2025-06-18

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

Correction code 18208052

2025-06-18: Added notes to replace TXV/EXV valves when debris is found on them.
2025-01-22: Added Note on separately adding correction code 18200102 and condensed procedure.

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

Set up the A/C machine and perform hose flush.
Set up the A/C machine with the flush kit.

Note
Attach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut.
Open all doors and lower the windows.
Prepare the vehicle for lifting. See Raise Vehicle - 2 Post Lift.
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)
Move both front seats fully forward.
Remove the underhood aprons.
Remove the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
Recover the refrigerant from the vehicle. See .
Remove the HEPA filter outlet duct from the vehicle. See Duct - HEPA Filter - Outlet (Remove and Replace).
Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install).
Disconnect 12V power. See Disconnect 12V Power.
Perform the vehicle disablement procedure. See Vehicle HV Disablement Procedure.
Remove the push clips that attach the LH and RH shock tower covers, and then remove the covers.
Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
Remove the fuse box cover.
Remove and discard the nyloc nut that attaches the 12V supply cable to DCDC.
Release the clips (x3) that attach the 12V battery supply cable to the fuse box and strut tower cross beam.
Disconnect the pyrotechnic fuse connector.
Remove the bolts (x2) that attach the fuse box to body.
Release the fuse box from the body.

Note
Slide the fuse box to the RH side to release the tabs (x2), and then lift up the fuse box.
Disconnect remaining connectors (x3) from the bottom of the fuse box.
Remove the clip that attaches the harness to the LH shock tower brace.
Remove the bolt that attaches the wiper motor to the LH shock brace.
Remove the bolts (x2) that attach the LH air suspension reservoir bracket to the LH shock brace.
Remove the bolt that attaches the A/C line bracket to the RH shock brace.
Remove the bolts (x2) that attach the air reservoir mounting bracket to the RH shock brace.
Remove the bolts (x3) that attach the LH shock tower brace.
Remove the bolts that attach the RH shock tower brace.
Remove the bolts (x3) that attach the wiper motor, and then disconnect the connector.
Remove the screws (x2) that attach the air suspension reservoir to the bracket.
Set the air suspension reservoir aside for access.

Note
Maneuver the suspension reservoir below the A/C line.
Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace)
Remove the bolts (x4) that attach the coolant reservoir to the shock tower cross member.
Shift the coolant reservoir to give access to the components behind.

Note
Use bungee or rag to hold the reservoir out of place.
Disconnect the coolant bottle level sensor.

Note
1x connector
Disconnect the A/C compressor logic connector.
Release the bolt that attaches the ground connection to the A/C compressor mount bracket.
Remove the screw that attaches the RH fender bracket to the front fascia.
Remove the bolt and clips (x2) that attach the RH side of the fascia to the front aero shield.

Note
Full aero shield does not need to come off.
Pull the RH side of the fascia away from the bracket and headlamp.

Note
Pull to release the clips.
Remove the cap from the condenser
Remove the filter screen from the condenser.
Remove the desiccant bag from the condenser.
Install the cap into condenser (torque 12 Nm).
Lower the vehicle until the tires are touching the ground.
Release PTC - Battery Heater - DC-DC HV connector from FJB to gain access to release the A/C compressor HV connector from the FJB.

Note
4x locking tab, 4x connector.
Remove the nuts (x2) that attach the A/C lines to the compressor.

Note
Inspect O-rings for damage before flushing. Discard O-rings and replace them with new ones during installation.
Remove the A/C compressor assembly from the vehicle.

Note
3x Torx bolts, T40, torque 20 Nm
Disconnect the TXV connector.
Remove the bolts (x2) that attach the TXV to the evaporator.

Note
Inspect o-rings for damage if flushing, Discard o-rings and replace on installation.

Note
If any debris is found at the rear TXV inlet, the TXV must be replaced by a new one during installation.
Remove the bolt that attaches the TXV to the A/C lines.

Note
Inspect O-rings for damage before flushing. Discard O-rings and replace them with new ones during installation.
Disconnect the connector at the EXV.
Remove nut that attaches the A/C lines to the EXV.

Note
Inspect O-rings for damage before flushing, Discard O-rings and replace them with new ones during installation.
Remove the bolts (x2) that attach the EXV to the chiller.

Note
Inspect O-rings for damage before flushing, Discard O-rings and replace them with new ones during installation.

Note
If any debris is found at the front chiller EXV, the EXV must be replaced by a new one during installation.
Attach the flush adapter to the low side compressor line.

Note
The low side hose is the bigger one. The O-ring can be reused, if not damaged.
Inspect the blue line nipple. Make sure the gasket is in place and in good condition.

Note
Be careful while installing not to damage the gasket.
Connect the blue line nipple to the adapter block marked with "Inlet" Low pressure.

Note
Wear appropriate PPE. Do not over-tighten the nipple since this may cause damage to the gasket. Tighten ONLY hand-tight.
Seal the High pressure adapter threads with PTFE/Teflon tape.
Thread on the quick connect fitting to the high pressure adapter.

Note
Wear appropriate PPE, do not over-tighten the fitting.
Attach the flush adapter to the high side compressor line.

Note
High side hose is the smaller one. The O-ring can be reused, if it is not damaged.
Install the bolts (x2) that attach the EXV adapter to the chiller (torque 6 Nm).
Install the nut that attaches the A/C lines to the EXV adapter (torque 12 Nm).

Note
The O-rings can be reused, if not damaged.
Install the bolt that attaches the TXV adapter to the A/C lines (torque 6 Nm).

Note
The O-rings can be reused, if not damaged.
Install the bolts (x2) that attach the A/C lines/TXV adapter to the evaporator (torque 6 Nm).

Note
The O-rings can be reused, if not damaged.
Remove the liquid inline filter drier.

Note
Remove the filter from the container (the gray filter attached to the flush unit) PR052FM.
Remove the nipple from the filter.

Note
1x fitting, 17mm, 1x filter, 12mm. Discard the filter.
Remove the Teflon tape from the container thread.
Wrap Teflon tape on the Container thread.

Note
Make sure that enough tape is applied.
Wrap the filter nipple with Teflon tape.

Note
Make sure that enough tape is applied.
Put 1 copper sealing ring on Low pressure nipple.
Install the Low pressure nipple on the filter.

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.
Put one copper sealing ring inside the filter.
Attach the filter to the container.

Note
Do not over-torque while installing.
Connect the blue line 1 from the flush unit to the adapter 2 block marked with "Inlet".

Note
Wear appropriate PPE. Make sure that the gasket is in place between hose connector and nipple. Hand tighten, do not over-tighten.
Connect the blue line from the A/C machine to the flush unit quick connector (on the liquid line filter drier).

Note
Wear appropriate PPE. Make sure that the gasket is in place. Do not over-tighten.
Connect the machine High pressure RED connector to adapter block "OUTLET".

Note
Wear appropriate PPE. Make sure that the gasket is in place, Do not over-tighten.
Flush 1. Clamp off the TXV.

Note
Clamp off at the Low pressure big hose.
On the Waeco A/C machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter.

Note
Wear appropriate PPE.
The flush will take 2 hours.

Note
Monitor flush regularly.
When flush 1 program has finished, unclamp the TXV line.
Clamp off EXV line at the big Low pressure hose.
On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter.

Note
Wear appropriate PPE.
The flush will take 2 hours.

Note
Monitor flush regularly.
When flush 2 program has finished, unclamp the EXV.
Remove machine hoses from adapter.

Note
1x quick release fitting, 1x union fitting. Wear appropriate PPE.
Remove adapter from the low side A/C line.

Note
1x nut, 10mm, 10 Nm, Low side hose is big. Discard the O-ring. Wear appropriate PPE.
Remove the adapter from the high side A/C line.
t

Note
1x nut, 10mm, 10 Nm, High side hose is small. Discard the O-ring. Wear appropriate PPE.
Remove the bolts (x2) that attach the TXV adapter to the evaporator.

Note
Discard the O-rings. Wear appropriate PPE
Remove the bolt that attaches the TXV adapter to the A/C lines.

Note
Discard the O-rings. Wear appropriate PPE.
Install the bolt that attaches the A/C lines to the TXV (torque 20 Nm).

Note
Install new O-rings
Install the bolts (x2) that attach the TXV to the evaporator (torque 6 Nm).

Note
Install new O-rings.

Note
If any debris is found at the rear TXV inlet, the TXV must be replaced by a new one.
Connect the connector at the TXV.
Remove the nut that attaches the A/C lines to the EXV adapter.

Note
Discard the O-rings. Wear appropriate PPE
Remove the bolts (x2) that attach the EXV adapter to the chiller.

Note
Discard the O-rings. Wear appropriate PPE.
Install the bolts that attach the EXV to the chiller (torque 6 Nm).

Note
Install new O-rings.

Note
If any debris was found at the EXV, replace the EXV by a new one.
Install the nut that attaches the A/C lines to the EXV (torque 12 Nm).

Note
Install new O-rings.
Connect the EXV coil connector and lock the locking tab.
Remove the NVH cover from the compressor.
Install the NVH cover to the new compressor.
Position the new A/C compressor into the vehicle, and then install the bolts (x3) that attach the compressor (torque 20 Nm).
Install the nuts (x2) that attach the A/C lines to the compressor (torque 10 Nm).

Note
Install new O-rings.
Install following connectors from above the A/C compressor: DC-DC HV - Battery Heater - PTC - Connector to the FJB.
Connect the A/C compressor logic connector.
Install the bolt that attaches the ground strap to the A/C compressor (torque 7 Nm).
Connect the coolant bottle level sensor connector.
Remove the bungee cord and put the coolant reservoir into position for installation.
Install the bolts (x4) that attach the coolant reservoir to the shock tower cross member (torque 6 Nm).
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.
Install the 12V battery bracket. See Bracket - 12V Battery (Dual Motor) (Remove and Replace).
Remove the cap from the condenser.
Install a new desiccant bag into the condenser.
Install the filter, and then install the cap onto the condenser (torque 12 Nm).
Attach the RH side of the fascia to the headlight and fender.
Reinstall the screw that attaches the RH side of the fascia to the fender (torque 1.5 Nm).

Note
Adjust flush between fascia and fender as necessary.
Install fasteners that attach the RH side of fascia to vehicle.

Note
1x bolt, 10mm, 3 Nm, 2x push clips.
Put the air suspension reservoir into position.
Loosely install the screws (x2) that attach the air suspension reservoir brackets.
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
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
Connect the wiper motor connector, and then install the bolts (x3) that attach the wiper motor (torque 6 Nm).
Install the bolts (x2) that attach the air suspension reservoir bracket to the LH shock brace (torque 6 Nm).
Install the bolt that attaches the A/C line bracket bolt to the RH shock brace (torque 6 Nm).
Install the bolt that attaches the wiper motor to LH shock brace (torque 6 Nm).
Install the wire harness fir tree clip to LH shock brace.
Torque the air suspension reservoir brackets to 2.5 Nm.
Position the fuse box into the vehicle and reconnect the harness connectors (x3)
Slide the fuse box onto the body to attach the tabs (x2) into the crossbar.
Install the bolts that attach the fuse box to the body (torque 6 Nm).
Reconnect the pyrotechnic fuse connector.
Attach the clips (x3) that hold the 12V battery supply cable to the fuse box and strut tower beam.
Install a new nyloc nut that attaches the 12V supply cable to DCDC (torque 12 Nm).
Install the fuse box cover.
Connect 12V power. See Disconnect 12V Power.
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)
Perform an A/C vacuum and leak test. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
Install the nuts that attach the LH and RH wiper arms (torque 31 Nm).
Install the clips that attach the LH and RH shock tower covers

Note
2x 4 push clips
Install underhood storage unit. See Underhood Storage Unit (Remove and Install).
Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace).
Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace).
Recharge the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)
Use the MCU to confirm proper A/C operation.

Note
Make sure that the air conditioning blows cold air.
Install the underhood aprons.