2025-03-12

Supermanifold (Remove and Install)

Correction code 1840011201 FRT 1.25 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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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.
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Warning
Only technicians who have been trained in High Voltage Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper personal protective equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.
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CAUTION
Thermal management components operate under very tight specifications and can malfunction if Service procedures are not carefully followed. DO NOT rely on past experience with other thermal management systems; read through the Service Manual and do not deviate from the instructions.
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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:Supermanifold (Remove and Install)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the A/C compressor HV harness bracket to the A/C compressor
9 Nm (6.6 lbs-ft)
  • 13 mm socket
 Reuse
Bolt that attaches the ground strap to the A/C compressor
7 Nm (5.2 lbs-ft)
  • Torx T25 socket
Reuse
Bolt that attaches the supermanifold to compressor A/C line to the supermanifold
22 Nm (16.2 lbs-ft)
  • 13 mm socket
Reuse
Bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly
22 Nm (16.2 lbs-ft)
  • 13 mm socket
Reuse
Nut that attaches the supermanifold to HVAC A/C line to the supermanifold
27 Nm (19.9 lbs-ft)
  • 13 mm socket
Reuse
Bolts (x2) that attach the supermanifold to the shock tower brace
31 Nm (22.9 lbs-ft)
  • 15 mm socket
 Reuse
The LH and RH bolts (x4) that attach the shock tower brace to the body
55 Nm (40.6 lbs-ft)
  • 15 mm socket
 Reuse
The LH and RH outer bolts that attach the shock tower brace to the body
62 Nm (45.7 lbs-ft)
  • 15 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. Fully lower the 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. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  11. Remove frunk reinforcement beam, See Beam - Reinforcement - Frunk (Remove and Replace).
  12. Place a fluid catcher underneath the front of the vehicle.
  13. Release the spring clip, disconnect the radiator inlet hose from the supermanifold, and then plug the hose and supermanifold.
  14. Release the spring clip, disconnect the radiator outlet hose from the supermanifold, and then plug the supermanifold.
  15. Release the spring clip, disconnect the bypass powertrain hose from the supermanifold, and then plug the hose and supermanifold.
  16. Release the clip that attaches the radiator inlet hose to the compressor bracket.
  17. Disconnect the electrical connector from the sensor on the chiller to battery hose, near the coolant bottle.
    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.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness with purple tape connects to the coolant temperature sensor which is close to coolant bottle.
  18. Disconnect the electrical connector from the sensor on the powertrain supply hose, near the coolant bottle.
    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.
  19. Release the spring clip, and then remove the chiller to battery hose from the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Install plugs to both ends to prevent coolant loss. Coolant loss greater than 1L will require vacuum fill.
  20. Release the spring clip, disconnect the powertrain supply hose from the supermanifold, and then plug the hose and supermanifold.
  21. Release the spring clip, disconnect the HV battery return hose from the supermanifold, and then plug the hose and supermanifold.
  22. Remove the LV battery. See LV Battery (Remove and Install).
  23. Use a clip pry tool to release the clips (x4) that attach the coolant hose to the A/C compressor bracket.
  24. Release the connector locking tab, and then disconnect the HVIL connector near the LH front strut tower.
    Informational PurposesAn informational icon, calling your attention
    Note
    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.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  25. Release the connector locking tab, then disconnect the A/C logic electrical connector from the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    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.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  26. Use a clip pry tool to release the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  27. Remove the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  28. Disconnect the HV harness electrical connector from the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  29. Release the tab and clips (x4) that attaches the HV harness to the A/C compressor, and set it aside.
  30. Release the clip that attaches the supermanifold harness to the front body controller module.
  31. Disconnect the thermal harness from the front body controller module connector.
  32. Remove the bolt that attaches the ground strap to the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  33. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
  34. Remove the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  35. 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
  36. Remove the LH and RH bolts (x4) that attach the shock tower brace to the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  37. Remove the LH and RH outer bolts (x2) that attach the shock tower brace to the body.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  38. Remove the shock tower brace together with the supermanifold and compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    2 technicians are required for this step. Mind the connectors and A/C lines, slowly lift the brace, and then put it on a cardboard pad.
  39. Remove the bolts (x2) that attach the supermanifold to the shock tower brace.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  40. Remove the nut that attaches the supermanifold to HVAC 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

Install

  1. Replace the seal washers (x5) on the supermanifold to HVAC A/C line assembly on supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  2. Replace the seal washers (x5) on the supermanifold to HVAC A/C line assembly on the HVAC side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  3. Position the supermanifold to HVAC A/C line on the supermanifold, and hand-tighten the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
  4. Position the supermanifold assembly to the shock tower beam, and hand-tighten the bolts (x2) that attach the supermanifold to the shock tower brace.
  5. Install the shock tower beam together with the supermanifold and A/C compressor to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2 technicians are required for this step. Mind the connectors and AC lines. If desiccant was exposed to air for more than 20 minutes, it needs to be replaced.
  6. Loosely install the LH and RH bolts (x6) that attach the shock tower brace to the body.
  7. Torque the LH and RH outer bolts (x2) that attach the shock tower brace to the body.
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  8. Torque the LH and RH bolts (x4) that attach the shock tower brace to the body.
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  9. Torque the bolts (x2) that attach the supermanifold to the shock tower brace.
    31 Nm (22.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 15 mm socket
  10. Torque the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
    27 Nm (19.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  11. Install the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    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
  12. Install new seal washers (x2) for the supermanifold to compressor A/C line assembly at the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  13. Hand-tighten the bolt that attaches the supermanifold to compressor A/C line to the supermanifold, and then torque the bolt.
    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
  14. Perform the vacuum leak test and oil injection, and A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
  15. Connect the thermal harness to the front body controller module connector.
  16. Install the clip that attaches the supermanifold harness to the front body controller module.
  17. Install the bolt that attaches the ground strap to the A/C compressor.
    7 Nm (5.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Torx T25 socket
  18. Route the HV harness to its original position, and then install the clips (x4) that attach the harness to the shock tower brace.
  19. Install the tab that attaches the HV harness to the A/C compressor.
  20. Connect the HV harness electrical connector to the A/C compressor.
  21. Install the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    9 Nm (6.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • 13 mm socket
  22. Install the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  23. Connect the A/C compressor logic electrical connector to the A/C compressor, and then engage the locking tab.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  24. Connect the HVIL connector near the LH front strut tower, and then engage the locking tab.
    Informational PurposesAn informational icon, calling your attention
    Note
    Push the red locking tab into the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  25. Remove the plugs, immediately connect the HV battery return hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  26. Remove the plugs, immediately connect the powertrain supply hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  27. Remove the plugs, immediately connect the chiller to battery hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test to verify that the hose is fully seated.
  28. Connect the electrical connector to the sensor on the powertrain supply hose, near the coolant bottle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness and coolant hose are color coded. Match harness color to coolant hose color.
  29. Connect the electrical connector to the sensor on the chiller to battery hose, near the coolant bottle.
  30. Install the clips (x4) that attach the coolant hose to the A/C compressor bracket.
  31. Remove the plugs, immediately connect the bypass powertrain hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test to verify that the hose is fully seated.
  32. Remove the plugs from the supermanifold and radiator outlet hose, immediately connect the radiator outlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  33. Remove the plugs from the supermanifold and radiator inlet hose, immediately connect the radiator inlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  34. Fasten the clip that attaches the radiator inlet hose to the compressor bracket.
  35. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill.
  36. Remove the fluid catcher from underneath the front of the vehicle.
  37. Install LV power. See LV Battery (Remove and Install).
  38. Connect the LV battery. See LV Power (Disconnect and Connect).
  39. Unlock the vehicle gateway. See Gateway (Unlock).
  40. 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.
  41. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  42. Install frunk reinforcement beam, See Beam - Reinforcement - Frunk (Remove and Replace).
  43. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  44. Install the 2nd row lower seat cushion. See 2nd Row Seat Cushion (Remove and Replace).
  45. 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.
  46. 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.
  47. Exit Service Mode. See Service Mode.
  48. Install the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  49. Install the HEPA filter assembly. See Service Kit - Hepa And Carbon Filters (Remove and Replace).
  50. Remove the vehicle from the lift.