10/12/2024 22:21:10

A/C Compressor (Remove and Replace)

Correction code 1820020012 FRT 1.02 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.

  • 2024-02-06: Remove the Flush steps and updated the routines and the amount of oil in the replacement compressor.
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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.

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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.
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CAUTION
The desiccant bag in the receiver dryer must be checked when replacing the A/C compressor to determine if debris resulting from failure of the compressor has entered the system.
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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: A/C Compressor (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the A/C compressor HV harness bracket to the A/C compressor
9 Nm (6.6 lbs-ft)
  • 13 mm 12-point deep socket
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench (for installation only)
 Reuse
Bolt that attaches the ground strap to the A/C compressor
7 Nm (5.2 lbs-ft)
  • Torx T25 socket
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
Reuse
Nut that attaches the low pressure fitting to the A/C compressor
22 Nm (16.2 lbs-ft)
  • 13 mm socket
  • 3 in extension
  • Ratchet/torque wrench (for installation only)
 Reuse
Nut that attaches the high pressure fitting to the A/C compressor
22 Nm (16.2 lbs-ft)
  • 13 mm socket
  • 3 in extension
  • Ratchet/torque wrench (for installation only)
 Reuse
Bolts (x2) that attach the A/C compressor assembly to the strut tower brace
31 Nm (22.9 lbs-ft)
  • 15 mm socket
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
Reuse
Bolts (x3) that attach the A/C compressor bracket to the A/C compressor
9 Nm (6.6 lbs-ft)
  • 10 mm deep socket
  • Cordless Ratchet/Impact Driver
  • Ratchet/torque wrench
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 > Refrigerant System > Start Thermal Fill Drain (Refrigerant only) > Run, and allow the routine to complete.
  4. Disconnect the LV battery. See LV Battery - Li-lon (Disconnect and Connect).
  5. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  6. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
    Informational PurposesAn informational icon, calling your attention
    Note
    Recover the refrigerant while continuing this procedure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Note the amount of the recovered oil.
  7. Remove the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  8. Perform Vehicle HV Disablement Procedure. See Vehicle HV Disablement Procedure.
  9. Remove the LV auxiliary battery. See LV Battery (Remove and Replace).
  10. Release the connector locking tab, then disconnect the A/C logic electrical connector from the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    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 to release the connector.
    Tip: Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  11. 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.
  12. Disconnect the HV harness electrical connector from the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  13. Remove the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm 12-point deep socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench (for installation only)
  14. Remove the A/C compressor HV harness from the A/C compressor and move it aside.
  15. Remove the bolt that attaches the ground strap to the A/C compressor, and then move the ground strap aside.
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  16. Use a clip pry tool to release the clip that attaches the coolant hose to the A/C compressor bracket.
  17. Use a clip pry tool to release the clips (x2) that attach the coolant hose to the A/C compressor bracket.
  18. Remove the nut that attaches the low pressure fitting to the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Ratchet/torque wrench (for installation only)
  19. Remove the nut that attaches the high pressure fitting to the A/C compressor, and then set the hose assembly aside.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Ratchet/torque wrench (for installation only)
  20. With an assistant, remove the bolts (x2) that attach the A/C compressor assembly to the strut tower brace, and then carefully maneuver the assembly towards the front of the vehicle, under the strut tower support brace. Rest the A/C compressor assembly on the front underhood storage unit reinforcement beam.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not rest the A/C compressor on the HV connector.
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  21. With an assistant, remove the bolts (x3) that attach the A/C compressor bracket to the A/C compressor, and then remove the bracket from the compressor.
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  22. Remove the HV harness cover from the A/C compressor.
  23. Take note of the part numbers on the old and new compressors.
  24. Use masking tape to protect LP and HP opening ports on the compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the ports are fully covered.
  25. Use a wire brush to remove as much acoustic material from the compressor as possible.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Failure to remove material will result in an inaccurate weight measurement.
  26. Use a digital scale to weigh the removed compressor and record its weight.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    This step is only to aid in potential diagnosis support. DO NOT add oil to the new A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not drain any oil from the removed compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    The amount of oil in the old compressor is equal to the weighed weight of the compressor minus the dry weight of the compressor.
  27. Repeat steps 24 through 26 to remove the acoustic blanket from the new compressor.

Install

  1. Use a 13mm socket to remove the transport plugs from the new compressor.
  2. Weigh the compressor and reset the compressor oil amount, adjust the amount of oil through the suction port of the compressor.
    • Denso - ND-11
    • Sanden - RB100EV
    Informational PurposesAn informational icon, calling your attention
    Note
    The amount of oil in the new compressor should be equal to the amount of oil in the old compressor (step 26) plus the amount of oil recovered (step 6).
    Informational PurposesAn informational icon, calling your attention
    Note
    Weight is measured in grams.
  3. Install the acoustic blanket onto the new compressor. See Acoustic Blanket - A/C Compressor (Remove and Replace).
  4. Install the HV harness cover to the A/C compressor.
  5. Position the A/C compressor bracket on the A/C compressor, and then install the bolts (x3) that attach the bracket to the compressor.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 10 mm deep socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  6. With an assistant supporting the A/C compressor assembly under the strut tower brace, hand-start the bolts (x2) that attach the A/C compressor assembly to the brace, and then torque the bolts.
    31 Nm (22.9 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 15 mm socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  7. Replace the o-rings on the high pressure and low pressure supermanifold to A/C compressor hose fittings.
  8. Position the supermanifold to A/C compressor high pressure fitting on the A/C compressor, and then install the nut that attaches the fitting to the A/C compressor.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Ratchet/torque wrench (for installation only)
  9. Position the supermanifold to A/C compressor low pressure fitting on the A/C compressor, and then install the nut that attaches the fitting to the A/C compressor.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Ratchet/torque wrench (for installation only)
  10. Perform the vacuum leak test and refill A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Maintenance).
  11. Install the clips (x2) that attach the coolant hose to the A/C compressor bracket.
  12. Install the clip that attaches the coolant hose to the A/C compressor bracket.
  13. 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)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench
  14. Position the A/C compressor HV harness to the A/C compressor.
  15. Install the bolt that attaches the A/C compressor 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 12-point deep socket
    • Cordless Ratchet/Impact Driver
    • Ratchet/torque wrench (for installation only)
  16. Connect the HV harness electrical connector to the A/C compressor.
  17. Install the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  18. Connect the A/C compressor logic electrical connector to the A/C compressor, and then engage the locking tab.
    Informational PurposesAn informational icon, calling your attention
    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.
  19. Install LV power. See LV Battery (Remove and Replace).
  20. Install the 2nd row lower seat cushion. See Seat Cushion - 2nd Row (Remove and Replace).
  21. Connect LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  22. Unlock the vehicle gateway. See Gateway Unlock.
  23. On the touchscreen, touch Controls > Thermal > Thermal Configurations > compressorType, and select and save the correct type.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to Toolbox for compressor configuration.
    Informational PurposesAn informational icon, calling your attention
    Note
    Check the compressorType and make sure it shows as intended.
  24. Reinstall the software. See Software Reinstall - Touchscreen.
  25. Unlock the vehicle gateway. See Gateway Unlock.
  26. On the touchscreen, perform the following steps:
    1. Touch Controls > Thermal > Sensors and Valves > Reset Compressor P-Metric, click Run to start the routine.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure the routine is passed, then touch Close to close it.
    2. Touch Thermal > Refrigerant System > Run Heat Pump Commissioning and select Run to start the routine.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure the routine is passed, then touch Close to close it.
    3. Touch Thermal > Actions > Test HVAC Performance and select Run to start the routine.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure the routine is passed, then touch Close to close it.
    4. Touch Thermal > Actions > Test Thermal Performance and select Run to start the routine.
      Informational PurposesAn informational icon, calling your attention
      Note
      Make sure the routine is passed, then touch Close to close it.
  27. Disable Service Mode. See Service Mode.
  28. Disconnect LV maintainer. See LV Maintainer (Connect and Disconnect) (Maintenance).
  29. Connect LV power. See LV Battery - Li-lon (Disconnect and Connect).
  30. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  31. Raise all windows and close all doors.