01/04/2024 14:01:40

Expansion Valve - Liquid Cooled Condenser (Remove and Replace)

Correction code 18209502 1.70 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. Connect A/C machine to power and switch on
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only, Machine will run various background tasks, Wait until Main Menu comes up before continuing
  2. Skip the following panels when prompted
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    Note
    Use selections indicated in pictures
  3. Perform hose flush
    Informational PurposesAn informational icon, calling your attention
    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
  4. Open LH front door
  5. Lower LH and RH front windows
  6. Using laptop connect to vehicle with ethernet diag kit and Toolbox 3
  7. Select Actions tab and search for "Refrigerant"
  8. Select PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTSearch for routine in ToolboxStart Thermal Fluid Fill/Drain (Refrigerant only)Thermal / Refrigerant System - Start Refrigerant Fill/DrainThermal / Actions - Start Refrigerant Fill/Drain, click Run, and allow routine to complete
    Informational PurposesAn informational icon, calling your attention
    Note
    Select "x" at the top right of the window to close once complete, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again, Verify EXV positions are open 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
  9. Open hood
    Informational PurposesAn informational icon, calling your attention
    Note
    Via center display > Quick Controls > Frunk Open
  10. Power off vehicle via center display
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    Note
    Controls > Safety & Security > Power Off
  11. Remove rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips
  12. 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
  13. Remove RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp
  14. Remove LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp
  15. Remove front underhood apron
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    Note
    12x clips, 3 datums
  16. Remove frunk access panel
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    Note
    3x clips, 3x hooks, 1x connector
  17. Remove frunk carpet
  18. Remove frunk assembly
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    Note
    8x bolts, 10mm, 5 Nm
  19. Release RH wiper arm hose nozzle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose
  20. Release LH wiper arm hose nozzle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose
  21. Remove LH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  22. Remove RH wiper arm nut covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x cover
  23. Remove RH wiper arm nuts and release assembly
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    Note
    2x nuts, 15mm, 32 Nm, Do not flex wiper arm to remove
  24. Remove LH wiper arm nut and release assembly
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    Note
    1x nut, 15mm, 32 Nm, Do not flex wiper arm to remove, Lower the hood slightly to fit wiper arm removal tool
  25. Release cowl screen washer supply hose located above LH shock tower cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose
  26. Remove LH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clips
  27. Remove RH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clips
  28. Remove wiper cowl screen panel
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, Pull cowl up out of lower windshield channel
  29. Remove wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm, 1x connector, Rotate module forward and up to access connector
  30. Remove caps from low side and high side AC ports
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    Note
    2x caps
  31. Connect hoses to vehicle and perform A/C recovery
    Informational PurposesAn informational icon, calling your attention
    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
  32. Remove AC hoses from vehicle
  33. Remove nut securing supermanifold to compressor discharge line to compressor and remove line
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    Note
    1x nut, 13mm, 22 Nm
  34. Remove nut securing supermanifold to compressor suction line to compressor and remove line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 22 Nm
  35. Remove AC manifold line from Supermanifold and remove AC manifold line assembly out of the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 22 Nm
  36. Disconnect high pressure PT High sensor connector
    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
  37. Disconnect connector from electronic expansion valve recirc
    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
  38. Disconnect connector from electronic expansion valve liquid cooled condenser
    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
  39. Disconnect connector from the shut off valve liquid cooled condenser
    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
  40. Disconnect connector from the electronic expansion valve cabin condenser right
    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
  41. Disconnect connector from High pressure PT sub cool sensor
    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
  42. Disconnect connector from the electronic expansion valve cabin condenser left
    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
  43. Disconnect electronic expansion valve chiller connector
    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
  44. Disconnect connector from the electronic expansion valve evap
    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
  45. Position thermal sub harness assembly away from the supermanifold
  46. Release locking tab at bottom of liquid cooled condenser expansion valve coil and remove expansion valve coil from expansion valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking tab, Pull EXV coil towards front of vehicle
  47. Remove liquid cooled condenser expansion valve from Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x valve, 28mm, 19 Nm
  48. Install liquid cooled condenser expansion valve into Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x valve, 28mm, 19 Nm, Ensure old o-rings removed from supermanifold, Use ND-11 Oil to lubricate valve threads and o-rings, Thread expansion valve in by hand
  49. Install liquid cooled condenser expansion valve coil onto expansion valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide coil seal onto expansion valve, Do not lubricate coil seal, Properly align expansion valve coil locking tab to Supermanifold, Slide expansion valve coil over coil seal, Perform push pull test on expansion valve coil to ensure coil is properly latched
  50. Connect connector for the electronic expansion valve evap
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  51. Connect electronic expansion valve chiller connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  52. Connect connector for the electronic expansion valve cabin condenser left
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  53. Connect connector for the electronic expansion valve right
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  54. Connect connector to High pressure PT sub cool sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  55. Connect connector for the shut off valve liquid cooled condender
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  56. Connect connector for the electronic expansion valve liquid cooled condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  57. Connect connector for the electronic expansion valve recirc
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  58. Connect high pressure PT sensor connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x electrical connector, Engage locking tab
  59. Replace seal washer on supermanifold to compressor AC line assembly on compressor discharge line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x seal washer, Lube seal washers with ND-11 oil
  60. Replace seal washer on supermanifold to compressor AC line assembly on compressor suction line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x seal washer, Lube seal washers with ND-11 oil
  61. Replace seal washers for supermanifold to compressor AC line on supermanifold side
    Informational PurposesAn informational icon, calling your attention
    Note
    2x seal washers, Lube seal washers with ND-11 oil
  62. Install AC manifold line onto Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 13mm, 22 Nm, Inspect o-rings replace if damaged, Hand start bolt to prevent stripped threads
  63. Install nut securing supermanifold to compressor suction line to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 22 Nm, Inspect o-rings replace if damaged
  64. Install nut securing supermanifold to compressor discharge line to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 13mm, 22 Nm, Inspect o-rings replace if damaged
  65. Connect AC hoses to vehicle
  66. Perform AC vacuum and run leak test
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    Note
    Open valves, 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
  67. Perform AC recharge
    Informational PurposesAn informational icon, calling your attention
    Note
    Enter refrigerant and oil amount noted at AC recovery, Settings should match notes, Select Both Sides for charge, Select ND-11 MSX using bottle icon, Machine will chime once process is complete, Vehicle may be left unattended, If desired use the Dye Inject option to inject leak detection dye
  68. 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 upper locking tab when fully seated
  69. Re-establish vehicle connection to Toolbox 3
  70. Select "Actions" and search for "Stop Thermal"
  71. 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
  72. Select "Actions/Autodiag" and search for "Commissioning"
  73. Select TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGSearch for routine in ToolboxHeat Pump Thermal System CommissioningThermal / Refrigerant System - Run Heat Pump Commissioninghv / Front Drive Inverter Replacement - Heatpump commissioning, click Run, and allow routine to complete
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    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
  74. Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine
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    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,
  75. Proceed with Hose Equalize steps to complete AC recharge process and follow instructions displayed on AC Machine
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    Note
    Remove low side coupler from vehicle, Turn vehicle off, Verify Hose Equalize settings, Machine will chime once process is complete
  76. Install caps onto AC ports
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    Note
    2x caps
  77. Select Actions/Autodiag and search for "Thermal Performance"
  78. 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
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    Note
    Select "X" at top right of window to close once complete, If thermal test fails follow https://toolbox.teslamotors.com/articles/206000
  79. Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
  80. Power off vehicle via center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Safety & Security > Power Off
  81. 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
  82. Install wiper module
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm, 1x connector, Secure connector before install, Rotate module rearward and up into place
  83. Install wiper cowl screen panel
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, Secure cowl into lower windshield channel
  84. Secure cowl screen washer supply hose located above LH shock tower cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose
  85. Install LH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clips
  86. Install RH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clips
  87. Install RH wiper arm assembly and secure nuts
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 15mm, 32 Nm, Line up wiper to reference mark on windshield
  88. Install LH wiper arm assembly and secure nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 15mm, 32 Nm
  89. Secure LH wiper arm hose nozzle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, Hose is routed above the arm pivot
  90. Secure RH wiper arm hose nozzle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose, Hose is routed below the arm pivot
  91. Install RH wiper arm nut covers
    Informational PurposesAn informational icon, calling your attention
    Note
    2x cover
  92. Install LH wiper arm nut cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover
  93. Install frunk assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    8x bolts, 10mm, 5 Nm
  94. Install frunk carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify carpet is properly seated under the seal
  95. Install frunk access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 3x hooks, 1x connector
  96. Install front underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips, 3x datums
  97. Install LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2 datums
  98. Install RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips, 2x datums
  99. 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 upper locking tab when fully seated
  100. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips
  101. Close hood
  102. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
  103. Raise LH and RH front windows
  104. Close LH front door