01/04/2024 14:05:40

Hose - Supermanifold To 3 Way Valve And Radiator (Remove and Replace)

Correction code 18302202 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. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Prepare to raise vehicle, 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
  2. Open LH front door
  3. Lower LH front window
  4. Place vehicle in service mode with touchscreen
    Informational PurposesAn informational icon, calling your attention
    Note
    Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box
  5. Access thermal system routines using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock
  6. Select Start' button at 'Start Thermal Fill Drain (Refrigerant Only)' using the UI and 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 window will appear
    Informational PurposesAn informational icon, calling your attention
    Note
    Select ‘X’ at top left of window to close once complete, Verify refrigerant status moves from yellow 'Moving to Reclaim Position' to green 'Ready for Recharge/Reclaim' status, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours EXV's will close and routine must be performed again
  7. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  8. Power off vehicle via center display
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Safety & Security > Power Off
  9. 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, Release red lock tab on FRL
  10. Release clip securing the supermanifold to battery pump supply hose from LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  11. Remove fasteners securing the LV battery and remove assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm, 2x locators
  12. Disconnect air quality sensor harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  13. Release upper connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Push in locking tabs and lift levers to release
  14. Release LH middle connection on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Push in locking tab and lift lever to release
  15. Release RH middle connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Slide locking mechanism outwards to release
  16. Release lower connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Slide red locking tab outwards to release
  17. Remove bolt securing front controller ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  18. Remove bolts securing front controller
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    Note
    3x bolts, 10mm, 10 Nm
  19. Remove front controller from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locating tabs, 1x ground cable
  20. Release front controller connector harnesses clip from vehicle
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    Note
    1x clip
  21. Secure front controller harness connectors to hood shock
    Informational PurposesAn informational icon, calling your attention
    Note
    Use a bungee cord to secure the harness
  22. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  23. Remove clips securing front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips
  24. Remove bolts securing front aero shield and remove from vehicle
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    Note
    9x bolts, 10mm, 6 Nm
  25. Place absorbent material below three way valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Place to cover steering gear and front skid plate, Will prevent build up of fluid
  26. Place coolant catcher below RH front of vehicle
  27. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  28. Release thermal bar battery return hose from three way valve
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    Note
    1x hose clip, 2x plugs, Plug both ends
  29. Disconnect the sensor for the powertrain supply hose
    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
  30. Disconnect powertrain supply hose from supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Spring is accessible from the front of the supermanifold
  31. Disconnect the HV battery return hose from the Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip
  32. Disconnect 12mm radiator hose from top LH side and allow coolant to drain
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Plug hose and radiator as needed
  33. Guide thermal bar battery return hose between AC compressor bracket and PT coolant pump and between supermanifold and front drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  34. Remove thermal bar battery return hose
    Informational PurposesAn informational icon, calling your attention
    Note
    Guide hose over multi-system beam, Pay attention to how the hose is oriented
  35. Position thermal bar battery return hose between supermanifold and front drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    Guide down hose over multi-system beam
  36. Guide thermal bar battery return hose between supermanifold and front drive unit and AC compressor bracket above PT coolant pump
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  37. Install 12mm radiator hose onto top LH side of radiator
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove plugs from both ends of each coolant connection, Perform push-pull-push test to make sure hose is fully seated
  38. Secure thermal bar battery return hose onto three way valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clip, 2x hose plugs, Remove any plugs and secure hose, Perform push-pull-push test
  39. Connect the HV battery return hose to the Supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Perform push-pull-push test to make sure hose is fully seated
  40. Secure powertrain supply hose to supermanifold
    Informational PurposesAn informational icon, calling your attention
    Note
    1x spring clip, Remove all plugs, Perform push-pull-push test to make sure hose is fully seated
  41. Connect the sensor for the powertrain supply hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking electrical connector, Engage locking tab
  42. Clean coolant residue from vehicle
  43. Release front controller harness connectors from hood shock
  44. Secure clip for front controller connector harnesses to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  45. Position front controller for installation and position ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locating tabs, 1x ground cable
  46. Install bolts securing front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 10 Nm, Start with the side bolt
  47. Install bolt securing front controller ground cable
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 10 Nm
  48. Secure lower connections on the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Engage red locking tab
  49. Secure RH middle connections on front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Verify yellow locking tabs are fully opened, Seat connectors and mechanism will begin to engage
  50. Secure LH middle connection for front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking connector, Verify lever is fully opened, Seat connector and lever will being to engage
  51. Secure upper connections for the front controller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x locking connectors, Verify levers are fully opened, Seat connectors and levers will begin to engage
  52. Raise vehicle fully and lower lift onto locks
    Informational PurposesAn informational icon, calling your attention
    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
  53. Remove absorbent material from below three way valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove absorbent material and clean away all excess residue
  54. Clean coolant residue from vehicle
  55. Remove coolant catcher from under vehicle
  56. Apply Loctite 222 onto front aero shield bolts and install fasteners securing front aero shield to vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    9x bolts, 10mm, 6 Nm
  57. Install clips securing front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips
  58. Lower vehicle until tires are touching the ground
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  59. Remove coolant bottle cap
  60. Place empty coolant container into front storage area
    Informational PurposesAn informational icon, calling your attention
    Note
    CFM fan shroud assembly cannot support a full coolant container, Ensure overflow container is empty, Place fender cover over FEM and front fascia
  61. Fill container with at least 15L of coolant
  62. Place filled coolant container onto coolant drain & fill cart
    Informational PurposesAn informational icon, calling your attention
    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
  63. Install vacuum refill cap onto coolant bottle assembly
  64. Setup coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify all valves on refill tool are in the closed position, See image for clarity
  65. Install vacuum refill hose into refill cap on coolant bottle
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to verify hose is fully installed
  66. Place refill hose inside filled coolant container
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end is fully submerged into coolant
  67. Position overflow hose into empty container
  68. Connect shop air supply to coolant refill tool
    Informational PurposesAn informational icon, calling your attention
    Note
    If not already done, Verify refill valve is set to off
  69. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
    Informational PurposesAn informational icon, calling your attention
    Note
    Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed
  70. Slowly open the refill valve to allow coolant to be drawn into the system
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure hose end of refill hose is fully submerged during entire process
  71. Once the gauge reads zero, close the coolant refill valve
  72. Remove coolant refill hose from coolant container
  73. Remove coolant overflow hose from coolant container
  74. Remove vacuum refill hose from refill cap on coolant bottle
  75. Remove vacuum refill cap from coolant bottle assembly
  76. Remove coolant refill tool from vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Move coolant drain & fill cart away from vehicle
  77. Remove both coolant containers from inside underhood area
  78. Connect air quality sensor harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  79. Install LV battery to multi-system beam
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm. 2x locators
  80. Install clip securing the supermanifold to battery pump supply hose onto LV battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  81. 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
  82. Access thermal system routines using the UI
    Informational PurposesAn informational icon, calling your attention
    Note
    Select quick controls > Service mode > Diagnostics > Thermal, Authorize routines by holding right turn signal, depressing brake pedal for 10 seconds with key on phone dock
  83. Select Start button at 'Start Coolant Air Purge' using the UI and ‘TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGESearch for routine in ToolboxCoolant Air PurgeThermal / Coolant System - Coolant Purge Starthv / Front Drive Inverter Replacement - Coolant Air Purgehv / Rear Drive Inverter Replacement - Coolant Air Purgehv / Rear Left Drive Inverter Replacement - Coolant Air Purgehv / Rear Right Drive Inverter Replacement - Coolant Air Purgehv / Front Drive Unit Replacement - Coolant Air Purgehv / Rear Drive Unit Replacement - Coolant Air PurgeThermal / Actions - Coolant Purge Stop or Coolant Purge Start - SUCCESS' window will appear
    Informational PurposesAn informational icon, calling your attention
    Note
    Coolant pumps will be audible, Test lasts approximately 10 mins, Putting vehicle into drive state will stop this routine, Monitor levels as required, Select ‘X’ at top left of window to close once complete
  84. Inspect coolant level and top off as necessary
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    Note
    Ensure that the fluid level is at the Max line, Top off fluid as required
  85. Install coolant bottle cap
  86. Exit Service Mode
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls>Software select Exit Service Mode button
  87. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  88. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
  89. Raise LH front window
  90. Close LH front door