Correction code 18400106 2.34 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.

1. Raise and support vehicle
   Note

   Ensure vehicle is not charging, Note the MYSP lifting points are more narrow than the MY

   

   

   

   

2. Open all four doors
3. Lower all four windows
4. Set up AC machine
   Note

   Touch time only

   

5. Open hood
6. Remove rear apron
   Note

   14x clips

   

   

7. Remove access panel
   Note

   3x clips, 1x connector

   

   

8. Remove fasteners securing the frunk assembly
   Note

   5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to reservoir neck

   

   

9. Remove frunk assembly from vehicle
   Note

   6x clips, Replace any clips if broken or missing

   

10. Remove fresh air intake duct
    Note

    1x bolt, 10mm, 4 Nm, 2x clips, 1x pin, Remove bolt, Gently pry pin out from thermal beam, then remove from bulkhead studs

    

    

    

    

11. Log into Tesla Garage
    Note

    https://garage.vn.teslamotors.com/vehicles
12. Enter vehicle VIN and select "Search"
13. Check Firmware version
    Note

    Firmware package installed must be 2021.36 or above for vehicle configuration update and Toolbox routine
14. Navigate to "CFG" tab on "Vitals" page
15. Perform inspection of the current coolant pump configuration
    Note

    If the config is DUAL or DUAL_SAN_P4, the config will need to change to DUAL_MIX – This will be required to identify the pumps in the replacement supermanifold
16. Perform inspection of the current revision supermanifold
    Note

    Determine the part number of the equipped supermanifold, If replacing a -A to -E (v1.0) with a -F (v1.1) then a manifold configuration change and replacement of Supermanifold to HVAC A/C pentaline will also be required

    

    

    

17. Perform inspection of the coolant hose temperature sensors and connectors
    Note

    2x connectors, 2x sensors, Inspect the type of coolant temperature sensors equipped, Early production Model Y had a different styled temperature sensor, If you encounter an early revision temperature sensor then it is possible the new replacement super manifold connections may not fit onto the old sensors, If this is the case, then the electrical connector cover must be swapped from the old supermanifold to the new replacement supermanifold, This will be done at a later step, If coolant temp sensors are the newer style then a rework is not required

    

    

    

18. Connect to vehicle using Toolbox 3.0
19. Select "Dashboards" tab, and select "Infotainment Dashboard"
20. Select "Vehicle Configuration"
    Note

    Configuration values should load automatically, if not select "Read Config" and "Run" to load
21. Select "Read Config" and select "Run" to pull current vehicle configuration
    Note

    Select ‘X’ at top right of window to close once complete
22. Scroll down to "coolantPumpType" and change to "Two coolant pumps installed, mixed pole pair batches"
23. Scroll down to "superManifoldType" and change to "TYPE1"
24. Select "Apply Changes" and select "Run" to save updated configuration
    Note

    Center display will reboot, Toolbox connection will be lost, Select ‘X’ at top right of window to close once complete, Verify configuration changes are complete
25. Turn HVAC on, Turn AC OFF and set the Blower Speed to 10. Set the Temperature to HI and run for 10 minutes
    Note

    This will clear most of the oil out of the cabin condenser

    

26. Turn off the HVAC and let it sit for 1 minute
    Note

    Make sure both compressor and blower are off, this allows refrigerant inside cabin condenser to return to the accumulator

    

27. Turn the HVAC back on, Turn the AC on, set the Blower Speed to 10 and the Temperature to LO, run the HVAC for 10 minutes
    Note

    This step will clear most of the oil out of the evaporator

    

28. Turn Off the AC and Blower motor

    

29. Move LH front seat forward
30. Move RH front seat forward
31. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
    • Thermal ➜ Actions ➜ Start Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
    via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    Note

    Select ‘X’ at top right of window to close once complete, For AC related repairs verify all EXV's are in proper position, For all coolant related repairs verify vehicle is in Series, Thermal Fluid Fill/Drain routine has a 5 hour timeout, Routine will continuously run and not end
32. Power off vehicle from center display
    Note

    Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box

    

    

33. Disconnect 12V negative terminal and first responders loop
    Note

    1x nut, 10mm, 6 Nm, 1x connector, Ensure vehicle is in park, climate control system is off, and vehicle is not charging before disconnecting 12V, Negative terminal should be disconnected before FRL, Allow 2 minutes for all electrical circuits to fully discharge

    

    

34. Remove 2nd row seat cushion
    Note

    1x connector, Lift front edge of seat cushion upward to release foam from frame

    

    

    

35. Remove all items from pockets and ensure not wearing metal items

    

    

36. Inspect HV insulating gloves
    Note

    Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R4.pdf

    

37. Put on HV insulating gloves and leather over gloves
    Note

    Make sure to wear Electrical Protective Gloves any time Hioki tester is used

    

38. Remove the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal

    

39. Remove the ancillary bay probe lid cover from the ancillary bay cover

    

40. Verify no high voltage
    Note

    Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering

    

    

    

    

41. Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover
    Note

    Confirm no visual damage present, Replace gasket if damage is found

    

    

42. Install the bolts securing ancillary bay probe lid cover to ancillary bay cover
    Note

    2x bolts, EP10 5-Lobe, 6 Nm, Install new rubber washer bolts

    

43. Remove HV insulating gloves
44. 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
45. Remove outer fasteners from front aero shield
    Note

    7x bolts, 10mm, 5 Nm

    

46. Remove remaining nuts and remove front aero shield from vehicle
    Note

    2x nuts, 15mm, 5 Nm

    

47. Lower vehicle fully
    Note

    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
48. Remove caps from low side and high side AC ports
    Note

    2x caps

    

    

49. Connect hoses to vehicle and perform AC recovery
    Note

    Touch time only, Connect couplers to vehicle, Open couplers by turning clockwise, Open Machine valves, Note the amount of refrigerant and oil recovered, If drained oil level increased more than 30 ml, refer to the drained oil loss chart.

    

    

50. Remove vent tube hose from LH side of 12V battery
    Note

    1x hose

    

51. Release terminal cover and remove positive terminal
    Note

    2x clips, 1x nut, 10mm, 6 Nm, Do not fully remove positive terminal nut

    

    

52. Remove bolt securing 12V battery upper tie down strap to AC compressor bracket
    Note

    1x bolt, 10mm, 5 Nm

    

53. Remove battery upper tie down strap
    Note

    Lift battery tie down strap up and remove it from the rear tie down hook strap

    

    

54. Remove 12V battery from vehicle

    

55. Remove bolts securing frunk support beam to vehicle
    Note

    2x bolts, E14, 48 Nm

    

56. Remove frunk support beam from cooling fan module assembly
    Note

    Slide the frunk support beam towards rear of vehicle

    

    

57. Position coolant drain container underneath front of vehicle

    

58. Remove coolant bottle cap

    

59. Disconnect the powertrain bypass hose from the Supermanifold
    Note

    1x spring clip, This will drain the coolant reservoir

    

    

60. Disconnect the radiator outlet hose from the Supermanifold
    Note

    1x spring clip

    

    

61. Disconnect the radiator inlet hose from the Supermanifold
    Note

    1x spring clip

    

    

62. Install 3 male plugs into the coolant ports at the front of the Supermanifold
    Note

    3x plugs, This will avoid any cross contamination

    

63. Disconnect the sensor for the chiller to battery hose
    Note

    1x locking electrical connector, Do not push down on Red tab, Pull red tab to disengage lock, Pull again to release connector, Harness with purple tape connects to coolant temperature sensor closest to coolant bottle

    

64. Disconnect chiller to battery hose from supermanifold
    Note

    1x spring clip, 1x plug, Plug supermanifold as quickly as possible to avoid coolant loss

    

65. 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, Harness with purple tape connects to coolant temperature sensor closest to coolant bottle

    

66. Disconnect powertrain supply hose from supermanifold
    Note

    1x spring clip, 1x plug, Plug supermanifold as quickly as possible to avoid coolant loss

    

    

67. Disconnect the HV battery return hose from the Supermanifold
    Note

    1x spring clip

    

68. Install 3 male plugs into the coolant ports at the rear of the Supermanifold
    Note

    3x plugs, This will avoid any cross contamination

    

69. Disconnect the supermanifold harness from the front controller
    Note

    1x connector

    

70. Remove retaining clip securing AC compressor logic harness to AC compressor HV harness bracket
    Note

    1x fir tree clip

    

71. Disconnect AC compressor logic connector
    Note

    1x locking electrical connector, Do not push down on red tab, pull to disengage lock, pull again to release connector

    

72. Overlap from AC refrigerant recovery

    

73. Remove AC hoses from vehicle

    

74. Remove nut securing low side of manifold to compressor pipe and move low side pipe out of the way
    Note

    1x nut, 13mm, 22 Nm

    

75. Remove nut securing high side of manifold to compressor pipe and move high side pipe out of the way
    Note

    1x nut, 13mm, 22 Nm

    

76. Remove bolt on supermanifold to compressor AC line from supermanifold
    Note

    1x bolt, 13mm, 22 Nm

    

77. Remove the AC manifold line from the Supermanifold and remove the AC manifold line assembly out of the vehicle

    

    

78. Remove nut securing AC manifold to HVAC line assembly to the Supermanifold
    Note

    1x nut, 13mm, 27 Nm, Picture 2 shows the AC manifold lines from the compressor removed for a better visual

    

    

79. Remove AC manifold to HVAC line from HVAC assembly
    Note

    2x bolts, 13mm, 22 Nm

    

    

80. Remove the AC manifold to HVAC line assembly from the Supermanifold and remove from the vehicle
    Note

    Release the AC manifold line assembly towards the rear of the vehicle and remove from the Supermanifold

    

    

81. Remove the bolts securing the supermanifold to the shock tower beam and remove the Supermanifold from the vehicle
    Note

    2x bolts, 15 mm, 31 Nm, Recommend assistance, Rotate the Supermanifold counter clockwise under the shock tower support beam

    

    

    

82. Document old and new part numbers and serial numbers for Supermanifold
    Note

    Label is located in front of accumulator, document part numbers and serial numbers into the repair order

    

83. Transfer plastic bracket from old to new Supermanifold to HVAC AC line
    Note

    1x tab, Engage tab and release bracket, Transfer bracket onto new A/C line

    

    

84. Install the Supermanifold into the vehicle and install the bolts securing the Supermanifold to the Shock tower beam
    Note

    2x bolts, 15mm, 31 Nm, Recommend assistance, Rotate the Supermanifold counter clockwise and install under the shock tower support beam, Hand start bolts to Supermanifold

    

    

    

85. Install the AC manifold to HVAC line assembly to the Supermanifold
    Note

    Lubricate seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications. Reach your hand under the Supermanifold to assist with installing the AC manifold to HVAC line. Look through the stud hole to locate the stud on the line and install it into the Supermanifold. Part being installed is updated version.

    

    

    

    

86. Install the nut securing the AC manifold to HVAC line to the Supermanifold
    Note

    1x nut, 13mm, 27 Nm

    

87. Install AC manifold to HVAC line to HVAC assembly
    Note

    2x bolts, 13mm, 22 Nm

    

    

88. Install the radiator inlet hose onto the Supermanifold
    Note

    1x spring clip

    

89. Install the radiator outlet hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seated

    

90. Install the powertrain bypass hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seated

    

91. Install frunk support beam into cooling fan module assembly
    Note

    Position CFM mounts onto tabs on CFM

    

92. Install bolts securing frunk support beam
    Note

    2x bolts, E14, 48 Nm

    

93. Connect the supermanifold harness to the front controller
    Note

    1x connector

    

94. 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

    

95. Connect the powertrain supply hose to the Supermanifold
    Note

    1x spring clip, 1x plug, Remove plug from coolant bottle as quickly as possibly to avoid coolant loss, Perform push-pull-push test to make sure hose is fully engaged

    

    

96. Connect the chiller to battery hose to the Supermanifold
    Note

    1x spring clip, Perform push-pull-push test to make sure hose is fully seatedRemove plug from coolant bottle as quickly as possibly to avoid coolant loss

    

97. Release front cover from coolant temp connector
    Note

    1x connector cover, If the new supermanifold connection does not fit onto the older style temp sensors then you will need to swap the front connector cover, Carefully shift cover to the right in order to release, Do not damage connector

    

98. Release front cover from coolant temp connection of the old supermanifold
    Note

    1x connector cover, Take connector cover from the old supermanifold harness Carefully shift cover to the right in order to release, Do not damage connector

    

    

99. Secure the appropriate front connector cover onto the new supermanifold harness
    Note

    1x connector cover, Carefully secure the correct cover onto new supermanifold harness, Verify terminals are properly locked, Do not damage connector

    

    

100. Connect the sensor for the chiller to battery hose
     Note

     1x locking connector, Engage locking tab, Note the connections are color coded, Do not swap the connectors

     

101. Connect the sensor for the powertrain supply hose
     Note

     1x locking connector, Engage locking tab, Note the connections are color coded, Do not swap the connectors

     

102. Remove the clips securing the coolant hoses to the AC compressor bracket
     Note

     4x fir tree clips, when replacing with 1501293-00-B proceed to next step

     

103. Remove fastener securing AC compressor HV harness bracket to AC compressor
     Note

     1x bolt, 13mm, 9 Nm

     

104. Remove AC compressor ground strap
     Note

     1x bolt, 10mm, 7 Nm, Fastener may vary depending on production

     

105. Remove the clip securing the coolant hose to the AC compressor bracket
     Note

     1x fir tree clip

     

106. Disconnect HV harness connector from AC compressor
     Note

     1x locking electrical connector, 3 stage locking connector, See photos for connector positions, Move black locking tab away form the AC compressor, position 1, then using a 45 degree pick, push down on position 2 of the locking connector while prying up on position 3 and disconnect

     

     

     

107. Remove AC compressor HV harness from the AC compressor and set aside
     Note

     Move AC compressor HV harness bracket toward the front of the vehicle, lift the bracket up to clear the upper bracket mount and carefully set harness and bracket aside

     

     

     

108. Remove the fasteners securing the AC compressor bracket to the strut tower support brace and remove the AC compressor and AC compressor bracket assembly
     Note

     2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while removing the fasteners, Carefully remove the AC compressor and AC compressor bracket towards the front of the vehicle, under the strut tower support brace

     

     

     

109. Remove the AC compressor bracket from the AC compressor
     Note

     3x bolts, 10mm, 9 Nm

     

110. Weigh compressor and reset compressor oil amount
     Note

     Remove NVH blanket (if equipped), port caps, and port nuts. The weight is measured in grams. Take note of the compressor weight. Add the appropriate A/C oil (see Fluids and Capacities for A/C oil specifications) through the suction port of the compressor until it weighs 7193 grams (Denso compressor) or 7809 grams (Sanden compressor).

     

111. Install the AC compressor bracket to the AC compressor
     Note

     3x bolts, 10mm, 9 Nm

     

112. Position AC compressor bracket assembly into vehicle and secure AC compressor assembly to strut tower support brace
     Note

     2x bolts, 15mm, 31 Nm, Recommend assistance, Support the AC compressor while installing the fasteners, Carefully install the AC compressor and AC compressor bracket towards the rear of the vehicle, under the strut tower support brace, Keep AC compressor caps on the compressor until manifold lines are installed, Hand start bolts

     

     

     

113. Position the AC compressor HV harness onto the AC compressor for installation
     Note

     Ensure the HV harness bracket engages the upper bracket mount on the AC compressor

     

114. Connect HV harness connector to AC compressor
     Note

     1x locking electrical connector, 3 stage locking connector, After fully seating the connector onto the AC compressor engage the black locking tab by pushing toward the AC compressor, Perform push-pull-push test to ensure proper seating

     

115. Install the clip securing the coolant hose to the AC compressor bracket
     Note

     1x fir tree clip

     

116. Install AC compressor ground strap
     Note

     1x bolt, 10mm, 7 Nm, Fastener may vary depending on production

     

117. Install fastener securing AC compressor HV harness bracket to AC compressor
     Note

     1x bolt, 13mm, 9 Nm

     

118. Install retaining clip securing AC compressor logic harness to AC compressor HV harness bracket
     Note

     1x fir tree clip

     

119. Connect the AC compressor logic connector
     Note

     1x locking electrical connector

     

120. Install the clips securing the coolant hoses to the AC compressor bracket
     Note

     4x fir tree clips

     

121. Install 12V battery into vehicle

     

122. Position battery tie down strap onto the battery
     Note

     Hook the upper tie down strap into the rear tie down hook strap and position for installation

     

123. Install bolt securing upper tie down strap to the AC compressor bracket
     Note

     1x bolt, 10mm, 5 Nm

     

124. Install vent tube hose in 12V battery

     

125. Install positive terminal and terminal cover
     Note

     1x nut, 10mm, 6 Nm, 2x clips

     

     

126. Replace seal washers for supermanifold to compressor AC line on supermanifold side
     Note

     2x seal washers. Lubricate the seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

127. Replace seal washer on supermanifold to compressor AC line assembly on compressor discharge line
     Note

     1x seal washer, Lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

128. Replace seal washer on supermanifold to compressor AC line assembly on compressor suction line
     Note

     1x seal washer, Lube seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.

     

129. Install supermanifold to compressor AC line onto supermanifold
     Note

     1x bolt, 13mm, 22 Nm, Hand start bolt to prevent stripped threads

     

     

130. Install AC manifold to compressor line high side to compressor
     Note

     1x nut, 13mm, 22 Nm

     

131. Install AC manifold to compressor line low side to compressor
     Note

     1x nut, 13mm, 22 Nm

     

132. Place empty coolant container into front storage area

     

133. Fill container with at least 15L of coolant

     

134. Place filled coolant container into front storage area

     

135. Setup vacuum refill tool
     Note

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

136. Install vacuum refill cap onto coolant bottle assembly

     

137. Setup vacuum refill tool
     Note

     Verify all valves on refill tool are in the closed position, See image for clarity

     

     

138. Install vacuum refill hose into refill cap on coolant bottle
     Note

     Perform push-pull-push test to verify hose is fully installed

     

139. Position overflow hose into empty container

     

140. Place refill hose inside filled coolant container
     Note

     Make sure hose end is fully submerged into coolant

     

     

141. Connect shop air supply to coolant refill tool
     Note

     If not already done, Verify refill valve is set to off

     

142. Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve
     Note

     Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed

     

     

143. Slowly open the refill valve to allow coolant to be drawn into the system
     Note

     Make sure hose end of refill hose is fully submerged during entire process

     

144. Once the gauge reads zero, close the refill valve

     

     

145. Disconnect shop air supply from coolant refill tool

     

146. Remove coolant refill hose from coolant container

     

147. Remove coolant overflow hose from coolant container

     

148. Remove vacuum refill hose from refill cap on coolant bottle

     

149. Remove coolant refill tool from vehicle

     

     

150. Remove refill tool cap from coolant bottle assembly

     

151. Remove both coolant containers from inside underhood area

     

152. Remove coolant drain container from underneath vehicle

     

153. 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
154. Position the front aero shield to vehicle and install nuts
     Note

     2x nuts, 15mm, 5 Nm

     

155. Apply Loctite 222 onto front aero shield bolts and install outer fasteners to front aero shield
     Note

     7x bolts, 10mm, 5 Nm

     

156. Lower vehicle fully
     Note

     Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
157. Connect first responder loop and 12V negative terminal
     Note

     1x nut, 10mm, 6 Nm, 1x connector, Engage locking tab, Connect FRL first before connecting 12V to avoid damage to car computer

     

     

158. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_FIVE-WAY-VALVEvia Toolbox: (link)via Service Mode: Thermal ➜ Coolant System ➜ Coolant Valve Test
     Note

     Select ‘X’ at top right of window to close once complete
159. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Start Thermal Fill/Drain
     • Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
     • Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
     via Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
     Note

     Select ‘X’ at top right of window to close once complete, For AC related repairs verify all EXV's are in proper position, For all coolant related repairs verify vehicle is in Series, Thermal Fluid Fill/Drain routine has a 5 hour timeout, Routine will continuously run and not end
160. Reconnect AC hoses to vehicle

     

161. Perform AC vacuum test
     Note

     2 minute vacuum leak test, 15 minute vacuum

     

162. Perform AC refrigerant refill
     Note

     Recharge refrigerant to 1.02 kg (1020g), For Robinair AC machines press ESC to NOT ACCEPT the step to clear out residual oil, Once complete press next to start End of Charge process

     

     

     

163. Perform step 1 for End of Charge process
     Note

     Close high and low machine valves, Press next to continue

     

     

164. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
     • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
     • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
     Note

     Select ‘X’ at top right of window to close once complete
165. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Toolbox: (link)via Service Mode: Thermal ➜ Refrigerant System ➜ Run Heat Pump Commissioningvia Service Mode Plus: Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioning
     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
166. Proceed with steps 2-4 for End of Charge process and follow instructions displayed on AC Machine
     Note

     Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 3, Verify Discharge pressure does not exceed 26 bar and Suction pressure is not below 1.15 bar, Turn AC OFF, allow pressures to stabilize and remove high side hose

     

     

     

     

167. Proceed with steps 5-6 for End of Charge process and follow instructions displayed on AC Machine
     Note

     Turn AC on, Temp setting LO, Panel mode on, Fresh air mode on, Blower speed set to 3, Turn machine valves to OPEN, Allow pressures to stabilize, Remove low side hose from vehicle, Continue with AC machine instructions and clear AC hoses

     

     

     

168. Install caps onto AC ports
     Note

     2x caps

     

     

169. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
     • Thermal ➜ Coolant System ➜ Coolant Purge Start
     via Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
     Note

     Make sure vehicle is not in drive state, Plan is still running despite the stop message, Coolant pumps will be audible, Test lasts approximately 10 mins, Speeds can be monitored in garage under PT Thermal tab, Idle speed = ~1500 RPM, Test will vary speeds from 3500-6500 RPM and actuate valve between SERIES and PARALLEL, Putting vehicle into drive state will stop this routine, If speeds hover at 7000 RPM, that means the pumps are air locked, perform vacuum fill again, Continue to add coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle, Select ‘X’ at top right of window to close once complete
170. Inspect coolant level and top off as necessary
     Note

     Ensure that the fluid level is at the Max line

     

171. Install coolant bottle cap

     

172. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_COOLANT-PUMPS-IDENTIFICATIONvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Run Coolant Pumps Identification
     • Thermal ➜ Coolant System ➜ Pump Identification
     Note

     Select ‘X’ at top right of window to close once complete, Ensure VCFRONT_a490_coolantPumpsNotIdentified has cleared
173. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCEvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Test Thermal Performancevia Service Mode Plus:
     • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Thermal System Test
     • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Thermal System Test
     • Drive Unit ➜ Front Drive Unit Replacement ➜ Thermal System Test
     • Drive Unit ➜ Rear Drive Unit Replacement ➜ Thermal System Test
     Note

     Select ‘X’ at top right of window to close once complete.
174. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCRIGHT_X_HVAC-PERFORMANCEvia Toolbox: (link)via Service Mode:
     • Thermal ➜ Actions ➜ Test HVAC Performance
     • Thermal ➜ Actions ➜ Test HVAC Performance
     , click Run and allow routine to complete
     Note

     Select ‘X’ at top right of window to close once complete
175. Install fresh air intake duct
     Note

     1x bolt, 10mm bolt, 4 Nm, 2x clips, 1x pin, Set clips on bulkhead studs, Secure to thermal bar

     

     

     

     

176. Install frunk assembly into vehicle
     Note

     6x clips, Replace any clips if broken or missing

     

177. Install fasteners securing the frunk assembly
     Note

     5x bolts, 10mm, 5 Nm, Newer vehicles may be equipped with 1x push clip securing frunk to washer bottle neck

     

     

178. Install access panel
     Note

     3x clips, 1x connector

     

     

179. Install rear apron
     Note

     14x clips, Hold rear wall of frunk to keep from flexing while engaging front clips

     

     

180. Close hood
181. Move RH front seat to original position
182. Move LH front seat to original position
183. Install 2nd row seat cushion
     Note

     1x connector, Slide rear cushion rearward then align foam with seat rail, Make sure cushion is fully seated with push & pull test

     

     

     

184. Raise all four windows
185. Close all four doors
     Note

     If 12V is powered up, Unlatch rear doors before closing