01/04/2024 14:00:45

Actuator - Octovalve (Remove and Replace)

Correction code 18209322 1.90 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.

Raise and support 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
Open LH front door
Lower LH and RH front windows
Open hood

Note
Via center display > Quick Controls > Frunk Open
Power off vehicle via center display

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

Note
11x 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 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

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1x hose
Release LH wiper arm hose nozzle

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1x hose
Remove LH wiper arm nut cover

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1x cover
Remove RH wiper arm nut covers

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2x cover
Remove RH wiper arm nuts and release assembly

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

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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

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1x clips
Remove wiper cowl screen panel

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4x push clips, Pull cowl up out of lower windshield channel
Release coolant hose from LV battery

Note
1x clip
Remove fasteners securing the LV battery and remove assembly

Note
3x bolts, 10mm, 9 Nm, 2x locators
Remove wiper module

Note
3x bolts, 10mm, 9 Nm, 1x connector, Rotate module forward and up to access connector
Remove wiper mount bracket

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4x bolts, 13mm, 25 Nm, Slide bracket to towards the RH shock tower along the multi-system beam to clear the HEPA filter housing to remove
Disconnect air quality sensor harness

Note
1x connector
Remove HEPA filter assembly cover

Note
2x tabs
Remove HEPA filter

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2x clips, Release clips, Pivot filter forward and out of housing
Remove coolant bottle cap
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 fluid extractor in front of vehicle

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Set Mityvac to evacuate, Make sure extractor tube is clean of oil so there won't be any contamination, Attach dipstick tube adapter from fluid transfer kit to Mityvac, guide tube through reservoir neck and down into reservoir
Evacuate coolant from coolant bottle

Note
Pump fluid into Mityvac evacuator, Maneuver tube in bottle during evacuation to scavenge as much fluid as possible
Disconnect the coolant bottle level sensor connector

Note
1x locking electrical connector, 1x clip, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector
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

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

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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

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

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2x locating tabs, 1x ground cable
Place rag on top of front drive unit heat exchanger below plastic coolant manifold
Remove the bolts securing the supermanifold to the multi-system beam and slowly rest on front drive unit

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath and rest on rag atop heat exchanger
Release multi-system beam

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4x bolts, 15mm, 31 Nm
Place a folded rag underneath RH and LH side of the multi-system beam

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Lift multi-system beam up only the amount required to clear the reservoir fill neck between top of supermanifold and bottom of beam, Recommend assistance if needed
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, Spring is accessible from the front of the supermanifold
Disconnect the HV battery return hose from the Supermanifold

Note
1x spring clip
Disconnect chiller to battery hose from supermanifold

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1x spring clip
Remove clips securing heat pump harness at the bottom of coolant bottle

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2x fir tree clips, Access from RH side of supermanifold
Remove screw at the rear of coolant bottle securing the coolant bottle to Supermanifold

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1x screw, T25, 5 Nm, Access from RH side of supermanifold, Loosen screw and remove with magnet
Remove screw at the front of coolant bottle securing coolant bottle to Supermanifold

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1x screw, T25, 5 Nm
Remove coolant bottle from Supermanifold

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Remove by sliding the bottle away from the Supermanifold towards the rear of the vehicle, and rotate out the top
Re-secure Supermanifold to multi-system beam

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2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath, Hand start bolts to Supermanifold, Torque at a later step
Disconnect low pressure PT sensor 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 harness from supermanifold
Release thermal harness from Supermanifold

Note
1x fir clip, 1x clip
Release thermal harness from PT coolant pump, Chiller pump, and Octovalve

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3x 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
Remove fasteners securing Octovalve to Supermanifold and remove Octovalve from vehicle

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4x screws, T25, 5 Nm
Remove octovalve body from actuator assembly

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3x bolts, T10, 1.5 Nm
Install octovalve body onto actuator assembly

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3x bolts, T10, 1.5 Nm
Position Octovalve onto Supermanifold and install fasteners securing Octovalve to Supermanifold

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4x screws, T25, 5 Nm, Ensure dowels on Octovalve engage the Supermanifold before installing fasteners, Octovalve must be flush with Supermanifold to properly seal
Install thermal harness to PT coolant pump, Chiller pump, and Octovalve

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3x locking electrical connectors, Engage locking tabs
Secure thermal harness to Supermanifold

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1x fir clip, 1x clip
Connect low pressure PT sensor connector

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1x locking electrical connector, Secure harness to supermanifold, Engage locking tab
Release Supermanifold from multi-system beam

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2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath
Position coolant bottle onto Supermanifold

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Ensure o-ring and spacer are present, Slide the bottle between the multi-system beam and top of supermanifold, Engage bottle fully into coolant manifold
Install screw at front of the coolant bottle securing the coolant bottle to Supermanifold

Note
1x screw, T25, 5 Nm
Install the screw at rear of coolant bottle securing coolant bottle to Supermanifold

Note
1x screw, T25, 5 Nm
Secure clips securing heat pump harness at the bottom of coolant bottle

Note
2x fir tree clips
Secure multi-system beam

Note
4x bolts, 15mm, 31 Nm, Remove folded rag, Position beam and start bolts by hand
Secure the supermanifold to the multi-system beam

Note
2x bolts, 15 mm, 31 Nm, Recommend assistance, Support from underneath, Hand start bolts to Supermanifold, Remove rag from heat exchanger
Connect the chiller to battery hose to the Supermanifold

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully seated
Connect the HV battery return hose to the Supermanifold

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

Note
1x spring clip, 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
Connect the coolant bottle level sensor and secure harness

Note
1x locking electrical connector, 1x clip, Engage locking tab
Fill coolant to the proper level

Note
Ensure that the fluid level filled to the Max line
Position front controller for installation and secure ground cable to multi system beam

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

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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 HEPA filter

Note
3x datums, 2x clips, Align 3 datums into bottom of housing, Confirm air flow direction, Ensure clips lock and secure filter into housing
Install HEPA filter assembly cover

Note
2x tabs, 2x datums, 2x slots, Fully engage seal and locking tabs
Connect air quality sensor harness

Note
1x connector
Install wiper mount bracket

Note
4x bolts, 13mm, 25 Nm, Slide bracket from the RH shock tower area along the multi-system beam to clear the HEPA filter housing for installation
Install wiper module

Note
3x bolts, 10mm, 9 Nm, 1x connector, Secure connector before install, Rotate module rearward and up into place
Install LV battery to multi-system beam

Note
3x bolts, 10mm, 9 Nm. 2x locators
Secure coolant hose to LV battery

Note
1x clip
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
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
Using laptop connect to vehicle with ethernet diag kit and Toolbox 3
Select ‘Actions/Autodiag’ and search for ‘Thermal’
Select Coolant Valve TestTEST-SELF_VCFRONT_X_FIVE-WAY-VALVEGen3/tasks/TEST-SELF_VCFRONT_X_FIVE-WAY-VALVE Model3/tasks/TEST-SELF_VCFRONT_X_FIVE-WAY-VALVELow Voltage Controllers Low Voltage ControllersThermal / Coolant System - Coolant Valve TestService Mode Service Plus Factory Mode Developer , click Run and allow routine to complete

Note
Select ‘X’ at top right of window to close once complete
Select "Actions/Autodiag" tab and search for "Purge"
Select Coolant Air PurgeTEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEGen3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGE Model3/tasks/TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGELow Voltage Controllers Low Voltage ControllersThermal / Actions - Coolant Air PurgeService Mode Service Plus Factory Mode Developer Thermal / Coolant System - Coolant Air PurgeService Mode Service Plus Factory Mode Developer hv / Procedures - Transport Service Plus Developer , 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
Select "Actions/Autodiag" and search for "Thermal Performance"
Select Heat Pump Thermal System Performance TestTEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCEModelY/tasks/TEST-SELF_VCFRONT_X_HEAT-PUMP-THERMAL-PERFORMANCELow Voltage Controllers, click "Run", and allow routine to complete

Note
Select "X" at top right of window to close once complete, If thermal test fails follow https://toolbox.teslamotors.com/articles/206000
Disconnect Toolbox 3 from vehicle and remove laptop and ethernet diag kit
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
Install rear underhood apron

Note
11x clips
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
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"
Calibrate the rear doors.

Note
If the "Calibration Needed" message appears on the vehicle touchscreen, touch and hold Calibrate to calibrate the rear doors.
Raise LH and RH front windows
Close LH front door