2026-04-02

Check Valves - Supermanifold (Remove and Replace)

Correction code 18402902 0.96 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. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure. NOTE: See Ergonomic Precautions for safe and healthy working practices.

  • 2026-04-02: Updated the procedure to most recent PDS validation.
  • 2024-01-23: Removed the steps of removing and installing the A/C line assembly and added the steps about the front aero shield. And updated the way of performing the routines from using Toolbox to using the touchscreen.
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.

Torque Specifications

Table 1. Torque Specifications:
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the A/C line to the supermanifold.
22 Nm (16.2 lbs-ft)
  • 13 mm socket
 Reuse

Remove

  1. Place the vehicle on the 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Ensure the vehicle is not charging.
  2. Open the LH front door and fully lower the LH front window.
  3. Enable Service Mode. See Service Mode.
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  5. If installed, remove the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Replace).
  6. Remove the front aero shield. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  7. Lower the vehicle fully.
  8. Position a coolant drain container underneath the front of the vehicle.
  9. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Start Thermal Fill Drain. and then fill in the Parameters fields: "1" for Coolant fill, and "1" for Refrigerant fill. Tap Run, and allow the routine to complete.
  10. Disconnect 12V/LV power. See 12V/LV Power (Disconnect and Connect).
  11. Recover the refrigerant. See A/C Refrigerant (Recovery and Recharge).
  12. Remove the 12V/LV battery. See 12V/LV Battery (Remove and Replace).
  13. Remove the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
  14. Remove the coolant bottle. See Coolant Bottle (Remove and Replace).
  15. When the A/C refrigerant recovery is complete, disconnect the A/C hoses from the vehicle and release the vacuum from the A/C lines by depressing the schrader valves.
  16. Remove the supermanifold-to-compressor A/C line. See A/C Line - Supermanifold to Compressor (Remove and Replace).
  17. Release the locking tab, and then disconnect the electrical connector from the high pressure and temperature sensor.
    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 the main body of the connector to fully disconnect it.
  18. Release the locking tab, and then disconnect the electrical connector from the recirc EXV (expansion valve).
    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 the main body of the connector to fully disconnect it.
  19. Release the locking tab, and then disconnect the electrical connector from the liquid cooled condenser 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 the main body of the connector to fully disconnect it.
  20. Release the locking tab, and then disconnect the electrical connector from the liquid cooled condenser shut off valve.
    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 the main body of the connector to fully disconnect it.
  21. Release the locking tab, and then disconnect the electrical connector from the right side cabin condenser 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 the main body of the connector to fully disconnect it.
  22. Release the locking tab, and then disconnect the electrical connector from the high pressure and temperature subcool sensor.
    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 the main body of the connector to fully disconnect it.
  23. Release the locking tab, and then disconnect the electrical connector from the left side cabin condenser 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 the main body of the connector to fully disconnect it.
  24. 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 the main body of the connector to fully disconnect it.
  25. Release the locking tab, and then disconnect the electrical connector from the evap 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 the main body of the connector to fully disconnect it.
  26. Position the thermal sub harness assembly away from the supermanifold.
  27. Remove and discard the liquid cooled condenser check valve snap ring from the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an inspection mirror as needed.
  28. Remove the liquid cooled condenser check valve from the supermanifold.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the check valve separates from the aluminum cap during removal, do not use metal tools. Metal tools may scrape the supermanifold housing causing internal damage. Use fingers or wrap electrical tape around a 90 degree pick.
  29. Remove and discard the check valve cabin condenser snap ring from the supermanifold.
  30. Remove the check valve cabin condenser from the supermanifold.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the check valve separates from the aluminum cap during removal, DO NOT use metal tools. Metal tools may scrape the supermanifold housing causing internal damage. Use fingers or wrap electrical tape around a 90 degree pick instead.
  31. Remove and discard the evaporator check valve snap ring from the supermanifold.
  32. Remove the evaporator check valve from the supermanifold.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the check valve separates from the aluminum cap during removal, do not use metal tools. Metal tools may scrape the supermanifold housing causing internal damage. Use fingers or wrap electrical tape around a 90 degree pick instead.

Install

  1. Lubricate O-rings on the liquid cooled condenser check valve with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications. Then install the check valve into the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an inspection mirror as needed.
  2. Install a new liquid cooled condenser check valve snap ring onto the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the snap ring is fully seated inside the groove in the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an inspection mirror as needed.
  3. Use the appropriate oil to lubricate the O-rings on the check valve cabin condenser. Fluids and Capacities for A/C oil specifications. Then install the check valve cabin condenser into the supermanifold.
  4. Install a new check valve cabin condenser snap ring into the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the snap ring is properly seated inside the groove on the supermanifold.
  5. Lubricate O-rings on the evaporator check valve with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications. Then install the check valve into the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use an inspection mirror as needed.
  6. Install a new evaporator check valve snap ring onto the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Verify the snap ring is properly seated inside the groove on the supermanifold.
  7. Connect the electrical connector on the evap 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.
  8. Connect the electrical connector on 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.
  9. Connect the electrical connector on the left side cabin condenser 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.
  10. Connect the electrical connector on the right side cabin condenser 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.
  11. Connect the electrical connector on the high pressure and temperature subcool sensor.
    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.
  12. Connect the electrical connector on the liquid cooled condenser shut off valve.
    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.
  13. Connect the electrical connector on the liquid cooled condenser 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.
  14. Connect the electrical connector on the recirc 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.
  15. Connect the electrical connector on the high pressure and temperature sensor.
    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.
  16. Install the supermanifold to compressor A/C line. See A/C Line - Supermanifold to Compressor (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Before installation, install new seal washers on the supermanifold to compressor A/C line.
  17. Start the vacuum leak test and refrigerant recharge procedure. See A/C Refrigerant (Recovery and Recharge).
  18. Install the coolant bottle. See Coolant Bottle (Remove and Replace).
  19. Perform the cooling system vacuum refill procedure. See Cooling System (Vacuum Refill).
  20. Install the 12V battery. See 12V/LV Battery (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not connect 12V power at this time.
  21. Remove the fluid catcher from underneath the vehicle.
  22. Raise the vehicle to a comfortable working height, and lower the lift onto locks.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION

    Make sure there is an audible click of the locks on both sides before lowering, otherwise the vehicle may tilt to one side.

    Make sure that the doors are clear of surrounding objects.

  23. Install the front aero shield. See Panel - Aero Shield - Front (Non-Structural Pack) (Remove and Replace).
  24. Connect LV power. See 12V/LV Power (Disconnect and Connect).
  25. Unlock the vehicle gateway. See Gateway (Unlock).
  26. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Refrigerant System > Stop Thermal Fill Drain, and allow the routine to complete.
  27. Tap Sensors and Valves > Run Heat Pump Commissioning, select Run, and allow the routine to complete.
  28. Tap Coolant System > Coolant Purge, select Run, and allow the routine to complete.
    Informational PurposesAn informational icon, calling your attention
    Note
    • The routine will last for a while after the stop message displays. The coolant pumps are audible.
    • The test lasts for approximately 10 mins. Do not start another routine during this time.
    • Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
    • The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
    • If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
  29. Inspect the coolant level and top off as necessary, then install the coolant bottle cap.
  30. Tap Actions > Test Thermal Performance, select Run, and allow the routine to complete.
  31. Tap Actions > Test HVAC Performance, select Run, and allow the routine to complete.
  32. Exit Service Mode. See Service Mode.
  33. Install the fresh intake duct. See Duct - Fresh Intake (Remove and Replace).
  34. If equipped, install the HEPA filter assembly. See Assembly - Filter - HEPA (Remove and Install).
  35. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  36. Raise the LH front window and close the LH front door.
  37. Remove the vehicle from the lift.