Tesla Model S Owners & Service Manuals

Tesla Model S: HVAC Assembly (Remove and Replace)

Tesla Model S (2012-2025) Service Manual / Thermal Management / HVAC Assembly (Remove and Replace)

Removal

  1. Remove cross car beam (refer to procedure).
  2. Recover refrigerant from AC system (refer to procedure).
  3. Disconnect AC connection to HVAC, discard 'O' rings (torque 22 Nm).

    HVAC Assembly (Remove and Replace)

  4. Remove screws (x2) securing bulkhead TXV valve to HVAC (torque 6 Nm).
  5. Disconnect TXV harness connector.

    HVAC Assembly (Remove and Replace)

  6. Remove and discard 'O' ring. Caution: Lubricate new O-rings with clean refrigerant oil.
  7. Disconnect HVAC harness connectors (x10).
  8. LHD vehicles only: Remove the body controller (BCM) (refer to procedure).
  9. Remove bolts (x7) securing HVAC to bulkhead (torque 6 Nm).

    HVAC Assembly (Remove and Replace)

  10. Disconnect HVAC drain tube.
  11. Remove plastic rivets (x3) securing front LH shock tower cover to body. Release cover and remove.

    HVAC Assembly (Remove and Replace)

  12. Working from above, disconnect harness connector from DC-DC module.

    Note: Components have been removed in this graphic to aid clarity.

    HVAC Assembly (Remove and Replace)

  13. Attach a tether to the PTC heater harness.
  14. With assistance carefully release PTC harness from bulkhead and withdraw into footwell.
  15. Disconnect tether from harness connector. Note: Do not withdraw tether from bulkhead.
  16. Carefully remove HVAC and place on padded surface to prevent damage.

Caution: Plug pipe connections to prevent ingress of moisture or dirt.

Installation
  1. Installation procedure is the reverse of removal. Caution: Lubricate new O-rings with clean refrigerant oil.
  2. With assistance carefully pull DC-DC harness through bulkhead. Follow route left by tether, check surrounding components are not compromised. Cable tie and clip harness and hoses to avoid rubbing.
  3. Disconnect tether from harness connector.

    READ NEXT:

     Actuator - Inlet (Remove and Replace)

    Removal Remove glove box assembly (refer to procedure) Disconnect actuator harness connector. Remove screws (x3) securing recirculation actuator to HVAC assembly (torque 1 Nm).

     Actuator - Driver's Temperature (Remove and Replace)

    Removal Remove IP carrier (refer to procedure) Disconnect duct temperature sensor harness connector. Remove screw securing duct to HVAC assembly and position duct aside (torque 1

     Actuator - Mode (Remove and Replace)

    Removal Remove IP carrier (refer to procedure) Disconnect duct temperature sensor harness connector. Remove screw securing duct to HVAC assembly and position duct aside (torque 1

    SEE MORE:

     Power Strut - Liftgate (Remove and Replace)

    Removal Open the liftgate. Support the liftgate in the open position. Remove the RH C-post upper trim (refer to procedure). Release the RH rear corner of the headlining from the body. Note: Do not remove the headlining. Disconnect the power s

     12V Positive Jump Post (Remove and Replace)

    Warning: Before disconnecting the 12 volt power supply, ensure that driver's door window is fully open. Failure to follow this instruction could result in vehicle lockout. Warning: If the 12 volt power supply is disconnected, do not attempt to open any doors with door glass in closed

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