01/04/2024 14:01:17

Chiller (Remove and Replace)

Correction code 18401602 2.94 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

Prepare to raise vehicle.

Note
Set air suspension to "Jack Mode", Position lift arm pads on vehicle jack pads, DO NOT position the lift arm pads under the battery or side rails, as shown in red.
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 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.
Open LH front door.
Lower LH and RH front windows.
Open hood.

Note
Via center display > Controls > Frunk Open.
Remove rear underhood apron.

Note
11x clips, 2x datums.
Remove RH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove LH underhood apron.

Note
11x clips, 2x datums, Remove brush clip at hinge cover first, Take note of clip at headlamp.
Remove front underhood apron.

Note
12x clips, 3 datums.
Remove frunk access panel.

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

Note
8x bolts, 10mm, 5 Nm .
Release RH wiper arm hose nozzle.

Note
1x hose.
Release LH wiper arm hose nozzle.

Note
1x hose.
Remove LH wiper arm nut cover.

Note
1x cover.
Remove RH wiper arm nut covers.

Note
2x cover.
Remove RH wiper arm nuts and release assembly.

Note
2x nuts, 15mm, 32 Nm, Do not flex wiper arm to remove.
Remove LH wiper arm nut and release assembly.

Note
1x nut, 15mm, 32 Nm, Do not flex wiper arm to remove, Lower the hood slightly to fit wiper arm removal tool.
Release cowl screen washer supply hose located above LH shock tower cover.

Note
1x hose.
Remove LH outer hood hinge cover.

Note
1x clips.
Remove RH outer hood hinge cover.

Note
1x clips.
Remove wiper cowl screen panel.

Note
4x push clips, Pull cowl up out of lower windshield channel.
Release IP service panel.

Note
2x tabs, 4x datums, Release top tabs and slide rearward.
Using laptop connect to vehicle with ethernet diag kit and Toolbox 3.

Note
Open Toolbox 3 website and establish connection to the vehicle. Media converter box is powered by laptop using USB, Ethernet connection will provide communication.
Select "Actions" and search for "Thermal".
Select "Start Thermal Fluid Fill/Drain", click "Run", and allow routine to complete.

Note
Enter '1' at 'coolant_fill' & 'refrigerant_fill' then 'Submit', Select "X" at top right of window to close once complete, For AC related repairs verify all EXV's are in proper position, For all coolant related repairs verify vehicle is in Series, Thermal Fluid Fill/Drain routine has a 5 hour timeout, Routine will continuously run and not end, 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 Coolant Loops is in Series Mode.
Power off vehicle via center display.

Note
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, Release red lock tab on FRL.
Remove wiper module.

Note
3x bolts, 10mm, 9 Nm, 1x connector, Rotate module forward and up to access connector.
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.
Remove AC hoses from vehicle.
Remove nut securing supermanifold to compressor discharge line to compressor and remove line.

Note
1x nut, 13mm, 22 Nm.
Remove nut securing supermanifold to compressor suction line to compressor and remove line.

Note
1x nut, 13mm, 22 Nm.
Remove AC manifold line from Supermanifold and remove AC manifold line assembly out of the vehicle.

Note
1x bolt, 13mm, 22 Nm.
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 .
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 .
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.
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.
Replace seal washers for supermanifold to compressor AC line on supermanifold side.

Note
2x seal washers, Lube seal washers with ND-11 oil.
Install AC manifold line onto Supermanifold.

Note
1x bolt, 13mm, 22 Nm, Inspect o-rings replace if damaged, Hand start bolt to prevent stripped threads.
Install nut securing supermanifold to compressor suction line to compressor.

Note
1x nut, 13mm, 22 Nm, Inspect o-rings replace if damaged.
Install nut securing supermanifold to compressor discharge line to compressor.

Note
1x nut, 13mm, 22 Nm, Inspect o-rings replace if damaged.
Remove female plugs from inlet, outlet, and bypass hoses.

Note
3x female plugs.
Connect the radiator inlet hose to the Supermanifold .

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated.
Connect the radiator outlet hose to the Supermanifold.

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated.
Connect the powertrain bypass hose to the Supermanifold.

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated.
Install vacuum refill cap onto coolant bottle assembly.
Place empty coolant container into front storage area.

Note
CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia.
Fill container with at least 15L of coolant.
Place filled coolant container onto coolant drain & fill cart.

Note
Do not place container with 15L of coolant on top of CFM fan shroud, Position cart as close as possible to front of vehicle.
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.
Position overflow hose into empty container.
Place refill hose inside filled coolant container .

Note
Make sure hose end is fully submerged into coolant.
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 shop air supply to coolant refill tool.

Note
If not already done, Verify refill valve is set to off.
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 cap from coolant bottle assembly.
Remove coolant refill tool from vehicle.

Note
Move coolant drain & fill cart away from vehicle.
Remove both coolant container and fender cover from inside underhood area.
Connect AC hoses to vehicle.
Perform AC vacuum and run leak test.

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.
Perform AC recharge.

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.
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 upper locking tab when fully seated.
Re-establish vehicle connection to Toolbox 3.

Note
Open Toolbox 3 website and establish connection to the vehicle.
Select "Actions/Autodiag" tab and search for "Purge".
Select TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE, click "Run", and allow routine to complete.

Note
Make sure vehicle is not in drive state, Routine 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, Top off fluid as required.
Install coolant bottle cap.
Blow off any residual coolant.
Select "Actions/Autodiag" and search for "Commissioning".
Select TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONING, click "Run", and allow routine to complete.

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.
Select "Actions/Autodiag" and search for "Thermal Performance".
Select TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCE, click "Run", and allow routine to complete.

Note
Select "X" at top right of window to close once complete.
Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit.
Install IP service panel.

Note
2x tabs, 4 datums, Slide forward engaging datums then secure tabs upward into IP.
Install wiper module.

Note
3x bolts, 10mm, 9 Nm, 1x connector, Secure connector before install, Rotate module rearward and up into place.
Install wiper cowl screen panel.

Note
4x push clips, Secure cowl into lower windshield channel.
Secure cowl screen washer supply hose located above LH shock tower cover.

Note
1x hose.
Install LH outer hood hinge cover.

Note
1x clips.
Install RH outer hood hinge cover.

Note
1x clips.
Install RH wiper arm assembly and secure nuts.

Note
2x nuts, 15mm, 32 Nm, Line up wiper to reference mark on windshield.
Install LH wiper arm assembly and secure nut.

Note
1x nut, 15mm, 32 Nm.
Secure LH wiper arm hose nozzle.

Note
1x hose, Hose is routed above the arm pivot.
Secure RH wiper arm hose nozzle.

Note
1x hose, Hose is routed below the arm pivot.
Install RH wiper arm nut covers.

Note
2x cover.
Install LH wiper arm nut cover.

Note
1x cover.
Install frunk assembly.

Note
8x bolts, 10mm, 5 Nm.
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
12x clips, 3x datums.
Install LH underhood apron.

Note
11x clips, 2 datums.
Install RH underhood apron.

Note
11x clips, 2x datums.
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 upper locking tab when fully seated.
Install rear underhood apron.

Note
11x clips, 2x datums.
Close hood.
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.
Install clips securing front aero shield.

Note
5x push clips.
Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle.

Note
9x bolts, 10mm, 6 Nm.
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".
Calibrate the rear doors.

Note
If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.

Model X Service Manual

Chiller (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3