30/11/2022 05:34:39
A/C Refrigerant Flush Due To Compressor Failure (Dual HVAC) (Europe)
Correction code 18208062
Warning
This procedure is a DRAFT,
although it has been validated. Warnings and Cautions might be missing. Follow safety
requirements and use extreme caution when working on or near high voltage systems and
components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.
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Set up A/C machine and perform hose flush
NoteTouch time only
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Set up A/C machine with flush kit
NoteAttach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut
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Open LH front door
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Using MCU, open hood, liftgate, and LH falcon door
Notevia Controls > Doors
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Raise and support vehicle
NotePlace air suspension into "Jack Mode" if equipped, Service > Jack Mode
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Fully open hood
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Remove RH front lug nut covers
Note5x covers
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Loosen RH front lug nuts
Note5x nuts, 21mm, 175 Nm
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Move LH 2nd row seat fully forward using easy entry mode
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Remove LH welcome plate
Note8x clips
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Remove front screw securing LH lower C-pillar
Note1x patch screw, T25, 2.5 Nm, Discard after removal
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Fold down LH 3rd row seat
NotePress button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
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Remove rear load floor
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Remove RH trunk sill side trim
Note4x clips
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Remove LH trunk sill side trim
Note4x clips
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Remove trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Discard after removal
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Remove trunk board
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Remove trunk floor carpet
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Remove rear load floor support
Note4x push clips, 2x clips
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Remove screw securing LH C-pillar mid trim
Note1x screw, T20, 2 Nm
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Release clips securing LH C-pillar mid trim and remove
Note9x clips
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Remove screws securing LH upper C-pillar trim panel
Note1x patch screw, T25, 3 Nm, Discard after removal, 3x screws, T20, 2 Nm
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Release clips and remove LH upper C-pillar trim panel
Note6x clips, 2 clips along front edge and 4 clips along top edge.
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Remove screws securing C-pillar lower panel to LH parcel shelf support
Note2x screws, T20, 2 Nm
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Release clips securing LH C-pillar lower panel along front edge and remove panel
Note9x clips, 1x magnet
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Remove vent cover from trunk side carpet
Note8x tabs
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Release clips securing LH rear trunk side carpet panel to bracket
Note5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
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Release load floor support from LH trunk side carpet
Note3x tabs, 1x clip
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Pull rear lower corner of LH trunk side carpet panel out and downwards to remove panel
Note2x connectors, Disconnect trunk light and 12V outlet connectors before removal
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Remove fasteners securing LH parcel support bracket and remove bracket
Note2x edge clips, 3x push clips, 2x screws, T25, 2.5 Nm
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Remove LH minion bracket from vehicle
Note3x push clips
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Remove bolt securing front edge of LH trunk trim bracket
Note1x bolt, T30, 2.5 Nm
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Remove fasteners securing LH trunk trim bracket and remove from vehicle
Note2x bolts, T30, 2.5 Nm, 1x push clip
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Release tab securing LH foam duct to plastic duct and move duct to the side
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Move RH 2nd row seat fully forward using easy entry mode
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Remove RH welcome plate
Note8x clips
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Remove screw securing RH C-pillar lower trim panel
Note1x screw, T25, 3 Nm, Discard after removal
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Remove screw securing RH C-pillar mid trim
Note1x screw, T20, 2 Nm
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Release clips securing RH C-pillar mid trim and remove
Note9x clips
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Remove fasteners securing RH upper C-pillar trim panel
Note1x screw, T25, 3 Nm, 3x screws, T20, 2 Nm, Discard T25 fastener after removal
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Release clips and remove RH upper C-pillar trim panel
Note6x clips
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Remove fasteners securing C-pillar lower panel to RH parcel shelf support
Note2x screws, T20, 2 Nm
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Remove load floor support from RH lower C-pillar
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Release clips securing rear edge of RH C-pillar lower panel to rear trunk side carpet panel and pull top edge of C-pillar lower panel out
Note2x clips, 1x magnet
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Release clips securing RH C-pillar lower panel along front edge and remove panel
Note9x clips, 1x magnet
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Release clips securing RH rear trunk side carpet panel to bracket
Note3x push clips, One is hidden between 3rd row seat and trunk side carpet panel
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Pull rear lower corner of RH trunk side carpet panel out and downwards to remove panel
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Remove rear underhood apron
Note11x clips
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Remove LH underhood apron
Note10x clips
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Remove RH underhood apron
Note10x clips
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Remove front underhood apron
Note12x clips
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Remove dust caps from vehicle’s high-side and low-side service ports
Note2x threaded caps
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Connect hoses to vehicle and perform A/C recovery
Note(Touch time only) Ensure quick connects are fully engaged, turn connector dials clockwise to fully connect to A/C service ports
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Remove frunk carpet
Note2x connectors
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Remove underhood storage unit
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
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Remove HEPA filter.
NoteLift up from bottom and pull out
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Remove LH outer hood hinge cover
Note1x fir tree clip, 1x clip
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Remove RH outer hood hinge cover
Note1x fir tree clip, 1x clip
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Remove LH wiper arm
Note1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl
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Remove RH wiper arm
Note2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl
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Disconnect washer hose to cowl at one-way valve
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Disconnect cowl drain hose from cowl trim
Note1x hose clamp
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Remove cowl screen from windshield
Note5x push pins, 1x edge clip
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Remove HEPA filter duct
Note1x push clip
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Power down vehicle using MCU
NoteControls > Safety & Security > Power off
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Disconnect 12V negative terminal
Note1x nut, 10mm, 5 Nm
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Disconnect first responder loop
Note1x connector
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Remove warranty label from charger cover panel
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Remove all items from pockets and ensure not wearing metal items
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Inspect HV insulating gloves
NoteCheck gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves. https://service.teslamotors.com/protected-doc/ServiceBulletins/External/TN/TN-15-92-003_High_Voltage_Awareness_Care_Points_R1.pdf
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Put on HV insulating gloves and leather over gloves
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Remove charger access panel
Note11x patch bolts, T20, 2 Nm, Discard after removal, Make sure to wear proper PPE
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Release tabs and open small access door
Note2x tabs
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Verify no high voltage
NoteMake sure to wear PPE (HV gloves, safety glasses) when working on high voltage components, Measure B+ to Ground, B- to Ground, B+ to B-, If voltage is greater than 10V, pack contactors are not open or welded, Stop work and reach out to Service Engineering
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Remove leather over gloves and HV insulating gloves
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Close small access door
Note2x tabs
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Remove positive 12V terminal cover
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Disconnect positive 12V terminal
Note1x nut, 10mm, 5 Nm
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Remove edge clips from battery cage
Note2x edge clips
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Remove barrel clip from battery cage
Note1x barrel tree clip
-
Remove plastic harness clip
Note1x clip
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Remove battery vent tube
Note1x vent tube
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Remove bolts from bottom of battery cage mounting assembly
Note2x bolts, 10mm, 6 Nm
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Remove bolts from top of battery cage mounting assembly
Note2x bolts, 13mm, 15 Nm
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Remove battery cage assembly from vehicle
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Remove wiper motor assembly
Note3x bolts, 10mm, 9 Nm
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Disconnect wiper motor assembly
Note1x connector
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Remove coolant reservoir cap
Note1x cap
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Use vacuum suction tool to remove coolant from reservoir
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Install coolant reservoir cap
Note1x cap
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Disconnect electrical connector for coolant level sensor
Note1x connector
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Remove coolant reservoir fasteners and wire harness edge clip
Note4x bolts, 10mm, 6 Nm, 1x edge clip
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Clamp and remove coolant hose and move reservoir off to the side
Note1x coolant hose
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Remove A/C hoses from vehicle
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Remove harness retaining clip from wiper bracket
Note1x retaining clip
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Remove wiper mount bracket
Note2x nuts, 13mm, 20 Nm, 2x bolts, 13mm, 20 Nm
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Remove fir tree clips securing blue airline to air tank reservoir brackets
Note2x fir tree clips
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Remove bolts securing air tank reservoir brackets to body
Note4x bolts, 10mm, 6 Nm
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Remove air tank from mounting location and set aside
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Disconnect A/C compressor logic connector
Note1x connector
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Release edge clip for A/C compressor logic connector
Note1x clip
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Release ground strap from compressor
Note1x bolt, T25, 7 Nm
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Remove both A/C lines from compressor
Note2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
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Disconnect A/C compressor harness at FJB and release cable from drive unit
Note1x connector, 1x fir tree clip
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Remove A/C compressor from vehicle
Note3x bolts, T30, 10 Nm
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Remove compressor NVH cover
Note1x velcro strap
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Raise vehicle fully and lower onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
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Remove RH subframe shear plate
Note3x screws, T20, 6 Nm, 1x nyloc nut, 15mm, 35 Nm, 2x push clips, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
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Remove LH subframe shear plate
Note3x screws, T20, 6 Nm, 1x nyloc nut, 15mm, 35 Nm, 2x push clips, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
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Remove mid aero shield
Note20x bolts, 10mm, 4 Nm, 2x push clips
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Remove rear diffuser
Note2x bolts, 10mm, 3 Nm, 2x bolts, T30, 3 Nm, 4x push clips, 13x tabs, Remove hardware, then pull diffuser rearwards to release tabs
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Disconnect AC lines from rear TXV
Note1x nut, 10mm, 10.5 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
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Remove TXV from rear HVAC and let hang by the harness
Note2x screws, T25, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on installNoteIf any debris is found at the rear TXV inlet, the TXV must be replaced by a new one at a later stage.
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Secure TXV adapter to rear HVAC
Note2x screws, T25, 6 Nm, O-rings OK to reuse if not damaged
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Secure AC lines to rear TXV adapter
Note1x nut, 10mm, 10 Nm, O-rings ok to reuse if not damaged
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Remove front aero shield
Note6x bolts, 10mm, 3 Nm, 14x push clips, Discard 4 rearmost bolts after removal
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Remove front fascia skid plate from fascia
Note6x tabs, 4x bolts, 10mm, 2.8 Nm
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Remove desiccant cover from LH side of condenser
Note1x cover, T50, 4 Nm
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Remove snap ring from condenser
Note1x snap ring
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Use the small slide hammer to pull out the inner plug.
NoteDiscard the inner plug. To avoid personal injury, eye protection must be worn when performing this operation.
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Remove desiccant bag from condenser
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Install tooling plug into condenser
NoteLubricate O-rings, AC flush kit may be supplied with wing nut style plug or modified desiccant screen. Only use this tool: 1492019-31-A
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Install snap ring into condenser
NoteMake sure snap ring is seated into groove, Not to be used with wing nut style plug
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Lower vehicle partially and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
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Remove RH front wheel with battery powered drill
Note5x nuts, 21mm, 175 Nm
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Remove push clips that secure RH front wheelhouse liner to body
Note14x push clips
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Remove nuts that secure RH front wheelhouse liner to the studs on the body
Note2x nuts, 10mm, 6 Nm
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Remove RH front wheelhouse liner from vehicle
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Lower vehicle and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Remove nut securing AC lines to EXV
Note1x nut, 10mm, 12 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
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Remove EXV from chiller
Note2x bolts, 3mm hex, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install.NoteIf any debris is found at the front chiller EXV, the EXV must be replaced by a new one on install.
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Release connector lock and disconnect the connector on EXV
Note1x connector, locking tab
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Secure flush adapter to low side compressor line
Note1x nut, 10mm, 10 Nm, Low side hose is big, O-ring ok to reuse if not damaged
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Apply sealer to High pressure adapter threads
NoteSeal the connection with PTFE / Teflon tape
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Thread on quick connect fitting to high pressure adapter
NoteWear appropriate PPE, do not over tighten fitting
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Secure flush adapter to high side compressor line
Note1x nut, 10mm, 10 Nm, High side hose is small, O-ring ok to reuse if not damaged
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Secure EXV adapter to chiller
Note2x bolts, 3mm hex, 6 Nm, O-rings ok to reuse if not damaged
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Secure AC lines to EXV adapter
Note1x nut, 10mm, 12 Nm, O-rings ok to reuse if not damaged
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Blue line nipple, Ensure gasket is in place and in good condition
Notebe careful while installing to not damage the gasket
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Connect the blue line nipple to the adapter block marked with "Inlet"
NoteWear appropriate PPE, do not over tight the nipple, gasket can damage. Tight ONLY with hands
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Remove the liquid inline filter drier
NoteRemove the filter from the container (the grey filter attached to the flush unit) PR052FM
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Remove nipple from filter
NoteSeparate Low Pressure nipple from filter
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Remove old Teflon tape from the container thread
NoteOld Teflon tape must be removed completely.
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Wrap the container nipple with Teflon tape
NoteUse Teflon tape. Make sure that enough tape is applied
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Wrap the filter nipple in Teflon tape
NoteUse Teflon tape. Make sure that enough tape is applied
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Place 1 copper sealing ring on place. Low pressure nipple
NoteGood to use the old copper ring.
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Installed Low pressure nipple on filter
NoteMake sure that enough tape is applied and 1 copper sealing ring in on place. Do not over torque
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Place 1 copper sealing ring on place. Inside the filter.
NoteGood to use the old copper ring.
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attach the filter to the container
NoteDo not over torque while installing.
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Connect the blue line 1 from the flush unit to the adapter 2 block marked with "Inlet"
NoteWear appropriate PPE, Ensure gasket is on place between 1 hose connector and 2 nipple , Tighten with hands, do not over tighten
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Connect the blue line from the AC machine to the flush unit quick connector (on the liquid line filter drier)
NoteWear appropriate PPE, Ensure gasket is on place, Do not over tighten
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Connect the machine High pressure RED connector to adapter block OUTLET
NoteWear appropriate PPE, Ensure gasket is on place, Do not over tighten
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Flush 1. Clamp off EXV
NoteAt the Low pressure thick hose
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On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
NoteWear appropriate PPE
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Flush will take 2 hours
Notemonitor the process from time to time
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When flush 1 is finished, unclamp EXV
NoteRemove the clamp from he big hose
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Flush 2. Clamp off Rear TXV at the Low Big pressure hose
NoteBehind the front right wheel arch liner.
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On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
NoteWear appropriate PPE
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Flush will take 2 hours
Notemonitor the process from time to time
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Flush 3. Clamp off EXV at the low
pressure thick hose.
NoteThe rear TXV must still be clamped off at the low big pressure hose at this stage.
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Unplug and release TXV connection
Note1x connector, 1x clip
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Remove fasteners securing TXV to evaporator
Note2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
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Remove TXV from A/C lines
Note1x bolt, 5mm, 20 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
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Secure TXV adapter to AC lines
Note1x bolt, 5mm hex, 6 Nm, O-rings ok to reuse if not damaged
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Secure AC lines/TXV adapter to evaporator
Note2x bolts, T30, 6 Nm, O-rings ok to reuse if not damaged
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On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
NoteWear appropriate PPE
-
Flush will take 2 hours
Notemonitor the process from time to time
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When flush 3 is finished, unclamp EXV
NoteRemove the clamp from he big hose
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After Flush 3 is finished Remove Clamp Rear TXV
NoteRemove Clamp from the Rear TXV blockage
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Remove machine hoses from adapter
Note2x quick release fittings, Wear appropriate PPE
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Remove adapter from low side AC line
Note1x nut, 10mm, 10 Nm, Low side hose is big, Discard o-ring, Wear appropriate PPE
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Remove adapter from high side AC line
Note1x nut, 10mm, 10 Nm, High side hose is big, Discard o-ring, Wear appropriate PPE
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Remove fasteners securing TXV adapter to evaporator
Note2x bolts, T30, 6 Nm, Discard o-rings, Wear appropriate PPE
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Remove TXV adapter from AC lines
Note1x bolt, 5mm hex, 20 Nm, Discard o-rings, Wear appropriate PPE
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Remove nut securing AC lines to EXV adapter
Note1x nut, 10mm, 12 Nm, Discard o-rings, Wear appropriate PPE
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Remove EXV adapter from chiller
Note2x bolts, 3mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE
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Remove clips securing RH minion bracket and remove bracket
Note3x push clips
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Remove the RH trunk bracket
Note2x bolts, T30, 7 Nm, 4x push clips
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Remove duct from rear HVAC
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Remove bolts that secure rear HVAC duct bracket to body
Note2x bolts, 10mm, 9 Nm
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Release PTC heater connector
Note1x connector, 1x locking tab
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Raise vehicle fully and lower onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
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Position oil drain container under rear TXV
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Disconnect A/C lines from rear TXV adapter
Note1x nut, 10mm, 10 Nm, Discard O-rings, Wear appropriate PPE, Residual fluid will drain from mating connections into oil container
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Remove the oil drain container from under the vehicle
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Lower vehicle and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Place absorbent towels and fluid catcher under rear TXV
-
Blow out low pressure line from AC compressor.
NoteUse caution to not blow too much pressure through the line, Blow out residual fluid until air can be heard coming from the back side of the vehicle
-
Blow out high pressure line from AC compressor
NoteUse caution to not blow too much pressure through the line, Blow out residual fluid until air can be heard coming from the back side of the vehicle
-
Remove fluid catcher and absorbent material from under vehicle
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Raise vehicle fully and lower onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
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Remove TXV adapter from rear HVAC
Note2x bolts, T25, 6 Nm
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Release the drain hose from the nipple on the bottom of the rear HVAC assembly._x000A_
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Remove nuts securing rear HVAC to underside of body
Note2x nuts, 10mm, 8 Nm
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Install TXV to rear HVAC
Note2x bolts, T25, 6 Nm
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Lower vehicle and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
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Release rear HVAC connectors from body harness
Note2x connectors
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Remove bolts securing rear HVAC to body
Note2x bolts, 10mm, 6 Nm
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Release TXV connector from body harness
Note1x connector
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Pull the HVAC assembly upward to remove it from the vehicle
NotePlace on work bench
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Remove the foam gasket from the bottom of the HVAC assembly
NoteReuse if not damaged
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Release the TXV valve electrical wire from the rear HVAC assembly.
Note2x clips
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Remove TXV from rear HVAC
Note2x screws, T25, 6 Nm, Discard O-rings
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Install the TXV to rear HVAC
(R1234YF)
Note2x screws, T25, 6 Nm, Install new O-rings.NoteIf any debris is found at the rear TXV inlet, the TXV must be replaced by a new one.
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Route TXV harness along HVAC
Note2x clips
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If damaged, install a new foam gasket to
the rear HVAC assembly.
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Install rear HVAC
NoteAlign TXV and mounting studs to corresponding holes
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Secure rear HVAC to body
Note2x bolts, 10mm, 6 Nm
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Raise vehicle fully and lower onto locks
NoteSet vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side
-
Install nuts that secure rear HVAC to underside of vehicle
Note2x nuts, 10mm, 8 Nm
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Reinstall the refrigerant lines to the TXV on the rear HVAC unit and hand tighten nut
Note1x nut, 10mm, 10.5 Nm, Install new O-rings, Use caution not to pinch O-ring during installation
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Torque the A/C lines to the rear TXV
Note1x nut, 10mm, 10 Nm
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Install drain hose to rear HVAC nipple
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Install rear diffuser
Note2x bolts, 10mm, 3 Nm, 2x bolts, T30, 3 Nm, 4x push clips,13x tabs, Secure diffuser tabs first, Install remaining hardware
-
Hand start the mid aero shield bolts and install the clips
Note20x bolts, 10mm, 4 Nm, 2x push clips
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Install RH shear plate
Note3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nyloc nut, 15mm, Install new nyloc nut
-
Install LH shear plate
Note3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nyloc nut, 15mm, Install new nyloc nut
-
Torque mid aero shield bolts
Note20x bolts, 10mm, 4 Nm
-
Remove snap ring from condenser
Note1x snap ring, Not used with wing nut style plug
-
Use the small slide hammer to pull out the inner tooling plug.
NoteDiscard the inner plug. To avoid personal injury, eye protection must be worn when performing this operation.
-
Install new desiccant bag into condenser
-
Install new desiccant screen into condenser
NoteLubricate O-rings
-
Install snap ring into condenser
NoteMake sure snap ring is seated into groove, Not to be used with wing nut style plug
-
Install desiccant cover into LH side of condenser
Note1x cover, T50, 4 Nm
-
Install front fascia skid plate onto fascia
Note6x tabs, 4x bolts, 10mm, 2.8 Nm
-
Install front aero shield
Note6x bolts, 10mm, 3 Nm, 14x push clips
-
Lower vehicle partially and set lift onto locks
NoteRaise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
-
Install RH front wheelhouse liner on vehicle
-
Install nuts that secure RH front wheelhouse liner to the studs on the body
Note2x nuts, 10mm, 6 Nm
-
Install push clips that secure RH front wheelhouse liner to body
Note14x push clips
-
Install RH front wheel with battery powered drill
Note5x nuts, 21mm, 175 Nm
-
Lower vehicle until tires are touching the ground
-
Torque RH front wheel
Note5x nuts, 21mm, 175 Nm
-
Install RH front lug nut covers
Note5x covers
-
Install charger access panel
Note11x patch bolts, T20, 2 Nm, Install new patch bolts
-
Clean area around charger access panel prior to installation of new warranty label
NoteAllow IPA to dry for at least 1 minute
-
Install new warranty label
-
Connect PTC connector
Note1x connector, 1x locking tab
-
Connect the rear HVAC connectors.
Note2x connectors
-
Connect rear TXV connector
Note1x connector
-
Install RH duct to rear HVAC
-
Install the RH trunk bracket
Note2x bolts, T30, 7 Nm_x000A_4x push clips
-
Install RH minion bracket and secure with clips
Note3x push clips
-
Secure rear HVAC duct bracket to body
Note2x bolts, 10mm, 9 Nm
-
Install foam HVAC ducting covering charger access panel_x0009_
-
Reinstall LH trunk trim bracket and loosely install fastener
Note1x bolt, T30, 2.5 Nm, 1x push clip
-
Fold LH 3rd row seat up
NotePress button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
-
Loosely install bolt securing front edge of LH trunk trim bracket
Note1x bolt, T30, 2.5 Nm
-
Install LH minion bracket into position and install all clips
Note3x push clips
-
Tighten fasteners securing LH trunk trim bracket
Note2x bolts, T30, 2.5 Nm, 1x push clip
-
Fold LH 3rd row seat down
-
Install LH mid zone C-pillar bracket and install fasteners
Note2x screws, T20, 2.5 Nm, 3x push clips, Need to secure 2x edge clips for charge port release cables as well
-
Reinstall LH trunk side carpet panel
Note2x connectors, Reconnect trunk light and 12V outlet connectors before positioning panel. Use caution not to pinch Rear PTC harness (see picture)
-
Install clips securing LH rear trunk side carpet panel to bracket
Note5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
-
Verify charge port mechanical release cable is in proper position in trunk side carpet panel
-
Install LH lower C-pillar and secure clips along front edge
Note9x clips, 1x magnet
-
Secure clips at rear edge of LH C-pillar lower panel
Note2x clips, 1x magnet
-
Install fasteners securing C-pillar lower panel to LH parcel shelf support
Note2x screws, T20, 2 Nm
-
Reinstall RH trunk side carpet panel
NoteUse caution not to pinch Rear PTC harness
-
Reinstall clips securing RH rear trunk side carpet panel to bracket
Note3x push clips, One is hidden between 3rd row seat and trunk side carpet panel
-
Install RH C-pillar lower panel and secure clips along front edge
Note9x clips, 1x magnet
-
Secure clips holding rear edge of RH C-pillar lower panel to rear trunk side carpet panel
Note3x clips, 1x magnet
-
Install fasteners securing C-pillar lower panel to RH parcel shelf support
Note2x screws, T20, 2 Nm
-
Install trunk side nub onto RH lower C-pillar
Note3x tabs, 1x clip
-
Install RH upper C-pillar trim panel
Note6x clips
-
Install fasteners securing RH upper C-pillar trim panel
Note1x screw, T25, 3 Nm, 3x screws, T20, 2 Nm, Install new T25 fastener
-
Install RH C-pillar mid trim
Note9x clips, Install front section first, then work around to rear
-
Install screw securing RH C-pillar mid trim
Note1x screw, T20, 2 Nm
-
Install LH upper C-pillar trim panel
Note6x clips
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Install fasteners securing LH upper C-pillar trim panel
Note1x bolt, T25, 3 Nm, 3x screws, T20, 2 Nm
-
Install trunk side nub to lower C-pillar
Note3x tabs, 1x clip
-
Install LH C-pillar mid trim and secure clips
Note9x clips, Install front section first, then work around to rear
-
Install screw securing LH C-pillar mid trim
Note1x screw, T20, 2 Nm
-
Reinstall front lower carpet trim panel
NoteSecure 3rd row seat wiring harnesses to panel
-
Install rear load floor support
Note4x push clips, 2x clips
-
Install trunk board
-
Install rear trunk sill trim
Note4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
-
Install LH trunk sill side trim
Note4x clips
-
Install RH trunk sill side trim
Note4x clips
-
Install rear load floor
-
Fold 3rd row seats up
-
Close liftgate
-
Install bolt securing front of LH lower C-pillar
Note1x patch bolt, T25, 2.5 Nm, Install new patch bolt
-
Install LH welcome plate
Note8x clips
-
Move LH 2nd row seat from the easy entry position to the regular upright seating position
NoteSlide seat track backwards by pushing towards rear of vehicle, Fold upper seat backwards until locked in an upright position
-
Secure RH lower C-pillar trim to body
Note1x patch screw, T25, 2.5 Nm, Install new screw
-
Install RH welcome plate
Note8x clips
-
Move RH 2nd row seat out of easy entry position
-
Install compressor NVH cover to new compressor
Note1x velcro strap, Do not drain oil
-
Install EXV to chiller
Note2x bolts, 3mm hex, 6 Nm, Install new O-ringsNoteIf any debris was found at the EXV, replace the EXV by a new one.
-
Secure AC lines to EXV
Note1x nut, 10mm, 12 Nm, Install new O-rings
-
Connect EXV coil and secure lock
Note1x connector, locking tab
-
Secure AC lines to TXV (R1234YF)
Note1x bolt, 5mm hex, 20 Nm, Install new O-ringsNoteIf any debris is found at the front TXV, replace the TXV by a new one.
-
Install bolts securing TXV (R1234YF) to evaporator
Note2x bolts, T30, 6 Nm, Install new O-rings
-
Connect the TXV connector.
-
Install A/C compressor
Note3x bolts, T30, 10 Nm
-
Install both A/C lines to compressor
Note2x nuts, 10mm, 10 Nm, Install new O-rings
-
Install ground strap to compressor
Note1x bolt, T25, 7 Nm
-
Connect A/C compressor harness to FJB and install cable fir tree to drive unit
Note1x connector, 1x fir tree clip _x000A_
-
Make low voltage connection to compressor
Note1x connector
-
Secure edge clip to A/C compressor bracket
Note1x clip
-
Connect coolant hose to reservoir and remove hose clamp
Note1x coolant hose
-
Install fasteners securing coolant reservoir to shock tower cross member
Note4x bolts, 10mm, 6 Nm
-
Connect coolant reservoir level sensor
Note1x connector
-
Top off coolant reservoir
NoteEnsure coolant is filled to nominal level
-
Position air tank into mounting location
-
Install bolts securing air tank reservoir brackets to vehicle body
Note4x bolts, 10mm, 6 Nm
-
Install fir tree clips securing blue airline to air tank reservoir brackets
Note2x fir tree clips
-
Install wiper mount bracket
Note2x nuts, 13mm, 20 Nm, 2x bolts, 13mm, 20 Nm
-
Install 12V harness to center support bracket
-
Install wiper motor assembly
Note3x bolts, 10mm, 9 Nm
-
Install HEPA filter duct
Note1x push clip
-
Install battery cage assembly into vehicle
-
Install bolts into top of battery cage assembly
Note2x bolts, 13mm, 15 Nm
-
Install bolts in bottom of battery cage assembly
Note2x bolts, 10mm, 6 Nm
-
Install plastic harness clip
Note1x clip
-
Install clip onto battery cage
Note1x barrel clip
-
Install edge clips onto battery cage
Note2x edge clips
-
Install battery vent tube back into battery
Note1x vent tube
-
Connect 12V positive terminal
Note1x nut, 10mm, 5 Nm
-
Install positive terminal cover
-
Connect first responder loop and then 12V negative terminal.
Note1x connector, 1x nut, 10mm, 5 Nm
- Connect a laptop to the diagnostic port of the vehicle, and then use Toolbox 3 to locally connect to the vehicle. See Toolbox 3 (Connect and Disconnect).
- Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
-
Using Toolbox 3:
- Select the Actions tab and search for "Fluid fill drain"
- Select the ODIN routine PROC_THC_X_FLUID-FILL-DRAINSearch for routine in ToolboxFluid Fill/DrainThermal / Actions - Stop Fluid Fill/Drain, and then click on the link of the routine.
- Under "Fluid Fill Target, select "Refrigerant".
- Click RUN, and allow the routine to complete.
-
Connect hoses to vehicle and perform A/C vacuum and leak test
Note(Touch time only) 30 minute vacuum, 10 minute leak test. Ensure quick connects are fully engaged, turn the connector dials clockwise to fully connect to A/C service ports.
-
Install cowl screen assembly
Note5x push pins, 1x edge clip
-
Install LH outer hood hinge cover
Note1x fir tree clip, 1x clip
-
Install RH outer hood hinge cover
Note1x fir tree clip, 1x clip
-
Install RH wiper arm
Note2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield
-
Install LH wiper arm
Note1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield
-
Install wiper arm hoses
-
Install cowl drain hose
Note1x hose clamp
-
Install wiper drain hose to one-way valve
Note1x washer hose
-
Install HEPA filter housing
-
Install underhood storage unit
Note10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
-
Install frunk carpet
Note2x connectors
-
Install front underhood apron
Note12x clips
-
Install RH underhood apron
Note10x clips
-
Install LH underhood apron
Note10x clips
-
Leak test overlap
-
Perform A/C refrigerant refill
NoteRun time, per fluid capacity spec
-
Remove A/C hoses from vehicle
-
Install rear underhood apron
Note11x clips
-
Close hood
-
Click finish when routine is complete
-
Disconnect laptop from vehicle and reinstall storage cubby
Note1x connect, 2x clips
-
Remove vehicle from lift
NoteLower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode"
-
Calibrate falcon doors using MCU
NoteRequired after 12V and FRL disconnect
-
Close LH front door