26/07/2023 16:57:08
A/C Refrigerant Flush Due To Compressor Failure (Dual Motor) (Europe)
Correction code 18208052
Warning
This procedure is a DRAFT,
although it has been validated. Warnings and Cautions might be missing. Follow safety
requirements and use extreme caution when working on or near high voltage systems and
components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
-
Set up A/C machine and perform hose
flush
NoteTouch time only
-
Set up A/C machine with flush kit
NoteAttach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut
- Open all four doors
- Lower all 4 windows
-
Raise and support vehicle
NoteSet air suspension to "Jack Mode" if equipped Via Controls > ''Service''
- Connect a laptop with Toolbox 3 to the vehicle.
- In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain.
- Under Action, select Start to open the valves before the service procedure.
- Under Fluid Fill Target, select Refrigerant to activate refrigerant valves.
- Click Run, and allow the routine to complete.
- Move both front seats fully forward
-
Open hood
NoteUsing MCU touchscreen > Controls > Frunk Trunk
-
Remove rear underhood apron
Note8x clips
-
Remove RH underhood apron
Note9x clips
-
Remove LH underhood apron
Note9x clips
-
Remove front underhood apron
Note7x clips
-
Release drainage hoses from HEPA filter
inlet duct
Note2x hoses
-
Remove clips securing HEPA filter inlet
duct to cowl panel
Note3x push clips
-
Remove HEPA filter inlet duct
Note2x clips on HEPA filter
-
Remove dust caps from high-side and
low-side service ports
Note2x caps
-
Connect hoses to vehicle and perform A/C
recovery
NoteTouch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports
-
Check if the internal A/C Machine
cylinder is filled at least with 5 KG
NoteFill the intern refrigerant tank
-
Remove HEPA filter outlet duct from
vehicle
NoteLift up, pull towards front of vehicle, then rotate clockwise
-
Disconnect light and release switch
connectors and remove underhood storage carpet
Note2x connectors, Release edge of carpet from underneath underhood storage unit seal
-
Remove underhood storage unit
Note2x bolts, 10mm, 7 Nm, 2x push clips
-
Push wiring harness grommet through
underhood storage unit and remove
Note1x grommet
-
Power down vehicle using MCU
NoteControls > Safety&Security > Power Off > ''POWER OFF''
-
Disconnect 12V negative terminal and
First Responder Loop
Note1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components
-
Remove 2nd row seat bottom cushion
Note2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side
-
Remove NVH padding from underneath 2nd
row seat cushion
NoteIf equipped
-
Remove bolts securing seat bottom
frame
Note8x bolts, 11mm, 26 Nm
-
Lift up and support seat bottom
frame
NoteRelease harness clips if necessary
-
Remove warranty label from charger cover
panel
-
Remove all items from pockets and ensure
not wearing metal items
-
Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC
-
Put on HV insulating gloves and leather
over gloves
-
Remove the charger HV access panel cover
and discard fasteners
Note11x bolts, T20, 2 Nm, Discard after removal
-
Release tabs and open both access
doors
Note4x tabs, Make sure to wear proper PPE
-
Verify no high voltage
NoteMeasure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, If voltage is greater than 10V, pack contactors are not open or welded, Stop work and reach out to Service Engineering
-
Install charger cover panel and torque
screws
Note11x bolts, T20, 2 Nm, Install new patch bolts
-
Install new warranty label onto charger
cover panel
NoteWipe charger with IPA prior to installation
- Remove HV insulating gloves
-
Lower seat frame into position and
secure harness clips to frame
Note8x clips
-
Install and torque bolts securing seat
frame to vehicle
Note8x bolts, 11mm, 26 Nm
-
Place NVH padding onto seat frame
-
Reinstall seat bottom cushion
Note2x clips, 7x connectors if equipped, Replace clips if necessary
-
Remove LH shock tower cover
Note4x push clips
-
Remove RH shock tower cover
Note4x push clips
-
Remove LH side wiper arm
Note1x nut, 17mm, 31 Nm
-
Remove RH side wiper arm
Note1x nut, 17mm, 31 Nm
-
Remove cowl screen panel
Note4x push clips, 2x end tabs
-
Disconnect high side and low side hoses
from vehicle
-
Remove fuse box cover
Note2x clips
-
Remove 12V supply cable to DCDC
Note1x nyloc nut, 13mm, 12 Nm, 1x clip, Discard nyloc nut
-
Release clips securing 12V battery
supply cable to fuse box and strut tower cross beam
Note3x clips
-
Disconnect pyrotechnic fuse
connector
Note1x connector, Gently lift up orange lock tab to release connector
-
Remove bolts securing fuse box to
body
Note2x bolts, 10mm, 6 Nm
-
Release fuse box from body
Note2x tabs, Slide fuse box to RH side to release tabs and then lift
-
Disconnect remaining connectors from
bottom of fuse box
Note3x connectors, Depress locking tabs on sides of flip type connector and flip lever on connector to reseal
-
Remove clip securing harness to LH shock
tower brace
-
Remove wiper motor fastener mounted to
LH shock brace
Note1x bolt, 10mm, 6 Nm
-
Remove LH air suspension reservoir
bracket from LH shock brace
Note2x bolts, 10mm, 6 Nm
-
Remove AC line bracket bolt on RH shock
brace
Note1x bolt, 10mm, 6 Nm
-
Remove air reservoir bracket mounting
bolts from RH shock brace
Note2x bolts, 10mm, 6 Nm
-
Remove LH shock tower brace
Note1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm
-
Remove RH shock tower brace
Note1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm
-
Remove wiper motor
Note3x bolts, 10mm, 6 Nm, 1x connector
-
Remove screws securing air suspension
reservoir to bracket
Note2x screws, T25, 2.5 Nm
-
Set air suspension reservoir aside for
access
NoteManeuver below AC line
-
Remove 12V positive terminal cover
Note2x tabs
-
Disconnect 12V positive terminal
Note1x nut, 10mm, 6 Nm
-
Remove fasteners securing 12V battery
bracket to shock tower cross member and the battery beam
Note2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
-
Remove the 12V battery bracket assembly
from vehicle
-
Remove fastener securing coolant hose to
battery beam
Note1x bolt, T30, 5 Nm
-
Remove fasteners securing the battery
beam to the LH and RH body beams
Note2x bolts, T30, 3.5 Nm, 1x edge clip
-
Remove the battery beam
-
Remove fasteners securing coolant
reservoir to shock tower cross member
Note4x bolts, 10mm, 6 Nm, This will allow room for reservoir to move to make room during front trunk harness removal
-
Shift coolant reservoir to give access
to components behind
NoteUse bungee or rag to hold out of place
-
Disconnect the coolant bottle level
sensor
Note1x connector
-
Disconnect A/C compressor logic
connector
Note1x connector
-
Release ground connection at the A/C
compressor mount bracket
Note1x bolt, T25, 7 Nm
-
Raise vehicle partially and lower onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Remove screw securing front fascia to RH
fender bracket
Note1x screw, T25, 1.5 Nm
-
Raise vehicle fully and lower lift onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Remove bolt and clips securing RH side
of fascia to front aero shield
Notefull aero shield does not need to come off - 1x bolt, 10mm, 3 Nm, 2x push clips_x000A_
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Pull RH side of fascia away from bracket
and headlamp
NotePull to release clips
-
Raise vehicle fully and lower lift onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Remove cap from condenser
Note1x cap, 10mm hex, 12 Nm
-
Remove filter screen from
condenser
-
Remove desiccant bag from
condenser
-
Install cap into condenser
Note1x cap, 10mm hex, 12 Nm
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Release PTC - Battery Heater - DC-DC HV
connector from FJB to gain access to release A/C compressor HV connector from FJB
Note4x locking tab, 4x connector
-
Remove A/C lines from compressor
Note2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Remove A/C compressor assembly from
vehicle
Note3x Torx bolts, T40, torque 20 Nm
-
Unplug TXV connector
Note1x connector
-
Remove fasteners securing TXV to
evaporator
Note2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Remove TXV from A/C lines
Note1x bolt, 5mm hex, 20 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Release connector lock and disconnect
the connector on EXV
Note1x connector, locking tab
-
Remove nut securing AC lines to
EXV
Note1x nut, 10mm, 12 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Remove EXV from chiller
Note2x bolts, 3mm hex, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
-
Secure flush adapter to low side
compressor line
Note1x nut, 10mm, 10 Nm, Low side hose is big, O-ring OK to reuse if not damaged
-
Blue line nipple, Ensure gasket is in
place and in good condition
Notebe careful while installing to not damage the gasket
-
Connect the blue line nipple to the
adapter block marked with "Inlet" Low pressure
NoteWear appropriate PPE, do not over tight the nipple, gasket can damage. Tight ONLY with hands
-
Apply sealer to High pressure adapter
threads
NoteSeal the connection with PTFE / Teflon tape
-
Thread on quick connect fitting to high
pressure adapter
NoteWear appropriate PPE, do not over tighten fitting
-
Secure flush adapter to high side
compressor line
Note1x nut, 10mm, 10 Nm, High side hose is small, O-ring OK to reuse if not damaged
-
Secure EXV adapter to chiller
Note2x bolts, 3mm hex, 6 Nm, O-rings OK to reuse if not damaged
-
Secure AC lines to EXV adapter
Note1x nut, 10mm, 12 Nm, O-rings OK to reuse if not damaged
-
Secure TXV adapter to AC lines
Note1x bolt, 5mm hex, 6 Nm, O-rings OK to reuse if not damaged
-
Secure AC lines/TXV adapter to
evaporator
Note2x bolts, T30, 6 Nm, O-rings OK to reuse if not damaged
-
Remove the liquid inline filter
drier
NoteRemove the filter from the container (the gray filter attached to the flush unit) PR052FM
-
Remove nipple from filter
Note1x fitting, 17mm, 1x filter, 12mm, Discard filter
-
Remove old Teflon tape from the
container thread
NoteOld Teflon tape must be removed completely.
-
Wrap Teflon tape on the Container thread
NoteUse Teflon tape. Make sure that enough tape is applied
-
Wrap the filter nipple in Teflon
tape
NoteUse Teflon tape. Make sure that enough tape is applied
-
Place 1 copper sealing ring on place.
Low pressure nipple
NoteGood to use the old copper ring.
-
Installed Low pressure nipple on
filter
Note1x filter, 12mm, 1x fitting, 17mm, Make sure that enough tape is applied and 1 copper sealing ring in on place, Do not over tighten
-
Place 1 copper sealing ring on place.
Inside the filter.
NoteGood to use the old copper ring.
-
attach the filter to the container
NoteDo not over torque while installing.
-
Connect the blue line 1 from the flush
unit to the adapter 2 block marked with "Inlet"
NoteWear appropriate PPE, Ensure gasket is on place between 1 hose connector and 2 nipple , Tighten with hands, do not over tighten
-
Connect the blue line from the AC
machine to the flush unit quick connector (on the liquid line filter drier)
NoteWear appropriate PPE, Ensure gasket is on place, Do not over tighten
-
Connect the machine High pressure RED
connector to adapter block OUTLET
NoteWear appropriate PPE, Ensure gasket is on place, Do not over tighten
-
flush 1. clamp off the TXV
NoteClamp off at the Low pressure big hose
-
On the Waeco AC machine select Menu>
Other selections > flushing> input vehicle details > Full flushing >
enter
NoteWear appropriate PPE
-
Flush will take 2 hours
NoteMonitor flush frequently
-
When the flush 1 program is finished,
unclamp the TXV line
-
Clamp off EXV line at the big hose Low
pressure
-
On the Waeco AC machine select Menu>
Other selections > flushing> input vehicle details > Full flushing >
enter
NoteWear appropriate PPE
-
Flush will take 2 hours
NoteMonitor flush frequently
-
When the flush 2 program is finished,
unclamp the EXV
NoteRemove clamp
-
Remove machine hoses from adapter
Note1x quick release fitting, 1x union fitting, Wear appropriate PPE
-
Remove adapter from low side AC
line
Note1x nut, 10mm, 10 Nm, Low side hose is big, Discard o-ring, Wear appropriate PPE
-
Remove adapter from high side AC
line
Note1x nut, 10mm, 10 Nm, High side hose is small, Discard o-ring, Wear appropriate PPE
-
Remove fasteners securing TXV adapter to
evaporator
Note2x bolts, T30, 6 Nm, Discard o-rings, Wear appropriate PPE
-
Remove TXV adapter from AC lines
Note1x bolt, 5mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE
-
Secure AC lines to TXV
Note1x bolt, 5mm hex, 20 Nm, Install new o-rings
-
Install bolts securing TXV to
evaporator
Note2x bolts, T30, 6 Nm, Install new o-rings
-
Make connection at TXV
Note1x connector
-
Remove nut securing AC lines to EXV
adapter
Note1x nut, 10mm, 12 Nm, Discard o-rings, Wear appropriate PPE
-
Remove EXV adapter from chiller
Note2x bolts, 3mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE
-
Secure EXV to chiller
Note2x bolts, 3mm hex, 6 Nm, Install new o-rings
-
Secure AC lines to EXV
Note1x nut, 10mm, 12 Nm, Install new o-rings_x000A_
-
Connect EXV coil and secure lock
Note1x connector, 1x locking tab
-
Remove compressor NVH cover
Note1x velcro strap
-
Install compressor NVH cover to new
compressor
Note1x velcro strap, Do not drain oil
-
install the new A/C compressor
Note3x Torx bolts, T40, torque 20 Nm
-
Secure A/C lines to compressor
Note2x nuts, 10mm, 10 Nm, Install new o-rings
-
Install from above A/C compressor -
DC-DC HV - Battery Heater - PTC - connector to the FJB
Note4x locking tab, 4x connector_x000A_
-
Connect A/C compressor connector
Note1x connector
-
Secure ground strap to A/C
compressor
Note1x bolt, T25, 7 Nm
-
Connect coolant bottle level sensor
Note1x connector
-
Remove bungee cord and place coolant
reservoir into position for installation
-
Re-position coolant bottle and install
the fasteners securing the coolant bottle to the shock tower cross member
Note4x bolts, 10mm, 6 Nm
-
Install 12V battery beam
Note2x bolts, T30, 3.5 Nm, 1x edge clip
-
Position 12V battery bracket assembly
onto battery beam for installation
-
Install fasteners securing 12V battery
bracket to shock tower cross member and the battery beam
Note2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm
-
Connect 12V positive terminal
Note1x nut, 10mm, 6 Nm
-
Install 12V positive terminal
cover
-
Raise vehicle fully and lower lift onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Remove cap from condenser
Note1x cap, 10mm hex, 12 Nm
-
Install new desiccant bag into
condenser
-
Install filter / cap into
condenser
Note1x cap, 10mm hex, 12 Nm
-
Lower vehicle partially and set lift
onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Secure RH side of fascia to headlight
and fender
-
Reinstall screw securing RH side of
fascia to fender
Note1x screw, T25, 1.5 Nm, Adjust fascia to fender flushness as necessary
-
Raise vehicle fully and lower lift onto
locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Install hardware securing RH side of
fascia to vehicle
Note1x bolt, 10mm, 3 Nm, 2x push clips
-
Lower vehicle until tires are touching
the ground
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
-
Place air suspension reservoir into
position
-
Loosely install air suspension reservoir
brackets
Note2x screws, T25, 2.5 Nm
-
Install LH shock tower brace
Note1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm
-
Install RH shock tower brace
Note2x bolts, 13mm, 20 Nm, 1x bolt, 13mm, 30 Nm
-
Install wiper motor
Note3x bolts, 10mm, 6 Nm, 1x connector
-
Install air suspension reservoir bracket
mounting fasteners to RH shock brace
Note2x bolts, 10mm, 6 Nm
-
Install AC line bracket bolt on RH shock
brace
Note1x bolts, 10mm, 6 Nm
-
Install wiper motor fastener mounted to
LH shock brace
Note1x bolt, 10mm, 6 Nm
-
Install air suspension reservoir bracket
mounting fasteners to LH shock brace
Note2x bolts, 10mm, 6 Nm
-
Clip wire harness to LH shock
brace
Note1x fir tree clip
-
Secure air suspension reservoir
brackets
Note2x screws, T25, 2.5 Nm
-
Place fuse box into vehicle and
reconnect harness connectors
Note3x connectors
-
Position fuse box onto body
Note2x tabs, Slide the fuse box to LH to attach the tabs into crossbar
-
Install bolts securing fuse box to
body
Note2x bolts, 10mm, 6 Nm
-
Reconnect pyrotechnic fuse
connector
Note1x connector, Be sure to secure locking clip
-
Secure clips holding 12V battery supply
cable to fuse box and strut tower beam
Note3x clips
-
Install new nut securing 12V supply
cable to DCDC
Note1x nyloc nut, 13mm, 12 Nm, Install new nyloc nut
-
Reinstall fuse box cover
Note2x clips
-
Install 12V negative terminal and first
responder loop
Note1x nut, 10mm, 10 Nm, 1x connector
-
Connect high side (red) and low side
(blue) hoses from AC machine to service ports
Note2x connections
- In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain.
- Under Action, select Start.
- Under Fluid Fill Target, select Refrigerant, click Run, and allow the routine to complete.
-
Perform A/C vacuum and leak test
NoteGreen check mark approves, Red X declines, 30 minute vacuum and leak test, Touch time only
- Leak test overlap
-
Install cowl screen
Note4x push clips, 2x end tabs
-
Install LH side wiper arm
Note1x nut, 17mm, 31 Nm
-
Install RH side wiper arm
Note1x nut, 17mm, 31 Nm
-
Install LH shock tower cover
Note4x push clips
-
Install RH shock tower cover
Note4x push clips
-
Install underhood storage unit
NoteInstall harness and grommet
-
Install bolts and clips securing
underhood storage unit
Note2x bolts, 10mm, 7 Nm, 2x push clips
-
Install underhood storage carpet and
reconnect light and release switch connectors
Note2x connectors, Secure edges of carpet underneath underhood storage unit seal
-
Install HEPA filter outlet duct
-
Install front underhood apron
Note7x clips
-
Perform A/C refrigerant refill
NoteGreen check mark approves, Red X declines, Run time only
-
After the refrigerant refill is
complete, perform the following:
- In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain.
- Under Action, select Stop.
- Under Fluid Fill Target, select Refrigerant, click Run, and allow the routine to complete.
-
Disconnect Toolbox from vehicle and
install cubby under the MCU
Note1x connector, 2x clips
-
Check A/C operation using MCU
NoteEnsure air conditioning blows cold
-
Disconnect high side and low side hoses
from vehicle
-
Install dust caps onto high and low side
service ports
Note2x threaded caps
-
Install HEPA filter inlet duct
Note2x tabs, One on each side
-
Install clips securing HEPA filter inlet
duct to cowl panel
Note3x push clips
-
Secure drainage hoses to HEPA filter
inlet duct
Note2x hoses
-
Install RH underhood apron
Note9x clips
-
Install LH underhood apron
Note9x clips
-
Install rear underhood apron
Note8x clips
-
Close hood
NotePress firmly in green highlighted areas (see image), Damage may result from pressure elsewhere on hood
-
Remove vehicle from lift
NoteLower rack arms fully and remove them from under vehicle, Remove air suspension from "Jack Mode"
- Close all four doors