01/04/2024 14:01:15

Check Valve - Liquid Cooled Condenser (Remove and Replace)

Correction code 18401102 3.30 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.
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 tab and search for "Refrigerant".
Select Start Thermal Fluid Fill/Drain (Refrigerant only)PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTGen3/tasks/PROC_VCFRONT_X_START-THERMAL-FILL-DRAIN-REFRIGERANTLow Voltage ControllersThermal / Actions - Start Refrigerant Fill/DrainService Mode Service Plus Factory Mode Developer Thermal / Refrigerant System - Start Refrigerant Fill/DrainService Mode Service Plus Factory Mode Developer , click Run, and allow routine to complete.

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 .
Open hood.

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

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

Note
11x clips, 2x datums.
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 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 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 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 bolt securing front controller ground cable.

Note
1x bolt, 10mm, 10 Nm.
Release RH FST cap from multi-system beam.

Note
3x bolts, 13mm, 22 Nm.
Release RH FST cap from shock tower and remove from vehicle.

Note
1x bolt, 13mm, 14 Nm, Release keyed ground strap from RH FST cap after removal.
Release remote brake fluid reservoir from LH FST cap.

Note
2x bolts, 10mm, 8 Nm, 1x datum, Rotate reservoir with bracket out of LH FST cap.
Release LH FST cap from multi-system beam.

Note
3x bolts, 13mm, 22 Nm, 1x clip.
Release LH FST cap from shock tower and remove from vehicle.

Note
1x bolt, 13mm, 14 Nm.
Remove wiper mount bracket.

Note
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.

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

Note
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.

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

Note
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 bolts securing front controller.

Note
3x bolts, 10mm, 10 Nm.
Remove front controller from vehicle.

Note
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.

Note
4x bolts, 15mm, 60 Nm.
Place a folded rag underneath RH and LH side of the multi-system beam.

Note
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.

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

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

Note
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.

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

Note
Remove by sliding the bottle away from the Supermanifold towards the rear of the vehicle, and rotate out the top.
Remove cabin condenser check valve snap ring from Supermanifold.

Note
1x snap ring, Discard after removal.
Remove liquid cooled condenser check valve from Supermanifold.

Note
If check valve separates from aluminum cap during removal do not use metal tools, Metal tools may scrape Supermanifold housing causing internal damage, Use fingers or wrap electrical tape around 90 degree pick .

Install

Install liquid cooled condenser check valve into Supermanifold.

Note
Use ND-11 oil to lubricate O-rings, Seat valve past snap ring landing.
Install liquid cooled condenser check valve snap ring into Supermanifold.

Note
1x snap ring, Install new snap ring, Verify snap ring is properly seated inside groove of Supermanifold.
Inspect new coolant bottle.

Note
1x o-ring, 1x spacer, Ensure both spacer and o-ring are present and seated before installation, Lubricate coolant bottle o-ring.
Position coolant bottle onto Supermanifold.

Note
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.
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.
Position front controller for installation and position ground cable.

Note
2x locating tabs, 1x ground cable.
Install bolts securing front controller.

Note
3x bolts, 10mm, 10 Nm, Start with the side bolt.
Secure lower connections on the front controller.

Note
2x locking connectors, Engage red locking tab.
Secure RH middle connections on front controller.

Note
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.
Secure RH FST cap to shock tower.

Note
1x bolt, 13mm, 14 Nm, Insert keyed ground strap into RH FST cap before installation.
Secure RH FST cap to multi-system beam.

Note
3x bolts, 13mm, 22 Nm.
Install bolt securing front controller ground cable.

Note
1x bolt, 10mm, 10 Nm.
Secure LH FST cap to shock tower.

Note
1x bolt, 13mm, 14 Nm.
Secure LH FST cap to multi-system beam.

Note
3x bolts, 13mm, 22 Nm, 1x clip.
Secure remote brake fluid reservoir to LH FST cap.

Note
2x bolts, 10mm 8 Nm, 1x datum, Rotate reservoir with bracket on to LH FST cap.
Install LV battery to multi-system beam.

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

Note
1x clip.
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 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 "Commissioning".
Select Heat Pump Thermal System CommissioningTEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGGen3/tasks/TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONING ModelY/tasks/TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGLow Voltage Controllers Low Voltage ControllersThermal / Refrigerant System - Run Heat Pump CommissioningService Mode Service Plus Factory Mode Developer , 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 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.
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.
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.
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.