2026-08-09

Super Manifold Assembly R134a (V2) (Remove and Install)

Correction code 18400100201 FRT 1.20 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and its associated 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 you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

Warning
Only technicians who have completed all required certification courses are permitted to perform this procedure. Tesla recommends third party service provider technicians undergo equivalent training before performing this procedure. For more information on Tesla Technician requirements, or descriptions of the subject matter for third parties, see HV Certification Requirements. 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.
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.
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 correction within the same activity to the Service Visit.
Note
Coolant loss greater than 1L will require vacuum fill.
Equipment:
  • 1050448-00-B COOLANT VACUUM FILL - JTC

Torque Specifications

Table 1. Torque Specifications:Supermanifold (V2) (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 (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly
28 Nm (20.6 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
Nut that attaches the supermanifold to HVAC A/C line to the supermanifold
36 Nm (26.5 lbs-ft)
  • 13 mm socket
Reuse

Remove

  1. Set up the AC machine.
  2. Unlock the vehicle gateway. See Gateway (Unlock).
  3. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Start Thermal Fill/Drain, enter 1 in the Coolant fill and Refrigerant fill fields, click Run, and allow the routine to complete.
    Note
    This routine has a 5-hour limit. After 5 hours, the routine needs to be performed again.
  4. Disconnect the LV battery power. See LV Power (Disconnect and Connect) (Modify).
  5. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  6. Remove the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  7. Remove the front aero shield. See Aero Shield - Front (Remove and Replace).
  8. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Restore).
    Warning
    Make sure there is no overpressure 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
    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.
  9. Remove A/C machine hoses from the vehicle.
  10. Carefully depress the Schrader valves (x2) to level out any pressure difference between the A/C system pressure and the actual ambient atmospheric pressure.
    CAUTION
    Make sure to depress both Schrader valves. Failure to do so may result in injury.
  11. Remove the frunk reinforcement beam. See Beam - Reinforcement - Frunk (Remove and Replace).
    Note
    It is not necessary to separate the isolation brackets from the frunk reinforcement beam.
  12. Place a fluid catcher underneath the front of the vehicle.
  13. Remove the coolant bottle cap.
    Note
    Coolant loss greater than 1L will require vacuum fill.
  14. Release the spring clip, disconnect the radiator inlet hose from the supermanifold, and then plug the hose and supermanifold.
  15. Release the spring clip, disconnect the radiator outlet hose from the supermanifold, and then plug the hose and supermanifold.
  16. Release the spring clip, disconnect the front drive unit return hose from the supermanifold, and then plug the hose and supermanifold.
  17. Disconnect the battery supply hose sensor connector.
    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. Disconnect the electrical connector from the sensor on the powertrain supply hose, near the coolant bottle.
    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 spring clip, and then remove the chiller to battery hose from the supermanifold, and then plug the hose and supermanifold.
    Note
    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.
    Note
    Coolant loss greater than 1L will require vacuum fill.
  22. Release the connector locking tab, then disconnect the A/C logic electrical connector from the A/C compressor.
    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. 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.
  24. Release the clip that attaches the supermanifold harness to the front body controller module.
  25. Disconnect the thermal harness from the front body controller module connector.
  26. Remove the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  27. Remove the bolt that attaches the supermanifold to compressor A/C line to the supermanifold.
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  28. Remove the supermanifold-to-compressor A/C line from the supermanifold, move it aside, and use a bungee cord to secure it.
  29. With assistance, remove the bolts (x2) that attach the supermanifold to the shock tower brace.
    Tip
    Use of the following tool(s) is recommended:
    • 15 mm socket
  30. Remove the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
    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.
    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.
    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. With assistance, 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. Torque the bolts (x2) that attach the supermanifold to the shock tower brace.
    31 Nm (22.9 lbs-ft)
    Tip
    Use of the following tool(s) is recommended:
    • 15 mm socket
  6. Torque the nut that attaches the supermanifold to HVAC A/C line to the supermanifold.
    36 Nm (26.5 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  7. Install the bolts (x2) that attach the supermanifold to HVAC A/C line to the HVAC assembly.
    28 Nm (20.6 lbs-ft)
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  8. Install new seal washers (x2) for the supermanifold to compressor A/C line assembly at the supermanifold side.
    Note
    Lubricate the new seal washers with the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  9. Remove the bungee cord, and return the the supermanifold to compressor AC line back to its original position.
  10. 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)
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  11. Connect the thermal harness to the front body controller module connector.
  12. Install the clip that attaches the supermanifold harness to the front body controller module.
  13. Install the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  14. Connect the A/C compressor logic electrical connector to the A/C compressor, and then engage the locking tab.
    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.
  15. Remove the plugs, immediately connect the HV battery return hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  16. Remove the plugs, immediately connect the powertrain supply hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  17. Remove the plugs, immediately connect the battery supply hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  18. Connect the electrical connector to the sensor on the powertrain supply hose, near the coolant bottle.
    Note
    Harness and coolant hose are color coded. Match harness color to coolant hose color.
  19. Connect the electrical connector to the sensor on the chiller to battery hose, near the coolant bottle.
  20. Remove the plugs, immediately connect the front drive unit powertrain return hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull test to verify that the hose is fully seated.
  21. Remove the plugs from the supermanifold and radiator outlet hose, immediately connect the radiator outlet hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  22. Remove the plugs from the supermanifold and radiator inlet hose, immediately connect the radiator inlet hose to the supermanifold, and then fasten the clip.
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  23. Install frunk reinforcement beam, See Beam - Reinforcement - Frunk (Remove and Replace).
  24. Perform the vacuum leak test and oil injection, and A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge) (Restore).
  25. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  26. Remove the fluid catcher from underneath the front of the vehicle.
  27. Connect the LV battery. See LV Power (Disconnect and Connect) (Modify).
  28. Unlock the vehicle gateway. See Gateway (Unlock).
  29. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Thermal Fill/Drain > Run, and allow the routine to complete.
  30. Tap Thermal > Coolant System > Coolant Purge Start > Run, and allow the routine to complete.
    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.
  31. Install the front aero shield. See Aero Shield - Front (Remove and Replace).
  32. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  33. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Note
    Ensure that the coolant level is at the "Max" line.
  34. Tap Thermal > Refrigerant System > Run Commission Heat Pump > Run, and allow the routine to complete.
  35. Exit Service Mode. See 0005 - Service Modes.
  36. Install the fresh intake duct. See Duct - Air Intake (Remove and Replace).
  37. Install the HEPA filter assembly. See HEPA And Carbon Filters (Remove and Replace).
  38. Remove the vehicle from the lift.