24/08/2020 16:07:37

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

Correction Code 18208032

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
1065131-00-A KIT, BATTERY COOLANT DRAIN & FILL
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 wiper motor assembly. See Wiper Module (LHD) (Remove and Replace) .
  2. Remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  3. Remove the 12V auxiliary battery cage from the vehicle, but do not remove the battery from the cage. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  4. Remove the A/C compressor. See Compressor (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    After checking for high voltage in the electrical isolation procedure, do not reinstall any components.
  5. Remove the RH parcel shelf support. See Support - Parcel Shelf - LH (Remove and Replace) .
  6. Remove the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).
  7. Remove the rear diffuser panel. See Diffuser Panel - Rear (Remove and Replace) .

Temporarily Remove Rear TXV Valve

  1. Remove the nut that attaches the A/C lines to the rear TXV, and then remove the A/C lines from the TXV.
  2. Inspect the A/C lines to rear TXV O-rings (x2), and if they are damaged, replace them.
  3. Remove the bolts (x2) that attach the rear TXV to the rear HVAC assembly, and then carefully set the TXV aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    The TXV will hang from its harness.
  4. Inspect the rear TXV to rear HVAC assembly O-rings (x2) and if they are damaged, replace them.
    Figure 1. Some assemblies hidden for clarity
  5. Position the TXV flush adapter on the rear HVAC assembly, and then install the bolts (x2) that attach the TXV flush adapter to the rear HVAC assembly (torque 6 Nm).
    Figure 2. Some assemblies hidden for clarity
  6. Position the rear TXV A/C lines on the TXV flush adapter, and then install the nut that attaches the A/C lines to the TXV flush adapter (torque 10 Nm).
    Figure 3. Some assemblies hidden for clarity

Remove Desiccant Bag

  1. Remove the front aero shield panel. See Panel - Aero Shield - Front (Remove and Replace) .
  2. Remove the skid plate chin spoiler. See Skid Plate Chin Spoiler (Remove and Replace) .
  3. Remove the desiccant bag, and then install the flush plug from the A/C flush adapter kit 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
    If the flush plug supplied in the kit is red-colored, secure the plug with the old snap ring.
    Informational PurposesAn informational icon, calling your attention
    Note
    If the flush plug supplied in the kit is white-colored, screw the plug into the condenser until the wing nut makes contact with the condenser; do not install the old snap ring.
    Informational PurposesAn informational icon, calling your attention
    Note
    A new desiccant plug and snap ring will be installed at the end of this procedure.
    Figure 4. Red-colored desiccant plug from A/C flush adapter kit and old snap ring installed
    Figure 5. White-colored desiccant plug from A/C flush adapter kit installed

Remove Front TXV Valve

  1. Release the clip that attaches the front TXV electrical harness to the vehicle, and then disconnect the electrical connector from the front TXV.
  2. Remove the bolts (x2) that attach the front TXV to the front HVAC assembly.
  3. Inspect the front TXV to front HVAC assembly O-rings (x2) and if they are damaged, replace them.
  4. Remove the bolt that attaches the A/C lines to the front TXV, and then remove the TXV from the vehicle.
  5. Inspect the A/C lines to front TXV O-rings (x2), and if they are damaged, replace them.

Remove EXV Valve

  1. Remove the nut that attaches the A/C lines to the EXV, and then remove the A/C lines from the EXV.
  2. Inspect the A/C lines to EXV O-rings (x2), and if they are damaged, replace them.
  3. Remove the bolts (x2) that attach the EXV to the chiller, and then remove the EXV from the vehicle.
  4. Release the locking tab, and then disconnect the electrical connector from the EXV.
  5. Inspect the EXV to chiller O-rings (x2) and if they are damaged, replace them.

Flush A/C System

  1. Inspect the low pressure A/C compressor line O-ring and if it is damaged, replace it.
    Tip: The low pressure line is thicker than the high pressure line.
  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 is damaged, replace it.
    Tip: The high pressure line is thinner than the low pressure line.
  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 (x2) that attach the adapter to the chiller (torque 6 Nm).
  6. Position the EXV 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 front TXV 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 front HVAC assembly, and then install the bolts (x2) that attach the adapter to the HVAC assembly (torque 6 Nm).
  9. If present, remove the old filter from the A/C refrigerant flush machine.
    Informational PurposesAn informational icon, calling your attention
    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.
    Informational PurposesAn informational icon, calling your attention
    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 (x2) that attach the TXV flush adapter to the front HVAC assembly.
  33. Remove the bolt that attaches the front TXV A/C lines to the TXV flush adapter, and then remove the adapter.
  34. Remove the nut that attaches the EXV A/C lines to the EXV flush adapter.
  35. Remove the bolts (x2) that attach the EXV flush adapter to the chiller, and then remove the adapter.

Remove Rear TXV Valve

  1. Release the clips (x3) that attach the RH minion bracket to the vehicle, and then remove the bracket.
  2. Remove the clips (x4) and bolts (x2) that attach the RH trunk bracket to the vehicle, and then remove the bracket.
  3. Remove the air ducts (x2) from the RH side of the trunk.
  4. Remove the bolts (x2) that attach the rear HVAC duct bracket to the vehicle.
  5. Release the locking tab, and then disconnect the electrical connector from the PTC heater.
  6. Raise the vehicle, and then place an oil drain container under the rear TXV.
  7. Remove the nut that attaches the rear TXV A/C lines to the TXV flush adapter.
  8. Carefully remove the rear TXV A/C lines from the TXV adapter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Residual fluid will drain out of the A/C lines and TXV adapter
  9. Remove the oil drain container from the working area.
  10. Lower the vehicle, and then place a fluid catcher and absorbent towels around the area underneath the rear TXV.
  11. Carefully blow compressed air through the low pressure A/C compressor line until residual flushing fluid is pushed out of the rear TXV A/C lines.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Slowly modulate the air gun trigger to blow just enough air to evacuate the fluid. Do not use maximum air pressure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only clean, dry (i.e., unlubricated) shop air when performing this step.
  12. Carefully blow compressed air through the high pressure A/C compressor line until residual flushing fluid is pushed out of the rear TXV A/C lines.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Slowly modulate the air gun trigger to blow just enough air pressure to evacuate the fluid. Do not use maximum air pressure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Use only clean, dry (i.e., unlubricated) shop air when performing this step.
  13. Remove the fluid catcher and absorbent towels from the working area, and then fully raise the vehicle.
  14. Remove the bolts (x2) that attach the TXV adapter to the rear HVAC assembly, and then remove the TXV adapter.
    Figure 6. Some assemblies hidden for clarity
  15. Release the drain nose from the nipple near the outside of the rear HVAC assembly.
  16. Remove the nuts (x2) that attach the bottom of the rear HVAC assembly to the vehicle
  17. Position the old rear TXV on the rear HVAC assembly, and then install the bolts that attach the TXV to the HVAC assembly (torque 6 Nm).
  18. Lower the vehicle, and then remove the rear HVAC assembly from the vehicle See HVAC Assembly - Rear (Remove and Replace) .
  19. Remove the rear TXV from the rear HVAC assembly. See TXV Valve - Evaporator - Rear (Remove and Replace) .

Install Rear TXV Valve and Partially Install Rear HVAC Assembly

  1. Install a new rear TXV on the rear HVAC assembly, but do not install the rear HVAC assembly on the vehicle. See TXV Valve - Evaporator - Rear (Remove and Replace) .
  2. Position the rear HVAC assembly on the vehicle, and then install the bolts (x2) that attach the HVAC assembly to the inside of the vehicle (torque 6 Nm).
  3. Raise the vehicle, and then install the bolts that attach the bottom of the rear HVAC assembly to the vehicle (torque 8 Nm).
  4. Install new O-rings (x2) on the A/C lines to the rear TXV.
  5. Position the A/C lines on the rear TXV, and then install the nut that attaches the A/C lines to the rear TXV (torque 10.5 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure not to pinch the O-rings during installation.
  6. Install the drain hose on the nipple near the outside of the rear HVAC assembly.
  7. Install the rear diffuser panel. See Diffuser Panel - Rear (Remove and Replace) .
  8. Install the mid aero shield panel. See Panel - Aero Shield - Mid (Remove and Replace).

Install Rear HVAC Assembly

  1. Connect the electrical connector to the PTC heater on the rear HVAC assembly.
  2. Connect the electrical connectors (x2) to the front side of the rear HVAC assembly.
  3. Connect the rear TXV electrical connector to the rear HVAC assembly.
  4. Install the air ducts (x2) on the RH side of the trunk.
  5. Position the RH trunk bracket on the vehicle, and then install the clips (x4) and bolts (x2) that attach the bracket to the vehicle (torque 7 Nm).
  6. Position the RH minion bracket on the vehicle, and then install the clips (x3) that attach the bracket to the vehicle.
  7. Position the rear HV duct bracket on the vehicle, and then install the bolts (x2) that attach the bracket to the vehicle (torque 9 Nm).
  8. Install the RH parcel shelf support. See Support - Parcel Shelf - LH (Remove and Replace) .
  9. Install the components that were removed to access the charger, but do not reconnect 12V power yet. See Vehicle HV Disablement Procedure .

Install EXV Valve

  1. Install new O-rings (x2) on the chiller to EXV ports.
  2. Position the new EXV on the chiller, and then install the bolts (x2) that attach the EXV to the chiller (torque 6 Nm).
  3. Install new O-rings (x2) on the A/C lines to the EXV.
  4. Position the A/C lines on the EXV, and then install the nut that attaches the A/C lines to the EXV (torque 12 Nm).
  5. Connect the electrical connector to the EXV, and then engage the locking tab.

Install Front TXV Valve

  1. Install new O-rings (x2) on the A/C lines to the front TXV.
  2. Position the new front TXV on the A/C lines, and then install the bolt that attaches the A/C lines to the TXV (torque 20 Nm).
  3. Install new O-rings (x2) on the front HVAC to front TXV assembly.
  4. Position the front TXV on the front HVAC assembly, and then install the bolts (x2) that attach the TXV to the HVAC assembly (torque 6 Nm).
  5. Connect the electrical connector to the front TXV, and then install the clip that attaches the electrical harness to the vehicle.

Install A/C Compressor and Reinstall Other Components

  1. Install the new A/C compressor, and then reinstall the coolant reservoir and air suspension reservoir. See Compressor (Remove and Replace).
  2. Position the wiper motor assembly in the vehicle, and then install the bolts (x3) that attach the motor to the vehicle (torque 9 Nm).
  3. Position the HEPA filter duct in the vehicle, and then install the clip that attaches the duct to the vehicle.
  4. Install the 12V auxiliary battery cage and battery, and then connect 12V power. See Cage - Battery - Auxiliary - 12V (Remove and Replace) .
  5. Perform an A/C refrigerant leak detection test. See A/C Refrigerant Leak Detection .
  6. Install the wiper motor assembly. See Wiper Module (LHD) (Remove and Replace) .
  7. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  8. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace) .
  9. 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) .
  10. Install all underhood aprons. See Assembly - Underhood Apron - Front (Remove and Replace) .
  11. Touch and hold the CALIBRATE button on the Model X touchscreen until the rear doors have been fully calibrated, close completely, and the message "CALIBRATION COMPLETE" is displayed.
  12. Disconnect the laptop and install the cubby under the touchscreen.