2025-01-23

Chiller (Remove and Replace)

Correction code 1840010802 0.8 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 wearing proper PPE when performing the below procedure.

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Note
This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate activity to the Service Visit.

Torque Specifications

Table 1. Torque Specifications: Chiller (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the supermanifold-to-compressor A/C line to the supermanifold
22 Nm (16.2 lbs-ft)
  • 13 mm socket
Reuse
Bolts (x4) that attach the chiller to the supermanifold
8 Nm (5.9 lbs-ft)
  • 8 mm socket
 Reuse

Remove

  1. Set up the AC machine.
  2. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  3. Position a fluid catcher underneath the front of vehicle.
  4. Unlock the vehicle gateway. See Gateway (Unlock).
  5. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Coolant System > Start Thermal Fill/Drain > Run, and allow the routine to complete.
  6. Remove the HEPA filter assembly. See SERVICE KIT - HEPA AND CARBON FILTERS (Remove and Replace).
  7. Disconnect the LV battery. See LV Power (Disconnect and Connect).
  8. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  9. Remove the air intake duct, See Duct - Air Intake (Remove and Replace).
  10. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure there is no pressure in the A/C system before performing the following steps. Failure to do so may result in damage to components and/or personal injury.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    HFO-R1234yf and R134a are considered hazardous and, if handled incorrectly, can cause serious injury. Suitable personal protective equipment, consisting of face and eye protection, safety glasses, face shield, heat-proof gloves, chemical resistant gloves, rubber boots and apron or waterproof overall must be worn when carrying out operations on the air conditioning system.
  11. Remove the bolt that attaches the supermanifold-to-compressor A/C line to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  12. Remove the supermanifold-to-compressor A/C line from the supermanifold, and move it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully position the line so that oil does not drip out.
  13. Release the locking tab, and then disconnect the electrical connector from the chiller EXV.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
  14. Use a pick to pull the locking tab downward, and then pull toward the front of the vehicle to remove the chiller EXV coil.
  15. Remove the bolts (x4) that attach the chiller to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
  16. Slightly release the RH side of the chiller from supermanifold and allow excess coolant to drain.
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the A/C ports intact to supermanifold while coolant drains to avoid cross contamination.
  17. Remove the chiller from the vehicle.
  18. Remove and discard the chiller gasket from supermanifold.

Install

  1. Install a new chiller gasket into supermanifold.
  2. Install the chiller to supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the O-rings on the chiller with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications. Then hand tighten the bolts that attach the chiller to the supermanifold.
  3. Torque the bolts (x4) that attach the chiller to the supermanifold.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Torque the bolts in the following sequence, as illustrated in the picture:
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 8 mm socket
  4. Use shop towels to wipe away any residue fluid.
  5. Install the chiller EXV coil onto the expansion valve.
    Informational PurposesAn informational icon, calling your attention
    Note
    Properly align the expansion valve coil locking tab to the supermanifold. Perform a push pull push test on the expansion valve coil to ensure the coils is properly latched.
  6. Connect the electrical connector of the chiller EXV.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Push the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  7. Install new seal washers on the supermanifold side of the supermanifold-to-compressor A/C line, and then lubricate the washers with a small amount of the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  8. Position the supermanifold to compressor A/C line onto the supermanifold, and then hand-tighten the bolt that attaches the A/C line to the supermanifold.
  9. Tighten the bolt that attaches the supermanifold to compressor A/C line to the supermanifold.
    22 Nm (16.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  10. Perform the vacuum leak test and oil injection, and A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
  11. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  12. Remove the fluid catcher from underneath the front of the vehicle.
  13. Connect the LV battery. See LV Power (Disconnect and Connect).
  14. Unlock the vehicle gateway. See Gateway (Unlock).
  15. On the touchscreen, perform the following steps.
    1. Touch Service Mode > Thermal > Coolant System > Stop Thermal Fill/Drain to complete the routine.
    2. Touch Service Mode > Thermal > Coolant System > Coolant Purge Start and select Run to start the routine, and allow the routine to complete.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure vehicle is not in Drive, shifting the vehicle into Drive will stop this routine. The test will last approximately 10 mins. The test will vary speeds from 3500-6500 RPM (idle speed = ~1500 RPM) and actuate the valve between series and parallel. If speed hovers at 7000 RPM, it indicates the pump is air locked, perform the vacuum fill again. Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  16. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  17. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  18. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the coolant loss is greater than 1L, vacuum refill is required to perform.
  19. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Sensors and Valves > Run Heat Pump Commissioning > Run, and close once the routine is passed.
  20. Exit Service Mode. See Service Mode.
  21. Install the cabin intake duct. See Duct - Air Intake (Remove and Replace).
  22. Install the HEPA filter assembly. See SERVICE KIT - HEPA AND CARBON FILTERS (Remove and Replace).