RH front of the vehicle.
  10. Remove the wiper module. See Wiper Module (Remove and Replace).
  11. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
  12. Remove the LV battery. See Battery - LV (Remove and Replace).
  13. Disconnect the A/C compressor logic connector.
  14. Release the A/C compressor logic harness from the AC compressor HV harness bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip
  15. Release the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
  16. Disconnect the HV harness connector from the A/C compressor.
  17. Remove the bolt that attaches the A/C compressor ground strap.
  18. Release the clip that attaches the coolant hose to the A/C compressor bracket.
  19. Release the PT coolant pump from the A/C compressor bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide pump assembly away from compressor off the lower bracket.
  20. Remove the coolant reservoir cap.
  21. Disconnect the powertrain bypass hose from the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    This will drain the coolant reservoir.
  22. Disconnect the radiator outlet hose from the supermanifold.
  23. Disconnect the radiator inlet hose from the supermanifold.
  24. Install 3 male plugs into the coolant ports at front of the supermanifold and 3 female plugs at the removed hoses.
  25. Disconnect the sensor for the powertrain supply hose.
  26. Disconnect the PT supply hose from the supermanifold.
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    Note
    Spring clip is accessible from the front of the supermanifold.
  27. Disconnect the HV battery return hose from the supermanifold.
  28. Disconnect the chiller to battery hose from the supermanifold.
  29. Install 3 male plugs into the coolant ports at the rear of the supermanifold and 3 female plugs at the removed hoses.
  30. Disconnect the supermanifold harness connector from the front controller.
  31. Remove the A/C machine hoses from the vehicle.
  32. Release the vacuum from the A/C lines.
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    Note
    Carefully depress the schrader valves to release the vacuum from the A/C lines.
  33. Remove the nut that attaches the suction line to the compressor.
  34. Remove the nut that attaches the discharge line to the A/C compressor.
  35. Remove the A/C compressor HV harness from the A/C compressor and move it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the A/C compressor HV harness bracket towards the front of the vehicle. Lift the bracket up to clear the upper bracket mount. Carefully set harness and bracket aside.
  36. Remove the bolts (x2) that attach the A/C compressor bracket to the multi-system beam and remove the A/C compressor and A/C compressor bracket from the vehicle.
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    Note
    Support the A/C compressor while removing the bolts.
  37. Remove the bolt that attaches the supermanifold to compressor A/C line to the supermanifold.
  38. Remove the A/C manifold line from the supermanifold.
  39. Remove the supermanifold to HVAC line from the HVAC assembly.
  40. Remove the nut that attaches the supermanifold to HVAC line assembly to the Supermanifold.
  41. Remove the supermanifold to HVAC line from the Supermanifold.
  42. Remove the supermanifold to HVAC A/C line from the vehicle.
  43. Remove the bolts )x2) that attach the supermanifold to the multi-system beam, and then remove the supermanifold from the vehicle.
  44. Document the old and new part numbers and serial numbers for the supermanifold.
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    Note
    Document part and serial numbers into the repair order.
  45. Replace the seal washers on the supermanifold to HVAC A/C line assembly on the supermanifold side.
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    Note
    1111740-00-A WASHER,3/4,STEEL ZN,SEAL (x1), 1111738-00-A WASHER,1/2,STEEL ZN,SEAL (x1), 1111737-00-A WASHER, 3/8, STL ZN, SEAL (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate new seal washers with ND-11 oil.
  46. Replace the seal washers on supermanifold to HVAC A/C line assembly on the HVAC side.
    Informational PurposesAn informational icon, calling your attention
    Note
    1111740-00-A WASHER,3/4,STEEL ZN,SEAL (x1), 1111738-00-A WASHER,1/2,STEEL ZN,SEAL (x1), 1111737-00-A WASHER, 3/8, STL ZN, SEAL (x3).
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with ND-11 oil.
  47. Install the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
  48. Install the -B adapter to the A/C lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    1838504-00-B Heat Pump HVAC Debris Flush Adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach supermanifold to compressor A/C line onto the -B adapter, then attach the supermanifold to HVAC A/C line onto the -B adapter.
  49. Install the A/C flush adapters onto the A/C manifold to compressor A/C line.
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    Note
    Install the flush adapters onto the suction and discharge lines on the compressor side. Leave seal washers on AC manifold line. Inspect o-rings and replace if damaged. Use 13 mm nuts from compressor to attach the flush adapters.
  50. Flush the A/C lines and HVAC. See #TASK_FQ5_BM4_HHC__GUID-EB9B4D30-8910-49FF-960E-B53DFBC54F18 or #TASK_FLUSH__GUID-FD2A82E6-105A-482A-8483-888457F0F7DC.

Flush HVAC system with Snap-On A/C Machine

  1. Connect the A/C machine hoses to the flush adapters.
  2. Connect Snap on A/C machine hoses to A/C flush adapters and run the full or fast flush procedure by selecting Menu > > Num 4 > OK > OK.
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    Note
    Flush procedure runs for approximately 40 minutes, minimum of 6 kg of refrigerant needed in tank to run system flush procedure.
  3. After flush is complete, disconnect the A/C machine hoses from the A/C flush adapters.
  4. Stop flushing on the A/C machine when flushing is complete.
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    Note
    Fast flush is 40 minutes, full flush is 1 hour and 40 minutes.
  5. Disconnect the A/C machine lines from the flush adapter and remove the flush adapter from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the supermanifold to HVAC A/C line attached to the HVAC case.

Flush HVAC system with Waeco A/C Machine

  1. Connect the A/C machine hoses to the flush adapters.
  2. Set up flush kit to A/C machine.
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    Note
    Attach the flush kit to the Waeco A/C machine. 2x bolts, 8mm, 1x Nyloc nut.
  3. Inspect the liquid line filter drier marking.
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    Note
    Mark the filter before every flush with paint marker, replace the filter after 10 flushes.
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    Note
    If replacement of the filter is not yet necessary, go to step #TASK_FLUSH__GUID-3C3235D2-1FCE-476D-A030-E3B40F3423D5.
  4. Remove the liquid inline filter drier
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    Note
    Remove the filter from the container (the grey filter attached to the flush unit) PR052FM, Good to re-use copper o-ring, use hand force no tools
  5. Replace the liquid inline filter drier (the grey filter attached to the flush unit) PR052FM
    Informational PurposesAn informational icon, calling your attention
    Note
    1x new filter, 2x new copper sealing rings, Wear appropriate PPE, Swap the nipple from old to new filter, Install copper sealing ring between connections, Do not over tighten, hand tight, due to copper line Ensure old sealing was removed before installing new filter, use pick tool to remove copper ring if needed
  6. Connect the low pressure hose from the A/C machine to the quick connector of the filter
  7. Connect A/C machine hoses to A/C flush adapters and flush the HVAC case and A/C lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    If one or more of the alerts mentioned in step#YGD_VMS_Q1C__GUID-E9DA8AD3-220D-4FEA-992A-8DE1C3AF8295 are present, choose Full flushing. If no alerts are present, choose Fast flushing.
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    Note
    Fast flush procedure runs for approximately 40 minutes, full flush runs around 1 hours 40 minutes. Must use A/C Service Machine WAECO ASC 5500G RPA R1234YF. Minimum of 6 kg of refrigerant needed in tank to run system flush procedure. Press Enter =>Other Selections =>Enter =>Flushing =>Enter =>Enter =>Enter =>=>Full Flushing =>Enter
  8. Press STOP on the machine after flush is complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    Fast flush is 40 minutes, full flush is 1 hour and 40 minutes.

Install

  1. Remove the -B flush adapter from the A/C lines.
  2. Install a new NVH blanket onto the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install the new NVH blanket. Put the NVH acoustic cover down with the adhesive side facing up. Align the cut outs of the NVH acoustic cover to the suction port on the A/C compressor. Install the NVH acoustic cover around the suction port on the A/C compressor, then continue to wrap the NVH acoustic cover around the compressor.
  3. Install the bolts (x3) that attach the A/C compressor bracket to the new A/C compressor.
  4. Install the supermanifold to the vehicle, and then install the bolts (x2) that attach the supermanifold to the multi-system beam.
  5. Connect the supermanifold harness connector to the front controller.
  6. Remove the 3 female plugs from the battery, battery return, & supply hoses.
  7. Connect the chiller to battery hose to the supermanifold.
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    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  8. Connect the HV battery return hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  9. Connect the powertrain supply hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  10. Connect the sensor for the powertrain supply hose.
  11. Remove the 3 plugs from the inlet, outlet, & bypass hoses.
  12. Connect the radiator inlet hose to the supermanifold .
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  13. Connect the radiator outlet hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  14. Connect the powertrain bypass hose to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test to make sure that the hose is fully seated.
  15. Install the supermanifold to HVAC line to the supermanifold.
  16. Install the nut that attaches the supermanifold to HVAC line assembly nut to the Supermanifold.
  17. Position the A/C compressor bracket assembly into the vehicle and then install the bolts (x2) that attach the A/C compressor assembly to the multi-system beam.
  18. Position the A/C compressor HV harness onto the A/C compressor for installation.
  19. Connect HV harness connector to the A/C compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    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
  20. Install the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
  21. Install the bolt that attaches the A/C compressor ground strap.
  22. Install the clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  23. Connect the A/C compressor logic connector.
  24. Install the PT coolant pump onto the A/C compressor bracket.
  25. Install the clip that attaches the coolant hose to the A/C compressor bracket.
  26. Replace seal washers for supermanifold to compressor A/C line on the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    1111738-00-A WASHER,1/2,STEEL ZN,SEAL (x1), 1111740-00-A WASHER,3/4,STEEL ZN,SEAL (x1).
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate seal washers with ND-11 oil.
  27. Install the bolt that attaches the supermanifold to compressor A/C line to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start the bolt to prevent stripped threads.
  28. Remove the transportation plugs from the new A/C compressor
  29. Replace the seal washer on the supermanifold to compressor A/C line assembly on the compressor discharge line.
    Informational PurposesAn informational icon, calling your attention
    Note
    1111738-00-A WASHER,1/2,STEEL ZN,SEAL.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal washers with ND-11 oil.
  30. Replace the seal washer on the supermanifold to compressor A/C line assembly on the compressor suction line.
    Informational PurposesAn informational icon, calling your attention
    Note
    1111740-00-A WASHER,3/4,STEEL ZN,SEAL.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the seal washer with ND-11 oil.
  31. Install the nut that attaches the supermanifold to compressor discharge line to the compressor.
  32. Install the nut that attaches the supermanifold to compressor suction line to the compressor.
  33. Install the LV battery. See Battery - LV (Remove and Replace).
  34. Connect LV power. See LV Power (Disconnect and Connect).
  35. On the touchscreen, tap Service Mode > Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant + Refrigerant) and tap Run to start the "Start Thermal Fill Drain (Coolant & Refrigerant)" routine.
  36. Power off vehicle via the touchscreen.
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    Note
    Via Controls > Safety & Security > Power Off
  37. Disconnect LV battery connector and First Responder Loop
  38. Perform a vacuum test and recharge the A/C system refrigerant. See A/C Refrigerant (Recovery and Recharge).
  39. Perform system vacuum and refrigerant refill
  40. Perform a cooling system vacuum refill. See Cooling System (Vacuum Refill).
  41. Connect a low voltage maintainer. See LV Maintainer (Connect and Disconnect).
  42. Enable Service Mode Plus. See Service Mode Plus.
  43. Run the routine for new compressor type.
    Informational PurposesAn informational icon, calling your attention
    Note
    On the touchscreen, touch Thermal > Thermal Configurations > compressorType, and then select the correct compressor type. For additional details on configuration changes, see toolbox article 5696900.
  44. Run ODIN routine PROC_ICE_X_SAFE-SET-VEHICLE-CONFIGSvia Toolbox: (link)
  45. Reinstall the vehicle software. See Firmware Reinstall - Touchscreen.
  46. Connect the LV battery connector, and then remove LV maintainer. See LV Maintainer (Connect and Disconnect).
  47. Select "Stop Thermal Fill Drain" through the touchscreen.
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    Note
    Touch Thermal > Refrigerant System > Stop Thermal Fill Drain, touch Run. Close once routine is completed.
  48. Select "Run Coolant Pump Identification" using the touchscreen.
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    Note
    Touch Thermal > Coolant System > Pump Identification, touch Run. Close once routine passed.
  49. Perform a coolant air purge. See Cooling System (Partial Refill and Bleed).
  50. Install the wiper module. See Wiper Module (Remove and Replace).
  51. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  52. Inspect coolant level and top off as necessary.
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    Note
    Make sure that the fluid level is at the Max line.
  53. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  54. Install the underhood storage unit carpet.
  55. Install the underhood storage unit access panel.
  56. Install the front underhood apron.
  57. Perform "Reset Compressor P-Metric" using the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Thermal > Refrigerant System > Reset Compressor P-Mode, and then touch Run. Close once routine is completed.
  58. Perform "Heat Pump Commissioning" using the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Thermal > Refrigerant System > Run Heat Pump Commissioning, and then touch Run. Close once routine is completed.
  59. Test HVAC Performance using the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Thermal > Actions > Test HVAC performance, and then touch Run. Close once routine is completed.
  60. Test Thermal Performance using the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Thermal > Actions > Test Thermal Performance, and then touch Run. Close once routine is completed
  61. Exit Service Mode.
  62. Calibrate LH and RH Falcon Wing doors through the touchscreen.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch Controls > Calibrate Doorsand then hold on to Calibrate Doors until Calibration Complete is displayed.