Replacement of the heat pump assembly on a 2024 Model S Plaid. This is a PROFESSIONAL-ONLY procedure that integrates with the HV battery thermal loop via the Octovalve and superbottle — Tesla Toolbox software is mandatory to safely depressurize and refill the system. Battery coolant inspection is recommended at 4 years / 50,000 mi.

Warnings

Tools required

Parts

• Heat pump assembly (Model S Plaid 2024 specific) × 1 — Manufacturer-specified heat pump for 2024 Model S Plaid — verify by VIN
• Coolant line O-rings / quick-disconnect seals × 1 — OEM seal kit for heat pump coolant lines
• Refrigerant (per Toolbox-specified type and charge weight) × 1 — Refer to underhood label and Service Manual

Fluids

• Tesla Battery/Motor Coolant (G-48 equivalent) — DO NOT mix with conventional coolant — 10 qt

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 12V (or 16V lithium, located under the rear seat on 2021+ Plaid — verify by VIN) low-voltage battery before any work begins.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. Connect Tesla Toolbox and run the thermal system service mode to depressurize the battery cooling loop and isolate the Octovalve.
7. Recover refrigerant from the A/C system using approved recovery equipment per Toolbox guidance.
8. Raise vehicle on a lift rated for Model S Plaid weight (~4,800 lb) using Tesla-approved lift pad locations.
9. Remove the frunk liner and nose cowl panel to access the heat pump assembly.

Procedure

1. 1

   Verify thermal system is depressurized
   With Toolbox connected, confirm the battery thermal loop, powertrain loop, and cabin loop are all in service/depressurized state. Confirm refrigerant has been fully recovered and the system reads 0 psi on both high and low side.
   ⚠️Do not proceed unless Toolbox confirms loop depressurization. Opening a pressurized line that connects to the HV battery can force coolant into HV components.
2. 2

   Remove frunk liner and access panels
   Remove the frunk tub fasteners and lift out the liner. Remove the nose cowl panel and any acoustic foam covering the heat pump assembly. Set fasteners aside in labeled containers.
3. 3

   Disconnect electrical connectors at heat pump
   Disconnect the low-voltage signal connectors at the heat pump compressor, pressure/temperature sensors, and any connectors routed to the Octovalve harness. Label each connector. If any connector has orange shielding, STOP — that is an HV connector and requires Tesla-certified handling.
   ⚠️If you encounter an orange (HV) connector or shielded HV harness, STOP. The compressor on some Tesla heat pumps is HV-driven.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
4. 4

   Catch coolant and disconnect coolant lines
   Position a catch pan beneath the heat pump. Using the quick-disconnect release tool, disconnect each coolant line from the heat pump body. Cap each line and the heat pump ports immediately to prevent contamination. Inspect O-rings — they must be replaced, not reused.
   ⚠️Improper handling of these lines can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components. Cap lines immediately and never allow coolant to drip into the battery enclosure or HV harness paths.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)

   Hose Clamps3 Nm (2 lb-ft)
5. 5

   Disconnect refrigerant lines
   With refrigerant fully recovered and confirmed at 0 psi, disconnect the high-side and low-side refrigerant lines from the heat pump. Cap all openings with manufacturer-specified caps to prevent moisture ingress.
   ⚠Any moisture introduced into the refrigerant circuit will require system evacuation and possibly desiccant replacement.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
6. 6

   Remove heat pump mounting hardware
   Support the heat pump assembly by hand or with a small jack. Remove the mounting bolts and bracket bolts securing the assembly to the front body structure. Carefully lift the assembly out, watching for any remaining harness routing.
   ⚠️Improper handling of the heat pump while still partially connected to the loop can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
7. 7

   Transfer sensors and brackets to new heat pump
   Transfer any temperature/pressure sensors and mounting brackets from the original unit to the replacement, using new seals where applicable. Torque sensor bolts to specification.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
8. 8

   Install replacement heat pump
   Position the replacement heat pump and start all mounting bolts by hand. Torque mounting bolts and bracket bolts to specification in a cross pattern. Verify the assembly is fully seated against its mounting points with no harness pinches.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Reconnect coolant lines with new seals
   Install new O-rings/seals on every coolant line. Connect each quick-disconnect fully — listen for the audible click and verify by gentle tug. Torque any threaded fittings and hose clamps to specification.
   ⚠️An improperly seated coolant line can leak into the HV battery enclosure. Damage to the HV battery (~$15,000+ to replace) and HV component coolant contact is possible. Verify every connection.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)

   Hose Clamps3 Nm (2 lb-ft)
10. 10

    Reconnect refrigerant lines and electrical connectors
    Install new refrigerant line seals/O-rings, connect high and low side lines, and torque to OEM specification — refer to Tesla Service Manual for refrigerant fitting torque. Reconnect all low-voltage electrical connectors and torque connector bolts to specification.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
11. 11

    Reinstall covers and cowl
    Reinstall any heat pump cover plates and torque cover screws to specification. Reinstall the nose cowl panel and frunk liner.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Vacuum fill coolant loop via Toolbox
    Reconnect 12V/16V battery. With Toolbox in thermal service mode, command the Octovalve to the fill position. Use a coolant vacuum fill tool to evacuate the loop, hold vacuum to verify no leaks, then draw in Tesla G-48 coolant. Use Toolbox-guided bleed cycles to circulate coolant through battery, powertrain, and cabin loops.
    ⚠️Filling without Toolbox-controlled valve sequencing will trap air in the HV battery loop. Improper handling can damage the HV battery (~$15,000+ to replace) and may cause coolant to contact HV components if overpressure forces a leak.
13. 13

    Evacuate and recharge refrigerant
    Evacuate the A/C system to deep vacuum, hold for the manufacturer-specified time, then recharge with the exact refrigerant type and charge weight specified on the underhood label. Use Toolbox to verify pressures.

Reassembly

1. Verify all electrical connectors are fully seated and locked.
2. Verify all coolant quick-disconnects are clicked and pressure-tested via Toolbox.
3. Reinstall any acoustic foam in original locations.
4. Reconnect 12V/16V low-voltage battery and torque the negative terminal to OEM specification.
5. Clear any thermal system DTCs in Toolbox after the loop is filled and bled.

Verification

• With Toolbox connected, run the thermal system self-test and verify no leaks, no trapped air, and correct Octovalve actuation.
• Verify battery, powertrain, and cabin coolant temperatures track normally during a 15-minute idle/condition cycle.
• Test cabin HVAC heat and A/C — verify supply air temperatures meet Tesla's spec at maximum heat and maximum cool settings.
• Drive the vehicle and monitor battery and motor temperatures via service screens for stable operation.
• Inspect heat pump area, all coolant fittings, and refrigerant fittings for leaks after the test drive.
• Document coolant condition and service date — Tesla recommends battery coolant inspection at 4 years / 50,000 mi.
• Confirm no thermal-related fault codes return after a full drive cycle.

More procedures for this vehicle