2025-01-23

A/C Refrigerant Flush Due To Compressor Failure (Dual Motor) (Europe)

Correction code 18208052

  • 2025-01-22: Added Note on separately adding correction code 18200102 and condensed procedure.
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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.

Procedure

  1. Set up the A/C machine and perform hose flush.
  2. Set up the A/C machine with the flush kit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Attach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut.
  3. Open all doors and lower the windows.
  4. Prepare the vehicle for lifting. See Raise Vehicle - 2 Post Lift.
  5. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain
  6. Move both front seats fully forward.
  7. Remove the underhood aprons.
  8. Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  9. Recover the refrigerant from the vehicle. See .
  10. Remove the HEPA filter outlet duct from the vehicle. See Duct - HEPA Filter - Outlet (Remove and Replace).
  11. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
  12. Disconnect 12V power. See Disconnect 12V Power.
  13. Perform the vehicle disablement procedure. See Vehicle HV Disablement Procedure.
  14. Remove the push clips that attach the LH and RH shock tower covers, and then remove the covers.
  15. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  16. Remove the fuse box cover.
  17. Remove and discard the nyloc nut that attaches the 12V supply cable to DCDC.
  18. Release the clips (x3) that attach the 12V battery supply cable to the fuse box and strut tower cross beam.
  19. Disconnect the pyrotechnic fuse connector.
  20. Remove the bolts (x2) that attach the fuse box to body.
  21. Release the fuse box from the body.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the fuse box to the RH side to release the tabs (x2), and then lift up the fuse box.
  22. Disconnect remaining connectors (x3) from the bottom of the fuse box.
  23. Remove the clip that attaches the harness to the LH shock tower brace.
  24. Remove the bolt that attaches the wiper motor to the LH shock brace.
  25. Remove the bolts (x2) that attach the LH air suspension reservoir bracket to the LH shock brace.
  26. Remove the bolt that attaches the A/C line bracket to the RH shock brace.
  27. Remove the bolts (x2) that attach the air reservoir mounting bracket to the RH shock brace.
  28. Remove the bolts (x3) that attach the LH shock tower brace.
  29. Remove the bolts that attach the RH shock tower brace.
  30. Remove the bolts (x3) that attach the wiper motor, and then disconnect the connector.
  31. Remove the screws (x2) that attach the air suspension reservoir to the bracket.
  32. Set the air suspension reservoir aside for access.
    Informational PurposesAn informational icon, calling your attention
    Note
    Maneuver the suspension reservoir below the A/C line.
  33. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace)
  34. Remove the bolts (x4) that attach the coolant reservoir to the shock tower cross member.
  35. Shift the coolant reservoir to give access to the components behind.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use bungee or rag to hold the reservoir out of place.
  36. Disconnect the coolant bottle level sensor.
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    Note
    1x connector
  37. Disconnect the A/C compressor logic connector.
  38. Release the bolt that attaches the ground connection to the A/C compressor mount bracket.
  39. Remove the screw that attaches the RH fender bracket to the front fascia.
  40. Remove the bolt and clips (x2) that attach the RH side of the fascia to the front aero shield.
    Informational PurposesAn informational icon, calling your attention
    Note
    Full aero shield does not need to come off.
  41. Pull the RH side of the fascia away from the bracket and headlamp.
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    Note
    Pull to release the clips.
  42. Remove the cap from the condenser
  43. Remove the filter screen from the condenser.
  44. Remove the desiccant bag from the condenser.
  45. Install the cap into condenser (torque 12 Nm).
  46. Lower the vehicle until the tires are touching the ground.
  47. Release PTC - Battery Heater - DC-DC HV connector from FJB to gain access to release the A/C compressor HV connector from the FJB.
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    Note
    4x locking tab, 4x connector.
  48. Remove the nuts (x2) that attach the A/C lines to the compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect O-rings for damage before flushing. Discard O-rings and replace them with new ones during installation.
  49. Remove the A/C compressor assembly from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    3x Torx bolts, T40, torque 20 Nm
  50. Disconnect the TXV connector.
  51. Remove the bolts (x2) that attach the TXV to the evaporator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  52. Remove the bolt that attaches the TXV to the A/C lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect O-rings for damage before flushing. Discard O-rings and replace them with new ones during installation.
  53. Disconnect the connector at the EXV.
  54. Remove nut that attaches the A/C lines to the EXV.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect O-rings for damage before flushing, Discard O-rings and replace them with new ones during installation.
  55. Remove the bolts (x2) that attach the EXV to the chiller.
    Informational PurposesAn informational icon, calling your attention
    Note
    Inspect O-rings for damage before flushing, Discard O-rings and replace them with new ones during installation.
  56. Attach the flush adapter to the low side compressor line.
    Informational PurposesAn informational icon, calling your attention
    Note
    The low side hose is the bigger one. The O-ring can be reused, if not damaged.
  57. Inspect the blue line nipple. Make sure the gasket is in place and in good condition.
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    Note
    Be careful while installing not to damage the gasket.
  58. Connect the blue line nipple to the adapter block marked with "Inlet" Low pressure.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE. Do not over-tighten the nipple since this may cause damage to the gasket. Tighten ONLY hand-tight.
  59. Seal the High pressure adapter threads with PTFE/Teflon tape.
  60. Thread on the quick connect fitting to the high pressure adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE, do not over-tighten the fitting.
  61. Attach the flush adapter to the high side compressor line.
    Informational PurposesAn informational icon, calling your attention
    Note
    High side hose is the smaller one. The O-ring can be reused, if it is not damaged.
  62. Install the bolts (x2) that attach the EXV adapter to the chiller (torque 6 Nm).
  63. Install the nut that attaches the A/C lines to the EXV adapter (torque 12 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The O-rings can be reused, if not damaged.
  64. Install the bolt that attaches the TXV adapter to the A/C lines (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The O-rings can be reused, if not damaged.
  65. Install the bolts (x2) that attach the A/C lines/TXV adapter to the evaporator (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    The O-rings can be reused, if not damaged.
  66. Remove the liquid inline filter drier.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the filter from the container (the gray filter attached to the flush unit) PR052FM.
  67. Remove the nipple from the filter.
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    Note
    1x fitting, 17mm, 1x filter, 12mm. Discard the filter.
  68. Remove the Teflon tape from the container thread.
  69. Wrap Teflon tape on the Container thread.
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    Note
    Make sure that enough tape is applied.
  70. Wrap the filter nipple with Teflon tape.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that enough tape is applied.
  71. Put 1 copper sealing ring on Low pressure nipple.
  72. Install the Low pressure nipple on the filter.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x filter, 12mm, 1x fitting, 17mm. Make sure that enough tape is applied and 1 copper sealing ring is in place. Do not over-tighten.
  73. Put one copper sealing ring inside the filter.
  74. Attach the filter to the container.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not over-torque while installing.
  75. Connect the blue line 1 from the flush unit to the adapter 2 block marked with "Inlet".
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE. Make sure that the gasket is in place between hose connector and nipple. Hand tighten, do not over-tighten.
  76. Connect the blue line from the A/C machine to the flush unit quick connector (on the liquid line filter drier).
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE. Make sure that the gasket is in place. Do not over-tighten.
  77. Connect the machine High pressure RED connector to adapter block "OUTLET".
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE. Make sure that the gasket is in place, Do not over-tighten.
  78. Flush 1. Clamp off the TXV.
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    Note
    Clamp off at the Low pressure big hose.
  79. On the Waeco A/C machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE.
  80. The flush will take 2 hours.
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    Note
    Monitor flush regularly.
  81. When flush 1 program has finished, unclamp the TXV line.
  82. Clamp off EXV line at the big Low pressure hose.
  83. On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE.
  84. The flush will take 2 hours.
    Informational PurposesAn informational icon, calling your attention
    Note
    Monitor flush regularly.
  85. When flush 2 program has finished, unclamp the EXV.
  86. Remove machine hoses from adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x quick release fitting, 1x union fitting. Wear appropriate PPE.
  87. Remove adapter from the low side A/C line.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Low side hose is big. Discard the O-ring. Wear appropriate PPE.
  88. Remove the adapter from the high side A/C line.
    t
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, High side hose is small. Discard the O-ring. Wear appropriate PPE.
  89. Remove the bolts (x2) that attach the TXV adapter to the evaporator.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the O-rings. Wear appropriate PPE
  90. Remove the bolt that attaches the TXV adapter to the A/C lines.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the O-rings. Wear appropriate PPE.
  91. Install the bolt that attaches the A/C lines to the TXV (torque 20 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings
  92. Install the bolts (x2) that attach the TXV to the evaporator (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings.
  93. Connect the connector at the TXV.
  94. Remove the nut that attaches the A/C lines to the EXV adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the O-rings. Wear appropriate PPE
  95. Remove the bolts (x2) that attach the EXV adapter to the chiller.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the O-rings. Wear appropriate PPE.
  96. Install the bolts that attach the EXV to the chiller (torque 6 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings.
  97. Install the nut that attaches the A/C lines to the EXV (torque 12 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings.
  98. Connect the EXV coil connector and lock the locking tab.
  99. Remove the NVH cover from the compressor.
  100. Install the NVH cover to the new compressor.
  101. Position the new A/C compressor into the vehicle, and then install the bolts (x3) that attach the compressor (torque 20 Nm).
  102. Install the nuts (x2) that attach the A/C lines to the compressor (torque 10 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Install new O-rings.
  103. Install following connectors from above the A/C compressor: DC-DC HV - Battery Heater - PTC - Connector to the FJB.
  104. Connect the A/C compressor logic connector.
  105. Install the bolt that attaches the ground strap to the A/C compressor (torque 7 Nm).
  106. Connect the coolant bottle level sensor connector.
  107. Remove the bungee cord and put the coolant reservoir into position for installation.
  108. Install the bolts (x4) that attach the coolant reservoir to the shock tower cross member (torque 6 Nm).
  109. Install the bolts(x2) that attach the 12V battery beam to the front frame rails (torque 3.5 Nm), and then install the edge clip.
  110. Install the 12V battery bracket. See Bracket - 12V Battery (Dual Motor) (Remove and Replace).
  111. Remove the cap from the condenser.
  112. Install a new desiccant bag into the condenser.
  113. Install the filter, and then install the cap onto the condenser (torque 12 Nm).
  114. Attach the RH side of the fascia to the headlight and fender.
  115. Reinstall the screw that attaches the RH side of the fascia to the fender (torque 1.5 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Adjust flush between fascia and fender as necessary.
  116. Install fasteners that attach the RH side of fascia to vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 10mm, 3 Nm, 2x push clips.
  117. Put the air suspension reservoir into position.
  118. Loosely install the screws (x2) that attach the air suspension reservoir brackets.
  119. Install the bolts that attach the LH shock tower brace and torque the bolts as illustrated.
    Figure 1. Torque 2x bolts at 20 Nm
    Figure 2. Torque 1x bolt at 30 Nm
  120. Install the RH shock tower brace and torque the bolts as illustrated.
    Figure 3. Torque 2x bolts at 20 Nm
    Figure 4. Torque 1x bolt at 20 Nm
  121. Connect the wiper motor connector, and then install the bolts (x3) that attach the wiper motor (torque 6 Nm).
  122. Install the bolts (x2) that attach the air suspension reservoir bracket to the LH shock brace (torque 6 Nm).
  123. Install the bolt that attaches the A/C line bracket bolt to the RH shock brace (torque 6 Nm).
  124. Install the bolt that attaches the wiper motor to LH shock brace (torque 6 Nm).
  125. Install the wire harness fir tree clip to LH shock brace.
  126. Torque the air suspension reservoir brackets to 2.5 Nm.
  127. Position the fuse box into the vehicle and reconnect the harness connectors (x3)
  128. Slide the fuse box onto the body to attach the tabs (x2) into the crossbar.
  129. Install the bolts that attach the fuse box to the body (torque 6 Nm).
  130. Reconnect the pyrotechnic fuse connector.
  131. Attach the clips (x3) that hold the 12V battery supply cable to the fuse box and strut tower beam.
  132. Install a new nyloc nut that attaches the 12V supply cable to DCDC (torque 12 Nm).
  133. Install the fuse box cover.
  134. Connect 12V power. See Disconnect 12V Power.
  135. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain
  136. Perform an A/C vacuum and leak test. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  137. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  138. Install the nuts that attach the LH and RH wiper arms (torque 31 Nm).
  139. Install the clips that attach the LH and RH shock tower covers
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    Note
    2x 4 push clips
  140. Install underhood storage unit. See Underhood Storage Unit (Remove and Install).
  141. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
  142. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
  143. Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  144. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain
  145. Use the MCU to confirm proper A/C operation.
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    Note
    Make sure that the air conditioning blows cold air.
  146. Install the underhood aprons.