15/08/2023 11:57:20

Compressor (Remove and Replace)

Correction Code 18203002 Correction Code 18203602 Correction Code 18203302 Correction Code 18203702 Correction Code 18203802

Choose the appropriate procedure based on the vehicle's configuration and date of manufacture:

1st Generation

Correction Code 18203002

Warning IconA warning icon, calling your attention to a possibly risky situation
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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Recover refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  2. If the vehicle has air suspension, activate "Jack" mode on the touchscreen.
  3. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  4. Remove the underhood storage unit for access. See Underhood Storage Unit (Remove and Install) .
  5. Disconnect the HV and LV harness connectors from the compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove and discard the HV connector label.
  6. Remove the bolt that secures the ground wire to the compressor (torque 9 Nm). Release the ground wire.
  7. Remove the 2 bolts that secure the A/C suction and discharge lines to the compressor (torque 10 Nm). Release the lines and remove the seals. Plug the holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The holes must be plugged to prevent contamination.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Remove and discard O-rings.
  8. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift .
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not work on an incorrectly supported vehicle.
  9. Remove the front skid plate. See Skidplate - Front (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    The compressor mounts to an inner bracket, which attaches to an outer bracket. The outer bracket mounts to the front subframe.
  10. Working beneath the vehicle, remove the nuts (x4) that secure the compressor and bracket assembly to the front subframe (torque 10 Nm).
  11. Lower the vehicle.
  12. Remove the compressor and bracket assembly.
  13. Remove the 2 bolts that secure the compressor to the inner bracket (torque 24 Nm).

Installation

Installation procedure is the reverse of removal, except for the following:

2nd Generation RWD

Correction Code 18203602

Warning IconA warning icon, calling your attention to a possibly risky situation
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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Recover refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  2. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  3. Remove the underhood storage unit for access. See Underhood Storage Unit (Remove and Install) .
  4. Raise and support the vehicle. See Raise Vehicle - 2 Post Lift .
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Do not work on an incorrectly supported vehicle.
  5. Remove the front skid plate. See Skidplate - Front (Remove and Replace) .
  6. Working beneath the vehicle, remove the nuts (x4) that secure the compressor and bracket assembly to the front subframe (torque 10 Nm).
  7. Lower the vehicle.
  8. Release the compressor harness (#3 in the figure below) from the orange connector on the top of the forward junction box (FJB).
    1 HV Battery heater harness
    2 DCDC converter harness
    3 Compressor harness
    4 PTC heater harness
  9. Disconnect the compressor logic harness.
  10. Remove the screw that secures the ground wire to the compressor (torque 7 Nm). Release the ground wire.
  11. Remove the nuts (x2) that secure the A/C suction and discharge lines to the compressor (torque 10 Nm). Release the lines and remove the seals. Plug the holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The holes must be plugged to prevent contamination.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Remove and discard O-rings.
  12. Remove the compressor and bracket assembly.
  13. Remove the screws (x2) that secure the compressor to the inner bracket (torque 24 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The HV cable is connected to the compressor; it cannot be removed.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
The new compressor is pre-filled with the total amount of oil used in the A/C system. Oil needs to be removed so that the amount of oil in the new compressor equals the amount of oil in the old one. To do this, use a digital scale to weigh both the old and new compressors. Turn the new one upside down to drain a small amount of oil, then re-weigh it. Repeat this process until the new compressor weighs the same as the old one.
  • Ensure that the HV cable is routed under the suction and discharge lines and that the clip is installed onto the suction line.
  • Perform the thermal system test. See Cooling System - Thermal Test.
  • Recharge the A/C system. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  • Ensure there is sufficient clearance between the HV connector and the bottom of the underhood storage compartment. If there is contact, adjust the position of the bracket that supports the HV connector.

3rd Generation RWD

Correction Code 18203302

Warning IconA warning icon, calling your attention to a possibly risky situation
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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Remove the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  2. Recover refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  3. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  4. Disconnect the low voltage harness from the compressor.
  5. Release the ground strap from the compressor.
  6. Disconnect the compressor HV cables from the forward junction box.
  7. Release the fasteners that secure the compressor to the bracket (torque 20 Nm).
  8. Remove the nuts that secure the A/C suction and discharge lines to the compressor (torque 10 Nm). Release the lines and remove the seals. Plug the holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The holes must be plugged to prevent contamination.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Remove and discard O-rings.
  9. Remove the compressor from the vehicle.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not spill oil from the compressor when removing it. The amount of oil remaining in the old compressor needs to be measured when the new compressor is installed.
  10. Remove the acoustic cover from the compressor.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
The new compressor is pre-filled with the total amount of oil used in the A/C system. Oil needs to be removed so that the amount of oil in the new compressor equals the amount of oil in the old one. To do this, use a digital scale to weigh both the old and new compressors. Turn the new one upside down to drain a small amount of oil, then re-weigh it. Repeat this process until the new compressor weighs the same as the old one.

Compressor - Dual Motor - LHD

Correction Code 18203702

Warning IconA warning icon, calling your attention to a possibly risky situation
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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Recover refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  2. Remove the wiper arms. See Wiper Arm - LH (Remove and Replace) .
  3. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  4. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  5. Remove the coolant from the coolant reservoir.
    1. Remove the coolant reservoir cap.
    2. Use a fluid evacuator tool to remove the coolant from the reservoir.
    3. Install the coolant reservoir cap.
  6. Release the 4 bolts that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.
    Informational PurposesAn informational icon, calling your attention
    Note
    At this point in the procedure, there are still 2 coolant hoses and 1 harness attached to the reservoir.
  7. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.
  8. Pull the reservoir forward into the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The reservoir hose is routed behind the hose that connects to the gearbox. Note the routing of the hoses and ensure that they are routed correctly during reinstallation.
  9. Gently pull down on the 2 coolant hoses to release the clips (x4) that secure them to the front crossmember.
  10. Release the clip that secures the coolant reservoir hose to the A/C line.
  11. On the LH side of the 3-way fitting, clamp the coolant hose that leads to the differential housing. Remove the hose from the front drive unit and plug the nipple.
  12. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The reservoir is still secured to 2 coolant hoses.
  13. Remove the LH and RH shock tower braces. See Shock Tower Brace - LH (Remove and Replace) .
  14. Release the bolts (x2) that secure the LH fuse box to the crossmember (torque 5 Nm).
  15. If the vehicle is equipped with air suspension, release the bolts (x2) that secure the air reservoir (torque 2.5 Nm). Carefully set the reservoir in the RH side of the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to disconnect the air lines.
  16. Disconnect the compressor connector from the forward junction box (FJB).
  17. Release the clip that secures the LH A/C line to the compressor HV harness.
  18. Release the 2 nuts that secure the A/C lines to the compressor (torque 10 Nm). Plug both holes and cap both lines.
  19. Disconnect the compressor LV harness.
  20. Release the ground strap from the compressor bracket (torque 7 Nm).
  21. Release the edge clip that secures the LV harnesses to the compressor bracket.
  22. Release the fir tree clip that secures the LV harnesses to the top of the front drive unit.
  23. Release the bolts (x3) that secure the compressor to the bracket (torque 20 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not spill oil from the compressor when removing it. The amount of oil remaining in the old compressor needs to be measured when the new compressor is installed.
  24. Remove the acoustic cover from the compressor.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
The new compressor is pre-filled with the total amount of oil used in the A/C system. Oil needs to be removed so that the amount of oil in the new compressor equals the amount of oil in the old one. To do this, use a digital scale to weigh both the old and new compressors. Turn the new one upside down to drain a small amount of oil, then re-weigh it. Repeat this process until the new compressor weighs the same as the old one.

Compressor - Dual Motor - RHD

Correction Code 18203802

Warning IconA warning icon, calling your attention to a possibly risky situation
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 any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Removal

  1. Recover refrigerant from the vehicle. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Continue this procedure while the refrigerant is being recovered.
  2. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  3. Remove the 12V battery. See Battery - Auxiliary - 12V (Remove and Replace) .
  4. Remove the 12V battery bracket beam. See 12V Battery Bracket Beam (Remove and Replace) .
  5. Remove the coolant from the coolant reservoir.
    1. Remove the coolant reservoir cap.
    2. Use a fluid evacuator tool to remove the coolant from the reservoir.
    3. Install the coolant reservoir cap.
  6. Release the bolts (x4) that secure the coolant reservoir to the front crossmember (torque 6 Nm). Do not remove the reservoir at this time.
    Informational PurposesAn informational icon, calling your attention
    Note
    At this point in the procedure, there are still 2 coolant hoses and 1 harness attached to the reservoir.
  7. Carefully lift up the coolant reservoir and disconnect the coolant level sensor harness.
  8. Pull the reservoir forward into the underhood area.
    Informational PurposesAn informational icon, calling your attention
    Note
    The reservoir hose is routed behind the hose that connects to the gearbox. Note the routing of the hoses and ensure that they are routed correctly during reinstallation.
  9. Gently pull down on the 2 coolant hoses to release the clips (x4) that secure them to the front crossmember.
  10. Release the clip that secures the coolant reservoir hose to the A/C line.
  11. On the LH side of the 3-way fitting, clamp the coolant hose that leads to the differential housing. Remove the hose from the front drive unit and plug the nipple.
  12. Disconnect the A/C machine from the vehicle.
  13. Move the coolant reservoir to the LH side of the vehicle and secure it out of the working area.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The reservoir is still secured to 2 coolant hoses.
  14. Disconnect the compressor connector from the forward junction box (FJB).
  15. Carefully cut the cable tie that secures the HV cable to the front drive unit.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not release the fir tree clip.
  16. Remove the nuts (x2) that secure the A/C suction and discharge lines to the compressor (torque 10 Nm). Release the lines and remove the seals. Plug the holes.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    The holes must be plugged to prevent contamination.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Remove and discard O-rings.
  17. Disconnect the compressor LV harness.
  18. Release the ground strap from the compressor bracket (torque 7 Nm).
  19. Release the edge clip that secures the LV harnesses to the compressor bracket.
  20. Release the fir tree clip that secures the LV harnesses to the top of the front drive unit.
  21. Release the bolts (x3) that secure the compressor to the bracket (torque 20 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not spill oil from the compressor when removing it. The amount of oil remaining in the old compressor needs to be measured when the new compressor is installed.
  22. Remove the acoustic cover from the compressor.

Installation

Installation procedure is the reverse of removal, except for the following:
Warning IconA warning icon, calling your attention to a possibly risky situation
CAUTION
The new compressor is pre-filled with the total amount of oil used in the A/C system. Oil needs to be removed so that the amount of oil in the new compressor equals the amount of oil in the old one. To do this, use a digital scale to weigh both the old and new compressors. Turn the new one upside down to drain a small amount of oil, then re-weigh it. Repeat this process until the new compressor weighs the same as the old one.