25/11/2024 14:34:31

Supermanifold (Remove and Replace)

Correction code 184001021.62 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.

  • 2024-11-25: Added information on manually configuring replacement coolant pumps (optional).
  • 2024-02-29: Re-organize the procedure.
  • 2024-01-10: Specified refrigerant oil for Sanden compressor.
  • 2023-06-20: Added compressor weight including oil for Sanden type compressor.
  • 2023 - 07-24: Add a step to change coolant pump type after installation.
Warning IconA warning icon, calling your attention to a possibly risky situation
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.
Informational PurposesAn informational icon, calling your attention
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.

Remove

  1. Set up the A/C machine.
  2. Raise and support the vehicle.
  3. Open all four doors and lower the windows.
    Informational PurposesAn informational icon, calling your attention
    Note
    Latch rear doors to prevent accidental closing when 12V/LV power is disconnected.
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  5. Remove the HEPA filter. See Assembly - Filter - HEPA (Remove and Replace).
  6. Enable Service Mode. See Service Mode.
  7. On the touchscreen, touch Service Mode > Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant & Refrigerant) and select Run, and then allow the routine to complete.
  8. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  9. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  10. Remove the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  11. Position a coolant drain container underneath the front of the vehicle.
  12. Recover the refrigerant from the vehicle. See A/C Refrigerant (Recovery and Recharge).
  13. Remove the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
  14. Remove the 12V battery. See 12V/LV Battery (Remove and Replace).
  15. Remove the coolant bottle cap.
  16. Disconnect the powertrain bypass hose from the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    This will drain the coolant reservoir.
  17. Disconnect the radiator outlet hose from the Supermanifold.
  18. Disconnect the radiator inlet hose from the Supermanifold.
  19. Install three male plugs into the coolant ports at the front of the Supermanifold.
  20. Before performing the next two steps, inspect the coolant hose temperature sensors and connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the vehicle is equipped with an earlier model temperature sensor (left image), the new super manifold connectors may not fit. In this case the electrical connector cover must be swapped from the old supermanifold to the new supermanifold. Perform Rework Connectors before installation.
  21. Disconnect the sensor for the chiller to battery hose.
  22. Disconnect the sensor for the powertrain supply hose.
  23. Disconnect the chiller to battery hose from the supermanifold.
  24. Disconnect the powertrain supply hose from the supermanifold.
  25. Disconnect the HV battery return hose from the Supermanifold.
  26. Install three male plugs into the coolant ports at the rear of the Supermanifold.
  27. Disconnect the supermanifold harness connector from the front controller.
  28. Remove the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  29. Disconnect the A/C compressor logic connector.
  30. Remove the desiccant bag from the supermanifold to determine the amount of oil that must be added later in the procedure, See Desiccant (Remove and Replace).
  31. Measure the refrigerant oil level inside the accumulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Level will vary per vehicle. Do not rely on picture. Keep steel ruler vertival during measurement. Record measurement in millimeters.
  32. Convert the accumulator oil level measurement to grams.
    Informational PurposesAn informational icon, calling your attention
    Note
    Multiply measurement by 5.6 and add 15. Record measurement in grams.
  33. Calculate the total oil loss from A/C recovery, desiccant bag, and accumulator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Add all measurements and record total in grams. Measurement will be used for oil injection at a later step.
    Informational PurposesAn informational icon, calling your attention
    Note
    AC recovery oil: If the quantity of oil recovered from the vehicle's A/C system is more than 30 grams, refer to the table in the A/C Refrigerant (Recovery and Recharge) to determine the final value of the AC recovery oil.
  34. Remove the nut that attaches the low side of the manifold to the compressor pipe and move the low side pipe out of the way.
  35. Remove the nut that attaches the high side of the manifold to compressor pipe and move the high side pipe out of the way.
  36. Remove the bolt on the A/C manifold to compressor line from the Supermanifold.
  37. Remove the A/C manifold line from the Supermanifold and remove the A/C manifold line assembly out of the vehicle.
  38. Remove the bolts (x2) that attach the A/C manifold to HVAC line assembly to the HVAC assembly.
  39. Release the clips (x4) that attach the coolant hose to the AC compressor bracket.
  40. Remove the rear battery tie down strap from the 12V/LV battery bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    The 12V/LV battery bracket also functions as the A/C compressor bracket.
  41. Release the clip that attaches the 12V battery vent tube to the battery bracket.
  42. Remove the bolt that attaches the HV harness bracket to the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  43. Remove the bolt that attaches the ground strap to the A/C compressor, and then set the ground strap aside.
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  44. Release the clip that attaches the coolant hose to the A/C compressor bracket, near the ground strap attachment point.
  45. Pull the A/C compressor HV connector black locking tab away from the A/C compressor.
  46. Using a 45-degree pick, simultaneously push on the central locking tab while pulling on the outer locking tab, and remove the HV connector from the A/C compressor.
  47. Move the HV harness bracket forward and up to release the bracket from the A/C compressor, and then carefully set the bracket aside.
  48. Disconnect the HVIL electrical connector.
  49. Remove the retaining clips that attach the AC compressor HV harness to the shock tower support brace.
    Informational PurposesAn informational icon, calling your attention
    Note
    Pull upward on clip to assist with removal, Do not pull on HV cable.
  50. Remove the LH and RH bolts that attach the shock tower brace to the body.
    55 Nm (40.6 lbs-ft)
    55 Nm (40.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  51. Remove the LH and RH outer bolts that attach the shock tower brace to the body, and then remove the shock tower brace from the vehicle.
    62 Nm (45.7 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  52. With assistance, remove the shock tower brace along with Supermanifold and compressor from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Mind the connectors and AC lines, slowly lift the brace, Put it on a cardboard pad
  53. Remove the bolts (x2) that attach the supermanifold to the shock tower brace, and then remove the supermanifold.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  54. Remove the nut that attaches the supermanifold to HVAC AC line assembly to the supermanifold, and remove the supermanifold to HVAC AC line assembly.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Cordless Ratchet/Impact Driver
    • Flex head ratchet/flex head torque wrench
  55. Document the old and new part numbers and serial numbers.
    Informational PurposesAn informational icon, calling your attention
    Note
    Label is located in front of accumulator.

Rework Connectors

Perform this part of the procedure only if the temperature sensor connectors must be reworked, as instructed in step 21 and 22. If rework is not necessary, proceed with the next part of the procedure. See Install.
  1. Remove the front covers from the new supermanifold coolant temperature sensor connectors (x2).
  2. Remove the front covers from the old supermanifold coolant temperature sensor connectors (x2).
  3. Install the front covers of the old supermanifold coolant temperature sensor connectors (x2) onto the new supermanifold coolant temperature sensor connectors.

Install

  1. Position the supermanifold assembly to the shock tower brace, and then hand-tighten the bolts that attach the supermanifold assembly to the brace.
  2. Tighten the bolts that attach the supermanifold assembly to the shock tower brace.
    31 Nm (22.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
  3. Replace the seal washers on supermanifold to HVAC AC line assembly on the supermanifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x seal washers, Install new seal washers, Lube seal washers with ND-11 oil
  4. Replace the seal washers on supermanifold to HVAC AC line assembly on the HVAC side.
    Informational PurposesAn informational icon, calling your attention
    Note
    5x seal washers, Install new seal washers, Lube seal washers with ND-11 oil
  5. Hand-tighten the nut that attach the supermanifold to HVAC AC line assembly to the supermanifold.
  6. Torque the nut that attach the supermanifold to HVAC AC line assembly 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
    • Flex head ratchet/flex head torque wrench
    • 6 in extension
  7. With assistance, install the supermanifold and compressor along with shock tower brace to the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    2 technicians are required for this step, Mind the connectors and AC lines, slowly lift the brace, Put it on a cardboard pad
  8. Install the LH and RH bolts that attach the shock tower brace to the body.
    55 Nm (40.6 lbs-ft)
    55 Nm (40.6 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  9. Install the LH and RH outer bolts that attach the shock tower brace to the body.
    62 Nm (45.7 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 15 mm socket
    • Flex head ratchet/flex head torque wrench
  10. Install the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 6 in extension
    • Flex head ratchet/flex head torque wrench
  11. Install the retaining clips that secure the AC compressor HV harness to the shock tower brace.
  12. Position the A/C compressor HV harness bracket on the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the HV harness bracket engages with the harness mount on the top of the A/C compressor.
  13. Connect the HVIL electrical connector.
  14. Fully seat the A/C compressor HV connector on the A/C compressor, and then engage the locking tab by pushing it toward the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test to verify that the connector is fully attached.
  15. Install the bolt that attaches the HV harness bracket to the A/C compressor.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Ratchet/torque wrench
    Tip:
  16. Install the clip that attaches the coolant hose to the A/C compressor bracket, near the ground strap attachment point.
  17. Connect the A/C compressor logic connector.
  18. Position the ground strap on the A/C compressor, and then 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
    Note
    This bolt is self-tapping. It is not necessary to tap the compressor bolt hole.
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  19. Install the radiator outlet hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  20. Install the radiator inlet hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  21. Install the powertrain bypass hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  22. Connect the supermanifold harness connector to the front controller.
  23. Connect the HV battery return hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  24. Connect the powertrain supply hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  25. Connect the chiller to battery hose to the Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform push-pull-push test to make sure hose is fully seated.
  26. Connect the sensor for the powertrain supply hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness with purple tape connects to coolant temperature sensor closest to coolant bottle.
  27. Connect the sensor for the chiller to battery hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    Harness with purple tape connects to coolant temperature sensor closest to coolant bottle.
  28. Install the clips (x4) that attach the coolant hoses to the A/C compressor bracket.
  29. Install the rear battery tie down strap on the 12V battery bracket.
  30. Install the clip that attaches the 12V battery vent tube to the 12V battery bracket.
  31. Install the 12V/LV battery into the vehicle. See 12V/LV Battery (Remove and Replace).
  32. Replace the seal washers (x2) for the A/C manifold to compressor line on the A/C manifold side.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate seal washers A/C refrigerant oil.
  33. Replace the seal washer on the high side A/C manifold to compressor line.
  34. Replace the seal washer on the low side A/C manifold to compressor line.
  35. Install the bolt that attaches the A/C manifold to compressor line onto the Supermanifold.
    22 Nm (16.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Hand start bolt to prevent stripped threads
  36. Install the nut that attaches the A/C manifold to compressor line high side to the compressor.
    22 Nm (16.2 lbs-ft)
  37. Install the nut that attaches the A/C manifold to compressor line low side to the compressor.
    22 Nm (16.2 lbs-ft)
  38. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  39. Unlock the vehicle gateway. See Gateway (Unlock).
  40. On the touchscreen, touch Service Mode > Thermal > Refrigerant System > Start Thermal Fill Drain (Coolant & Refrigerant) and select Run, and then allow the routine to complete.
  41. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  42. Perform a coolant vacuum refill. SeeCooling System (Vacuum Refill).
  43. Install the front aero shield panel. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  44. Perform A/C vacuum leak test and oil injection. See A/C Refrigerant (Recovery and Recharge).
  45. Perform A/C recharge. See A/C Refrigerant (Recovery and Recharge).
  46. Connect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  47. Reinstall the software. See Software Reinstall - Touchscreen.
  48. Unlock the vehicle gateway. See Gateway (Unlock).
  49. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Stop Thermal Fill Drain, and allow the routine to complete.
  50. Tap Coolant System > Run Coolant Pumps Identification > Run, and close once the routine is passed.
    Informational PurposesAn informational icon, calling your attention
    Note
    If necessary, the coolant pumps can be manually configured via: Service Mode Plus > Gateway Unlock > Vehicle Configurations > coolantPumpType.
  51. Tap Sensors and Valves > Run Heat Pump Commissioning > Run, and close once the routine is passed.
  52. Tap Coolant System > Coolant Purge > Run, and close once the routine is passed.
  53. Inspect the coolant level and make sure the fluid level is at the Max line.
  54. Tap Actions > Test Thermal Performance > Run, and close once the routine is passed.
  55. Tap Actions > Test HVAC Performance > Run, and close once the routine is passed.
  56. Exit Service Mode. See Service Mode.
  57. Install the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
  58. Install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  59. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  60. Install the 2nd row seat cushion. See Seat Cushion - Lower - 2nd Row (Remove and Replace).
  61. Remove the vehicle from the lift.