02/11/2023 00:36:25

A/C Compressor (Remove and Replace)

Correction code 18203912 2.64 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure proper PPE is worn when performing the below procedure.

  • 2023-10-31: Reorganized the procedure.
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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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, High Voltage Awareness Care Points for additional safety information.

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CAUTION
Thermal management components operate under very tight specifications and can malfunction if Service procedures are not carefully followed. DO NOT rely on past experience with other thermal management systems; read through the Service Manual and do not deviate from the instructions.
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CAUTION
The desiccant bag in the receiver dryer must be checked when replacing the A/C compressor to determine if debris resulting from failure of the compressor has entered the system.

Remove

  1. Recover the A/C refrigerant. See Recovery.
    Informational PurposesAn informational icon, calling your attention
    Note
    Recover the refrigerant while continuing this procedure.
  2. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  3. Release the connector locking tab, then disconnect the A/C logic electrical connector from the A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling to release the connector.
    Tip: Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 90 degree tip, 6 in
  4. Use a clip pry tool to release the retaining clip that attaches the A/C compressor logic harness to the A/C compressor HV harness bracket.
  5. Remove the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
  6. Disconnect the HV harness electrical connector from the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • Pick Miniature Soft Grip, 45 degree tip, 6 in
  7. Remove the bolt that attaches the ground strap to the A/C compressor, and then move the ground strap aside.
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • 2 in extension
    • Flex head ratchet/flex head torque wrench
  8. Use a clip pry tool to release the clip that attaches the coolant hose to the A/C compressor bracket.
  9. Remove the powertrain coolant pump from the A/C compressor bracket.
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide the coolant pump assembly away from the A/C compressor bracket.
  10. Remove the A/C hoses from vehicle.
  11. Remove the nut that attaches the low pressure fitting to the A/C compressor.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  12. Remove the nut that attaches the high pressure fitting to the A/C compressor, and then set the hose assembly aside.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  13. Install the nuts that attach the A/C flush adapters to the A/C high pressure and low pressure ports.
    Informational PurposesAn informational icon, calling your attention
    Note
    The high pressure and low pressure ports are of different sizes, and match the hose couplers accordingly.
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  14. Connect the A/C machine hoses to the A/C flush adapters.
  15. On the A/C machine, touch Manual > FLUSHING KIT and enter 25 min vacuum time, and then follow the A/C machine instructions to perform the flush process.
    Informational PurposesAn informational icon, calling your attention
    Note
    Touch time only. It runs for approximately 90 minutes and performs multiple flush cycles.
  16. Remove the A/C compressor HV harness from the A/C compressor and move it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Move the A/C compressor HV harness bracket toward the front of the vehicle, lift the bracket up to clear the upper bracket mount, carefully move the harness and bracket aside.
  17. Remove the A/C compressor bracket. See Bracket - Compressor (Remove and Replace).
  18. Take note of the part numbers on the old and new compressors.
  19. Use masking tape to protect LP and HP opening ports on the compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the ports are fully covered.
  20. Use a wire brush to remove as much acoustic material from the compressor as possible.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Failure to remove material will result in an inaccurate weight measurement.
  21. Use a digital scale to weigh the removed compressor and record its weight.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    This step is only to aid in potential diagnosis support. DO NOT add oil to the new A/C compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not drain any oil from the removed compressor.
  22. Repeat steps 20 through to 21 remove the acoustic blanket from the new compressor.

Install

  1. Use a 13mm socket to remove the transport plugs from the new compressor.
  2. Weigh the compressor and reset the compressor oil amount, add ND-11/RB100EV oil through the suction port of the compressor until it weighs equal to new compressor's dry weight + 250g.
    • Denso - ND-11
    • Sanden - RB100EV
    Informational PurposesAn informational icon, calling your attention
    Note
    Weight is measured in grams.
  3. Clean the A/C compressor surface with IPA wipes and allow the surface to dry before continuing.
  4. Make 2 cuts on the acoustic blanket as indicated by the red lines so that the blanket will fit around the A/C pipes.
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not remove the adhesive backing yet.
  5. Without removing the adhesive backing, perform a test fitting of the acoustic blanket on the A/C compressor, making sure the blanket properly fits around all mounts, pipes, and electrical connections.
  6. Remove the adhesive backing, and then install the acoustic blanket on the A/C compressor.
  7. Install the A/C compressor bracket. See Bracket - Compressor (Remove and Replace).
  8. Install the A/C compressor HV harness to the A/C compressor.
  9. Connect the HV harness electrical connector to the A/C compressor.
  10. Install the bolt that attaches the A/C compressor HV harness bracket to the A/C compressor.
    9 Nm (6.6 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
  11. Install the bolt that attaches the ground strap to the A/C compressor.
    7 Nm (5.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • Torx T25 socket
    • 2 in extension
    • Flex head ratchet/flex head torque wrench
    • Ratchet/torque wrench
  12. Install the powertrain coolant pump to the A/C compressor bracket.
  13. Fasten the clip that attaches the coolant hose to the A/C compressor bracket.
  14. Disconnect the A/C machine hoses from the A/C flush adapters.
  15. Remove the nuts that attach the A/C flush adapters to the A/C high pressure and low pressure hoses.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm socket
    • 3 in extension
    • Flex head ratchet/flex head torque wrench
  16. Replace the o-rings on the high pressure and low pressure supermanifold to A/C compressor hose fittings.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate o-rings with oil.
  17. Position the supermanifold to A/C compressor high pressure fitting on the A/C compressor, and then install the nut that attaches the fitting to the A/C compressor.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  18. Position the supermanifold to A/C compressor low pressure fitting on the A/C compressor, and then install the nut that attaches the fitting to the A/C compressor.
    22 Nm (16.2 lbs-ft)
    Tip: Use of the following tool(s) is recommended:
    • 13 mm deep socket
    • Flex head ratchet/flex head torque wrench
  19. Reconnect the A/C machine hoses to the A/C compressor.
  20. Perform the vacuum leak test. See Vacuum Leak Test and Oil Injection.
  21. Recharge the A/C refrigerant. See Recharge.
  22. Connect LV power. See LV Power (Disconnect and Connect).
  23. Reinstall the firmware. See Firmware Reinstall - Touchscreen.
  24. Unlock the vehicle gateway. See Gateway (Unlock).
  25. Run the performance tests. See Performance Tests.
  26. On the touchscreen, touch Controls > Thermal > Refrigerant System > Reset Compressor P-Metric, click Run to start the "Reset compressor P metric compressor replacement" routine.
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure the routine is passed, then touch Close to close it.
  27. Disconnect LV power. See LV Power (Disconnect and Connect).
  28. Install the wiper module. See Wiper Module (Remove and Replace).
  29. Install the cowl screen panel. See Panel - Cowl Screen (Remove and Replace).
  30. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  31. Connect LV power. See LV Power (Disconnect and Connect).
  32. Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
  33. Calibrate the rear doors.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the "Calibration Needed" message appears on the vehicle touchscreen, press and hold Calibrate to calibrate the rear doors.