02/03/2020 13:50:14

A/C Refrigerant Flush Due To Compressor Failure (RWD) (NA)

Correction Code 18208002

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
To avoid personal injury, eye protection must be worn while using compressed air.
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Warning
Wear appropriate Personal Protective Equipment (PPE), including nitrile gloves, safety glasses, and a face shield, when working with refrigerants and other A/C related fluids. For more information, see A/C Refrigerant Recovery and Recharge (Remove and Replace).
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Warning
Perform this procedure in a well-ventilated area.
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Warning
Store opened and unspent solvent containers in a flammables cabinet.
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Warning
Dispose of used solvent in an oil waste container. Use a funnel and full PPE during disposal.

Special tools required for this procedure:

Supplier Part Number Description
Tesla 1526195-00-A Robinair 17580 AC Flush Machine
Tesla 1492019-00-A Kit, AC Flush Adapters
Tesla 1526197-00-A Replaceable Filter
Tesla 1527940-00-A Kit, A/C Flush Solvent – Johnsens 6544 1-Gal
1058696-00-A Wiper Arm Removal Tool
1120026-00-A AC SERVICE MACHINE, ROBINAIR, 34988NI (North America, Asia Pacific)
1120026-01-A AC SERVICE MACHINE, WAECO, ASC5500RPA (Europe, Middle East, Africa)

Remove

  1. Remove the cowl screen panel. See Panel - Cowl Screen (Remove and Replace) .
  2. Remove the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  3. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  4. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  5. Perform the vehicle electrical isolation procedure. See Vehicle HV Disablement Procedure .
  6. Remove the fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace) .
  7. Remove the LH and RH shock tower braces. See Shock Tower Brace - LH (Remove and Replace) .
  8. Remove the wiper motor.
  9. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  10. Remove the desiccant bag, and then install the cap on the condenser. See Receiver Dryer and Desiccant (Remove and Replace) .
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not install a new desiccant bag at this time.
    Informational PurposesAn informational icon, calling your attention
    Note
    Reuse the old desiccant cap for the A/C flush. A cap will be installed at the end of this procedure.
  11. Remove the A/C compressor. See Compressor (Remove and Replace) .
  12. Remove the evaporator TXV. See TXV Valve - Evaporator (Remove and Replace) .
  13. Inspect the O-rings (x2) on the evaporator and if they're damaged, replace them.
  14. Inspect the O-rings (x2) on the A/C lines to the evaporator TXV and if they're damaged, replace them.
  15. Remove the chiller TXV. See TXV Valve - Chiller (Remove and Replace) .
  16. Inspect the O-rings (x2) on the chiller and if they're damaged, replace them.
  17. Inspect the O-rings (x2) on the A/C lines to the chiller TXV and if they're damaged, replace them.

Flush A/C System

  1. Inspect the low pressure A/C compressor line o-ring and if it's damaged, replace it.
  2. Position the flush adapter on the low pressure A/C compressor line, and then install the nut that attaches the line to the adapter (torque 10 Nm).
  3. Inspect the high pressure A/C compressor line o-ring and if it's damaged, replace it.
  4. Position the flush adapter on the high pressure A/C compressor line, and then install the nut that attaches the line to the adapter (torque 10 Nm).
  5. Position the EXV flush adapter on the chiller, and then install the bolts that attach the adapter to the chiller (torque 6 Nm).
  6. Position the A/C lines on the EXV flush adapter, and then install the nut that attaches the lines to the adapter (torque 12 Nm).
  7. Position the A/C lines on the TXV flush adapter, and then install the bolt that attaches the lines to the adapter (torque 6 Nm).
  8. Position the TXV flush adapter on the evaporator, and then install the bolts that attach the adapter to the evaporator (torque 6 Nm).
  9. If present, remove the old filter from the flush machine.
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate Personal Protective Equipment (PPE)
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    Note
    Make sure to also remove the old filter gasket.
  10. Lubricate the new filter gasket, and then hand-tighten the filter on the flush machine.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not overtighten the filter.
  11. Set the "Selection Valve" to the "OFF" position.
  12. Connect the ground wire to the flush machine ground terminal.
  13. Connect the shop air line to the flush machine "Air Inlet" port.
  14. Connect the flush machine "Return Hose" to the flush adapter on the high pressure A/C compressor line.
  15. Connect the flush machine "Discharge Hose" to the flush adapter on the low pressure A/C compressor line.
  16. Use a flexible funnel to add solvent to the flush machine until it is full, as indicated by the fill indicator on the side of the machine.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not fill the flush machine outdoors or near floor drainage.
  17. Close the "Air Agitation" valve by turning it completely clockwise.
  18. Set the "Filter Valve" to the "FILTER" position.
  19. Set the "Selection Valve" to the "FLUSH" position and let the flush run for 1 hour.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not leave the machine unattended while it is flushing.
  20. As the machine is flushing, check all connections for leaks, and add solvent if the machine pump runs dry.
  21. After 1 hour has elapsed, turn the "Air Agitation" knob counter-clockwise 1 full turn and let the air agitation run for 10 minutes.
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    Note
    Do not leave the machine unattended while it is agitating.
  22. After 10 minutes have elapsed, set the "Selection Valve" to the "OFF" position and close the "Air Agitation" valve by turning it completely clockwise.
  23. Wait for 1 minute, and then slowly set the "Selection Valve" to the "PURGE" position.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not leave the machine unattended while waiting.
  24. Let the purge run for 5 minutes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not leave the machine unattended while it is purging.
  25. After 5 minutes have elapsed, set the "Filter Valve" to the "BYPASS" position.
  26. Let the purge run for another 2 hours.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not leave the machine unattended while it is purging.
  27. After 2 hours have elapsed, slowly set the "Selection Valve" to the "OFF" position.
  28. Disconnect the flush machine hoses from the flush adapters on the low and high pressure A/C compressor lines.
  29. Remove the nut that attaches flush adapter to the low pressure A/C compressor line, and then remove the adapter.
  30. Remove the nut that attaches flush adapter to the high pressure A/C compressor line, and then remove the adapter.
  31. Disconnect the ground wire from the flush machine ground terminal.
  32. Remove the bolts that attach the TXV flush adapter to the evaporator.
  33. Remove the bolt that attaches the A/C lines to the TXV flush adapter, and then remove the flush adapter.
  34. Remove the nut that attaches the A/C lines to the EXV flush adapter.
  35. Remove the bolts that attach the EXV flush adapter to the chiller, and then remove the flush adapter.

Installation

  1. Install the front skid plate and a new A/C compressor. See Compressor (Remove and Replace) .
  2. Install a new desiccant bag and condenser cap. See Receiver Dryer and Desiccant (Remove and Replace) .
  3. Install the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  4. Install a new chiller TXV. See TXV Valve - Chiller (Remove and Replace) .
  5. Install a new evaporator TXV. See TXV Valve - Evaporator (Remove and Replace) .
  6. Carefully position the air suspension reservoir in the vehicle.
  7. Install the LH and RH shock tower braces. See Shock Tower Brace - LH (Remove and Replace) .
  8. Install the wiper motor. See Wiper Module (Remove and Replace) .
  9. Install the fuse box. See Fusebox - Underhood - 2nd Generation (Remove and Replace) .
  10. Reconnect 12V power. See Disconnect 12V Power .
  11. Perform an A/C refrigerant leak detection test. See .
  12. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace) .
  13. Install the wiper arms. See Wiper Arm - LH (Remove and Replace) .
  14. Install the LH and RH shock tower covers.
  15. Install the underhood storage unit. See Underhood Storage Unit (Remove and Install) .
  16. Install the HEPA filter outlet duct. See Duct - HEPA Filter - Outlet (Remove and Replace) .
  17. Install the front underhood apron. See Underhood Apron - Front (Remove and Replace) .
  18. After the A/C refrigerant leak detection test is complete, refill the A/C system with refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  19. Disconnect the laptop and install the cubby under the touchscreen.
  20. Install the HEPA filter inlet duct. See Duct - HEPA Filter - Inlet (Remove and Replace) .
  21. Install the LH and RH underhood aprons. See Underhood Apron - LH (Remove and Replace) .
  22. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace) .