30/11/2022 05:34:39

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

Correction code 18208062

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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.
  1. Set up A/C machine and perform hose flush
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    Note
    Touch time only
  2. Set up A/C machine with flush kit
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    Note
    Attach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut
  3. Open LH front door
  4. Using MCU, open hood, liftgate, and LH falcon door
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    Note
    via Controls > Doors
  5. Raise and support vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Place air suspension into "Jack Mode" if equipped, Service > Jack Mode
  6. Fully open hood
  7. Remove RH front lug nut covers
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    Note
    5x covers
  8. Loosen RH front lug nuts
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    Note
    5x nuts, 21mm, 175 Nm
  9. Move LH 2nd row seat fully forward using easy entry mode
  10. Remove LH welcome plate
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    Note
    8x clips
  11. Remove front screw securing LH lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch screw, T25, 2.5 Nm, Discard after removal
  12. Fold down LH 3rd row seat
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    Note
    Press button located on LH 3rd row seat back assembly near headrest, fold seat back down towards front of vehicle into a flat position
  13. Remove rear load floor
  14. Remove RH trunk sill side trim
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    Note
    4x clips
  15. Remove LH trunk sill side trim
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    Note
    4x clips
  16. Remove trunk sill trim
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    Note
    4x clips, 2x patch bolts, T25, 2.5 Nm, Discard after removal
  17. Remove trunk board
  18. Remove trunk floor carpet
  19. Remove rear load floor support
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    Note
    4x push clips, 2x clips
  20. Remove screw securing LH C-pillar mid trim
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    Note
    1x screw, T20, 2 Nm
  21. Release clips securing LH C-pillar mid trim and remove
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    Note
    9x clips
  22. Remove screws securing LH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch screw, T25, 3 Nm, Discard after removal, 3x screws, T20, 2 Nm
  23. Release clips and remove LH upper C-pillar trim panel
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    Note
    6x clips, 2 clips along front edge and 4 clips along top edge.
  24. Remove screws securing C-pillar lower panel to LH parcel shelf support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2 Nm
  25. Release clips securing LH C-pillar lower panel along front edge and remove panel
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    Note
    9x clips, 1x magnet
  26. Remove vent cover from trunk side carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    8x tabs
  27. Release clips securing LH rear trunk side carpet panel to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
  28. Release load floor support from LH trunk side carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x clip
  29. Pull rear lower corner of LH trunk side carpet panel out and downwards to remove panel
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    Note
    2x connectors, Disconnect trunk light and 12V outlet connectors before removal
  30. Remove fasteners securing LH parcel support bracket and remove bracket
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    Note
    2x edge clips, 3x push clips, 2x screws, T25, 2.5 Nm
  31. Remove LH minion bracket from vehicle
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    Note
    3x push clips
  32. Remove bolt securing front edge of LH trunk trim bracket
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    Note
    1x bolt, T30, 2.5 Nm
  33. Remove fasteners securing LH trunk trim bracket and remove from vehicle
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    Note
    2x bolts, T30, 2.5 Nm, 1x push clip
  34. Release tab securing LH foam duct to plastic duct and move duct to the side
  35. Move RH 2nd row seat fully forward using easy entry mode
  36. Remove RH welcome plate
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    Note
    8x clips
  37. Remove screw securing RH C-pillar lower trim panel
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    Note
    1x screw, T25, 3 Nm, Discard after removal
  38. Remove screw securing RH C-pillar mid trim
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    Note
    1x screw, T20, 2 Nm
  39. Release clips securing RH C-pillar mid trim and remove
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips
  40. Remove fasteners securing RH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 3 Nm, 3x screws, T20, 2 Nm, Discard T25 fastener after removal
  41. Release clips and remove RH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips
  42. Remove fasteners securing C-pillar lower panel to RH parcel shelf support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2 Nm
  43. Remove load floor support from RH lower C-pillar
  44. 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
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x magnet
  45. Release clips securing RH C-pillar lower panel along front edge and remove panel
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, 1x magnet
  46. Release clips securing RH rear trunk side carpet panel to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, One is hidden between 3rd row seat and trunk side carpet panel
  47. Pull rear lower corner of RH trunk side carpet panel out and downwards to remove panel
  48. Remove rear underhood apron
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    Note
    11x clips
  49. Remove LH underhood apron
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    Note
    10x clips
  50. Remove RH underhood apron
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    Note
    10x clips
  51. Remove front underhood apron
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    Note
    12x clips
  52. Remove dust caps from vehicle’s high-side and low-side service ports
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    Note
    2x threaded caps
  53. Connect hoses to vehicle and perform A/C recovery
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    Note
    (Touch time only) Ensure quick connects are fully engaged, turn connector dials clockwise to fully connect to A/C service ports
  54. Remove frunk carpet
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    Note
    2x connectors
  55. Remove underhood storage unit
    Informational PurposesAn informational icon, calling your attention
    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
  56. Remove HEPA filter.
    Informational PurposesAn informational icon, calling your attention
    Note
    Lift up from bottom and pull out
  57. Remove LH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip, 1x clip
  58. Remove RH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip, 1x clip
  59. Remove LH wiper arm
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 17mm, 35 Nm, Disconnect washer hose at cowl
  60. Remove RH wiper arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 17mm, 35 Nm, Disconnect washer hose at cowl
  61. Disconnect washer hose to cowl at one-way valve
  62. Disconnect cowl drain hose from cowl trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clamp
  63. Remove cowl screen from windshield
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push pins, 1x edge clip
  64. Remove HEPA filter duct
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  65. Power down vehicle using MCU
    Informational PurposesAn informational icon, calling your attention
    Note
    Controls > Safety & Security > Power off
  66. Disconnect 12V negative terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 5 Nm
  67. Disconnect first responder loop
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    Note
    1x connector
  68. Remove warranty label from charger cover panel
  69. Remove all items from pockets and ensure not wearing metal items
  70. Inspect HV insulating gloves
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    Note
    Check 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
  71. Put on HV insulating gloves and leather over gloves
  72. Remove charger access panel
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    Note
    11x patch bolts, T20, 2 Nm, Discard after removal, Make sure to wear proper PPE
  73. Release tabs and open small access door
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    Note
    2x tabs
  74. Verify no high voltage
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    Note
    Make 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
  75. Remove leather over gloves and HV insulating gloves
  76. Close small access door
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    Note
    2x tabs
  77. Remove positive 12V terminal cover
  78. Disconnect positive 12V terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 5 Nm
  79. Remove edge clips from battery cage
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    Note
    2x edge clips
  80. Remove barrel clip from battery cage
    Informational PurposesAn informational icon, calling your attention
    Note
    1x barrel tree clip
  81. Remove plastic harness clip
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    Note
    1x clip
  82. Remove battery vent tube
    Informational PurposesAn informational icon, calling your attention
    Note
    1x vent tube
  83. Remove bolts from bottom of battery cage mounting assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  84. Remove bolts from top of battery cage mounting assembly
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    Note
    2x bolts, 13mm, 15 Nm
  85. Remove battery cage assembly from vehicle
  86. Remove wiper motor assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm
  87. Disconnect wiper motor assembly
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    Note
    1x connector
  88. Remove coolant reservoir cap
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    Note
    1x cap
  89. Use vacuum suction tool to remove coolant from reservoir
  90. Install coolant reservoir cap
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    Note
    1x cap
  91. Disconnect electrical connector for coolant level sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  92. Remove coolant reservoir fasteners and wire harness edge clip
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 6 Nm, 1x edge clip
  93. Clamp and remove coolant hose and move reservoir off to the side
    Informational PurposesAn informational icon, calling your attention
    Note
    1x coolant hose
  94. Remove A/C hoses from vehicle
  95. Remove harness retaining clip from wiper bracket
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    Note
    1x retaining clip
  96. Remove wiper mount bracket
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    Note
    2x nuts, 13mm, 20 Nm, 2x bolts, 13mm, 20 Nm
  97. Remove fir tree clips securing blue airline to air tank reservoir brackets
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    Note
    2x fir tree clips
  98. Remove bolts securing air tank reservoir brackets to body
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    Note
    4x bolts, 10mm, 6 Nm
  99. Remove air tank from mounting location and set aside
  100. Disconnect A/C compressor logic connector
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    Note
    1x connector
  101. Release edge clip for A/C compressor logic connector
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    Note
    1x clip
  102. Release ground strap from compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 7 Nm
  103. Remove both A/C lines from compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  104. Disconnect A/C compressor harness at FJB and release cable from drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x fir tree clip
  105. Remove A/C compressor from vehicle
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    Note
    3x bolts, T30, 10 Nm
  106. Remove compressor NVH cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x velcro strap
  107. Raise vehicle fully and lower onto locks
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    Note
    Set 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
  108. Remove RH subframe shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T20, 6 Nm, 1x nyloc nut, 15mm, 35 Nm, 2x push clips, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
  109. Remove LH subframe shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T20, 6 Nm, 1x nyloc nut, 15mm, 35 Nm, 2x push clips, 1x bolt, 10mm, 4 Nm, Discard nyloc nut after removal
  110. Remove mid aero shield
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    Note
    20x bolts, 10mm, 4 Nm, 2x push clips
  111. Remove rear diffuser
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    Note
    2x bolts, 10mm, 3 Nm, 2x bolts, T30, 3 Nm, 4x push clips, 13x tabs, Remove hardware, then pull diffuser rearwards to release tabs
  112. Disconnect AC lines from rear TXV
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10.5 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  113. Remove TXV from rear HVAC and let hang by the harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
    Informational PurposesAn informational icon, calling your attention
    Note
    If any debris is found at the rear TXV inlet, the TXV must be replaced by a new one at a later stage.
  114. Secure TXV adapter to rear HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 6 Nm, O-rings OK to reuse if not damaged
  115. Secure AC lines to rear TXV adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, O-rings ok to reuse if not damaged
  116. Remove front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 3 Nm, 14x push clips, Discard 4 rearmost bolts after removal
  117. Remove front fascia skid plate from fascia
    Informational PurposesAn informational icon, calling your attention
    Note
    6x tabs, 4x bolts, 10mm, 2.8 Nm
  118. Remove desiccant cover from LH side of condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, T50, 4 Nm
  119. Remove snap ring from condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    1x snap ring
  120. Use the small slide hammer to pull out the inner plug.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the inner plug. To avoid personal injury, eye protection must be worn when performing this operation.
  121. Remove desiccant bag from condenser
  122. Install tooling plug into condenser
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    Note
    Lubricate O-rings, AC flush kit may be supplied with wing nut style plug or modified desiccant screen. Only use this tool: 1492019-31-A
  123. Install snap ring into condenser
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    Note
    Make sure snap ring is seated into groove, Not to be used with wing nut style plug
  124. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  125. Remove RH front wheel with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  126. Remove push clips that secure RH front wheelhouse liner to body
    Informational PurposesAn informational icon, calling your attention
    Note
    14x push clips
  127. Remove nuts that secure RH front wheelhouse liner to the studs on the body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 6 Nm
  128. Remove RH front wheelhouse liner from vehicle
  129. Lower vehicle and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  130. Remove nut securing AC lines to EXV
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 12 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  131. Remove EXV from chiller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 3mm hex, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install.
    Informational PurposesAn informational icon, calling your attention
    Note
    If any debris is found at the front chiller EXV, the EXV must be replaced by a new one on install.
  132. Release connector lock and disconnect the connector on EXV
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    Note
    1x connector, locking tab
  133. Secure flush adapter to low side compressor line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Low side hose is big, O-ring ok to reuse if not damaged
  134. Apply sealer to High pressure adapter threads
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    Note
    Seal the connection with PTFE / Teflon tape
  135. Thread on quick connect fitting to high pressure adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE, do not over tighten fitting
  136. Secure flush adapter to high side compressor line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, High side hose is small, O-ring ok to reuse if not damaged
  137. Secure EXV adapter to chiller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 3mm hex, 6 Nm, O-rings ok to reuse if not damaged
  138. Secure AC lines to EXV adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 12 Nm, O-rings ok to reuse if not damaged
  139. Blue line nipple, Ensure gasket is in place and in good condition
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    Note
    be careful while installing to not damage the gasket
  140. Connect the blue line nipple to the adapter block marked with "Inlet"
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    Note
    Wear appropriate PPE, do not over tight the nipple, gasket can damage. Tight ONLY with hands
  141. Remove the liquid inline filter drier
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the filter from the container (the grey filter attached to the flush unit) PR052FM
  142. Remove nipple from filter
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    Note
    Separate Low Pressure nipple from filter
  143. Remove old Teflon tape from the container thread
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    Note
    Old Teflon tape must be removed completely.
  144. Wrap the container nipple with Teflon tape
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    Note
    Use Teflon tape. Make sure that enough tape is applied
  145. Wrap the filter nipple in Teflon tape
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    Note
    Use Teflon tape. Make sure that enough tape is applied
  146. Place 1 copper sealing ring on place. Low pressure nipple
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    Note
    Good to use the old copper ring.
  147. Installed Low pressure nipple on filter
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure that enough tape is applied and 1 copper sealing ring in on place. Do not over torque
  148. Place 1 copper sealing ring on place. Inside the filter.
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    Note
    Good to use the old copper ring.
  149. attach the filter to the container
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not over torque while installing.
  150. Connect the blue line 1 from the flush unit to the adapter 2 block marked with "Inlet"
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE, Ensure gasket is on place between 1 hose connector and 2 nipple , Tighten with hands, do not over tighten
  151. Connect the blue line from the AC machine to the flush unit quick connector (on the liquid line filter drier)
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE, Ensure gasket is on place, Do not over tighten
  152. Connect the machine High pressure RED connector to adapter block OUTLET
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE, Ensure gasket is on place, Do not over tighten
  153. Flush 1. Clamp off EXV
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    Note
    At the Low pressure thick hose
  154. On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE
  155. Flush will take 2 hours
    Informational PurposesAn informational icon, calling your attention
    Note
    monitor the process from time to time
  156. When flush 1 is finished, unclamp EXV
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the clamp from he big hose
  157. Flush 2. Clamp off Rear TXV at the Low Big pressure hose
    Informational PurposesAn informational icon, calling your attention
    Note
    Behind the front right wheel arch liner.
  158. On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE
  159. Flush will take 2 hours
    Informational PurposesAn informational icon, calling your attention
    Note
    monitor the process from time to time
  160. Flush 3. Clamp off EXV at the low pressure thick hose.
    Informational PurposesAn informational icon, calling your attention
    Note
    The rear TXV must still be clamped off at the low big pressure hose at this stage.
  161. Unplug and release TXV connection
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x clip
  162. Remove fasteners securing TXV to evaporator
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  163. Remove TXV from A/C lines
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 5mm, 20 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install
  164. Secure TXV adapter to AC lines
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 5mm hex, 6 Nm, O-rings ok to reuse if not damaged
  165. Secure AC lines/TXV adapter to evaporator
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 6 Nm, O-rings ok to reuse if not damaged
  166. On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter
    Informational PurposesAn informational icon, calling your attention
    Note
    Wear appropriate PPE
  167. Flush will take 2 hours
    Informational PurposesAn informational icon, calling your attention
    Note
    monitor the process from time to time
  168. When flush 3 is finished, unclamp EXV
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the clamp from he big hose
  169. After Flush 3 is finished Remove Clamp Rear TXV
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove Clamp from the Rear TXV blockage
  170. Remove machine hoses from adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    2x quick release fittings, Wear appropriate PPE
  171. Remove adapter from low side AC line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Low side hose is big, Discard o-ring, Wear appropriate PPE
  172. Remove adapter from high side AC line
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, High side hose is big, Discard o-ring, Wear appropriate PPE
  173. Remove fasteners securing TXV adapter to evaporator
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 6 Nm, Discard o-rings, Wear appropriate PPE
  174. Remove TXV adapter from AC lines
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 5mm hex, 20 Nm, Discard o-rings, Wear appropriate PPE
  175. Remove nut securing AC lines to EXV adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 12 Nm, Discard o-rings, Wear appropriate PPE
  176. Remove EXV adapter from chiller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 3mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE
  177. Remove clips securing RH minion bracket and remove bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  178. Remove the RH trunk bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 7 Nm, 4x push clips
  179. Remove duct from rear HVAC
  180. Remove bolts that secure rear HVAC duct bracket to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  181. Release PTC heater connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x locking tab
  182. Raise vehicle fully and lower onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  183. Position oil drain container under rear TXV
  184. Disconnect A/C lines from rear TXV adapter
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm, Discard O-rings, Wear appropriate PPE, Residual fluid will drain from mating connections into oil container
  185. Remove the oil drain container from under the vehicle
  186. Lower vehicle and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  187. Place absorbent towels and fluid catcher under rear TXV
  188. Blow out low pressure line from AC compressor.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use 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
  189. Blow out high pressure line from AC compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    Use 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
  190. Remove fluid catcher and absorbent material from under vehicle
  191. Raise vehicle fully and lower onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  192. Remove TXV adapter from rear HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T25, 6 Nm
  193. Release the drain hose from the nipple on the bottom of the rear HVAC assembly._x000A_
  194. Remove nuts securing rear HVAC to underside of body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 8 Nm
  195. Install TXV to rear HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T25, 6 Nm
  196. Lower vehicle and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered
  197. Release rear HVAC connectors from body harness
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  198. Remove bolts securing rear HVAC to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  199. Release TXV connector from body harness
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  200. Pull the HVAC assembly upward to remove it from the vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    Place on work bench
  201. Remove the foam gasket from the bottom of the HVAC assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    Reuse if not damaged
  202. Release the TXV valve electrical wire from the rear HVAC assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  203. Remove TXV from rear HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 6 Nm, Discard O-rings
  204. Install the TXV to rear HVAC (R1234YF)
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T25, 6 Nm, Install new O-rings.
    Informational PurposesAn informational icon, calling your attention
    Note
    If any debris is found at the rear TXV inlet, the TXV must be replaced by a new one.
  205. Route TXV harness along HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips
  206. If damaged, install a new foam gasket to the rear HVAC assembly.
  207. Install rear HVAC
    Informational PurposesAn informational icon, calling your attention
    Note
    Align TXV and mounting studs to corresponding holes
  208. Secure rear HVAC to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  209. Raise vehicle fully and lower onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Set 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
  210. Install nuts that secure rear HVAC to underside of vehicle
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 8 Nm
  211. Reinstall the refrigerant lines to the TXV on the rear HVAC unit and hand tighten nut
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10.5 Nm, Install new O-rings, Use caution not to pinch O-ring during installation
  212. Torque the A/C lines to the rear TXV
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 10 Nm
  213. Install drain hose to rear HVAC nipple
  214. Install rear diffuser
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 3 Nm, 2x bolts, T30, 3 Nm, 4x push clips,13x tabs, Secure diffuser tabs first, Install remaining hardware
  215. Hand start the mid aero shield bolts and install the clips
    Informational PurposesAn informational icon, calling your attention
    Note
    20x bolts, 10mm, 4 Nm, 2x push clips
  216. Install RH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nyloc nut, 15mm, Install new nyloc nut
  217. Install LH shear plate
    Informational PurposesAn informational icon, calling your attention
    Note
    3x screws, T25, 6 Nm, 35 Nm, 1x bolt, 10mm, 4 Nm, 2x push clips, 1x nyloc nut, 15mm, Install new nyloc nut
  218. Torque mid aero shield bolts
    Informational PurposesAn informational icon, calling your attention
    Note
    20x bolts, 10mm, 4 Nm
  219. Remove snap ring from condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    1x snap ring, Not used with wing nut style plug
  220. Use the small slide hammer to pull out the inner tooling plug.
    Informational PurposesAn informational icon, calling your attention
    Note
    Discard the inner plug. To avoid personal injury, eye protection must be worn when performing this operation.
  221. Install new desiccant bag into condenser
  222. Install new desiccant screen into condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    Lubricate O-rings
  223. Install snap ring into condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    Make sure snap ring is seated into groove, Not to be used with wing nut style plug
  224. Install desiccant cover into LH side of condenser
    Informational PurposesAn informational icon, calling your attention
    Note
    1x cover, T50, 4 Nm
  225. Install front fascia skid plate onto fascia
    Informational PurposesAn informational icon, calling your attention
    Note
    6x tabs, 4x bolts, 10mm, 2.8 Nm
  226. Install front aero shield
    Informational PurposesAn informational icon, calling your attention
    Note
    6x bolts, 10mm, 3 Nm, 14x push clips
  227. Lower vehicle partially and set lift onto locks
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height
  228. Install RH front wheelhouse liner on vehicle
  229. Install nuts that secure RH front wheelhouse liner to the studs on the body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 6 Nm
  230. Install push clips that secure RH front wheelhouse liner to body
    Informational PurposesAn informational icon, calling your attention
    Note
    14x push clips
  231. Install RH front wheel with battery powered drill
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  232. Lower vehicle until tires are touching the ground
  233. Torque RH front wheel
    Informational PurposesAn informational icon, calling your attention
    Note
    5x nuts, 21mm, 175 Nm
  234. Install RH front lug nut covers
    Informational PurposesAn informational icon, calling your attention
    Note
    5x covers
  235. Install charger access panel
    Informational PurposesAn informational icon, calling your attention
    Note
    11x patch bolts, T20, 2 Nm, Install new patch bolts
  236. Clean area around charger access panel prior to installation of new warranty label
    Informational PurposesAn informational icon, calling your attention
    Note
    Allow IPA to dry for at least 1 minute
  237. Install new warranty label
  238. Connect PTC connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x locking tab
  239. Connect the rear HVAC connectors.
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  240. Connect rear TXV connector
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  241. Install RH duct to rear HVAC
  242. Install the RH trunk bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 7 Nm_x000A_4x push clips
  243. Install RH minion bracket and secure with clips
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  244. Secure rear HVAC duct bracket to body
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 9 Nm
  245. Install foam HVAC ducting covering charger access panel_x0009_
  246. Reinstall LH trunk trim bracket and loosely install fastener
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 2.5 Nm, 1x push clip
  247. Fold LH 3rd row seat up
    Informational PurposesAn informational icon, calling your attention
    Note
    Press button located on LH 3rd row seat back assembly near headrest, lift seat back into an upright position
  248. Loosely install bolt securing front edge of LH trunk trim bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T30, 2.5 Nm
  249. Install LH minion bracket into position and install all clips
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips
  250. Tighten fasteners securing LH trunk trim bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 2.5 Nm, 1x push clip
  251. Fold LH 3rd row seat down
  252. Install LH mid zone C-pillar bracket and install fasteners
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2.5 Nm, 3x push clips, Need to secure 2x edge clips for charge port release cables as well
  253. Reinstall LH trunk side carpet panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors, Reconnect trunk light and 12V outlet connectors before positioning panel. Use caution not to pinch Rear PTC harness (see picture)
  254. Install clips securing LH rear trunk side carpet panel to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push clips, One is hidden between 3rd row seat and trunk side carpet panel
  255. Verify charge port mechanical release cable is in proper position in trunk side carpet panel
  256. Install LH lower C-pillar and secure clips along front edge
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, 1x magnet
  257. Secure clips at rear edge of LH C-pillar lower panel
    Informational PurposesAn informational icon, calling your attention
    Note
    2x clips, 1x magnet
  258. Install fasteners securing C-pillar lower panel to LH parcel shelf support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2 Nm
  259. Reinstall RH trunk side carpet panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Use caution not to pinch Rear PTC harness
  260. Reinstall clips securing RH rear trunk side carpet panel to bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    3x push clips, One is hidden between 3rd row seat and trunk side carpet panel
  261. Install RH C-pillar lower panel and secure clips along front edge
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, 1x magnet
  262. Secure clips holding rear edge of RH C-pillar lower panel to rear trunk side carpet panel
    Informational PurposesAn informational icon, calling your attention
    Note
    3x clips, 1x magnet
  263. Install fasteners securing C-pillar lower panel to RH parcel shelf support
    Informational PurposesAn informational icon, calling your attention
    Note
    2x screws, T20, 2 Nm
  264. Install trunk side nub onto RH lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x clip
  265. Install RH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips
  266. Install fasteners securing RH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T25, 3 Nm, 3x screws, T20, 2 Nm, Install new T25 fastener
  267. Install RH C-pillar mid trim
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, Install front section first, then work around to rear
  268. Install screw securing RH C-pillar mid trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2 Nm
  269. Install LH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    6x clips
  270. Install fasteners securing LH upper C-pillar trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 3 Nm, 3x screws, T20, 2 Nm
  271. Install trunk side nub to lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    3x tabs, 1x clip
  272. Install LH C-pillar mid trim and secure clips
    Informational PurposesAn informational icon, calling your attention
    Note
    9x clips, Install front section first, then work around to rear
  273. Install screw securing LH C-pillar mid trim
    Informational PurposesAn informational icon, calling your attention
    Note
    1x screw, T20, 2 Nm
  274. Reinstall front lower carpet trim panel
    Informational PurposesAn informational icon, calling your attention
    Note
    Secure 3rd row seat wiring harnesses to panel
  275. Install rear load floor support
    Informational PurposesAn informational icon, calling your attention
    Note
    4x push clips, 2x clips
  276. Install trunk board
  277. Install rear trunk sill trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips, 2x patch bolts, T25, 2.5 Nm, Make sure to seat liftgate seal properly, Install new patch bolts
  278. Install LH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  279. Install RH trunk sill side trim
    Informational PurposesAn informational icon, calling your attention
    Note
    4x clips
  280. Install rear load floor
  281. Fold 3rd row seats up
  282. Close liftgate
  283. Install bolt securing front of LH lower C-pillar
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch bolt, T25, 2.5 Nm, Install new patch bolt
  284. Install LH welcome plate
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  285. Move LH 2nd row seat from the easy entry position to the regular upright seating position
    Informational PurposesAn informational icon, calling your attention
    Note
    Slide seat track backwards by pushing towards rear of vehicle, Fold upper seat backwards until locked in an upright position
  286. Secure RH lower C-pillar trim to body
    Informational PurposesAn informational icon, calling your attention
    Note
    1x patch screw, T25, 2.5 Nm, Install new screw
  287. Install RH welcome plate
    Informational PurposesAn informational icon, calling your attention
    Note
    8x clips
  288. Move RH 2nd row seat out of easy entry position
  289. Install compressor NVH cover to new compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x velcro strap, Do not drain oil
  290. Install EXV to chiller
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 3mm hex, 6 Nm, Install new O-rings
    Informational PurposesAn informational icon, calling your attention
    Note
    If any debris was found at the EXV, replace the EXV by a new one.
  291. Secure AC lines to EXV
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 12 Nm, Install new O-rings
  292. Connect EXV coil and secure lock
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, locking tab
  293. Secure AC lines to TXV (R1234YF)
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, 5mm hex, 20 Nm, Install new O-rings
    Informational PurposesAn informational icon, calling your attention
    Note
    If any debris is found at the front TXV, replace the TXV by a new one.
  294. Install bolts securing TXV (R1234YF) to evaporator
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, T30, 6 Nm, Install new O-rings
  295. Connect the TXV connector.
  296. Install A/C compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, T30, 10 Nm
  297. Install both A/C lines to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 10mm, 10 Nm, Install new O-rings
  298. Install ground strap to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x bolt, T25, 7 Nm
  299. Connect A/C compressor harness to FJB and install cable fir tree to drive unit
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x fir tree clip _x000A_
  300. Make low voltage connection to compressor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  301. Secure edge clip to A/C compressor bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  302. Connect coolant hose to reservoir and remove hose clamp
    Informational PurposesAn informational icon, calling your attention
    Note
    1x coolant hose
  303. Install fasteners securing coolant reservoir to shock tower cross member
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 6 Nm
  304. Connect coolant reservoir level sensor
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector
  305. Top off coolant reservoir
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure coolant is filled to nominal level
  306. Position air tank into mounting location
  307. Install bolts securing air tank reservoir brackets to vehicle body
    Informational PurposesAn informational icon, calling your attention
    Note
    4x bolts, 10mm, 6 Nm
  308. Install fir tree clips securing blue airline to air tank reservoir brackets
    Informational PurposesAn informational icon, calling your attention
    Note
    2x fir tree clips
  309. Install wiper mount bracket
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 13mm, 20 Nm, 2x bolts, 13mm, 20 Nm
  310. Install 12V harness to center support bracket
  311. Install wiper motor assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    3x bolts, 10mm, 9 Nm
  312. Install HEPA filter duct
    Informational PurposesAn informational icon, calling your attention
    Note
    1x push clip
  313. Install battery cage assembly into vehicle
  314. Install bolts into top of battery cage assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 13mm, 15 Nm
  315. Install bolts in bottom of battery cage assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    2x bolts, 10mm, 6 Nm
  316. Install plastic harness clip
    Informational PurposesAn informational icon, calling your attention
    Note
    1x clip
  317. Install clip onto battery cage
    Informational PurposesAn informational icon, calling your attention
    Note
    1x barrel clip
  318. Install edge clips onto battery cage
    Informational PurposesAn informational icon, calling your attention
    Note
    2x edge clips
  319. Install battery vent tube back into battery
    Informational PurposesAn informational icon, calling your attention
    Note
    1x vent tube
  320. Connect 12V positive terminal
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 10mm, 5 Nm
  321. Install positive terminal cover
  322. Connect first responder loop and then 12V negative terminal.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connector, 1x nut, 10mm, 5 Nm
  323. 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).
  324. Unlock the vehicle gateway for diagnostic communication. See Gateway Unlock.
  325. Using Toolbox 3:
    1. Select the Actions tab and search for "Fluid fill drain"
    2. 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.
    3. Under "Fluid Fill Target, select "Refrigerant".
    4. Click RUN, and allow the routine to complete.
  326. Connect hoses to vehicle and perform A/C vacuum and leak test
    Informational PurposesAn informational icon, calling your attention
    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.
  327. Install cowl screen assembly
    Informational PurposesAn informational icon, calling your attention
    Note
    5x push pins, 1x edge clip
  328. Install LH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip, 1x clip
  329. Install RH outer hood hinge cover
    Informational PurposesAn informational icon, calling your attention
    Note
    1x fir tree clip, 1x clip
  330. Install RH wiper arm
    Informational PurposesAn informational icon, calling your attention
    Note
    2x nuts, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield
  331. Install LH wiper arm
    Informational PurposesAn informational icon, calling your attention
    Note
    1x nut, 17mm, 35 Nm, Align tip of wiper blade to mark on windshield
  332. Install wiper arm hoses
  333. Install cowl drain hose
    Informational PurposesAn informational icon, calling your attention
    Note
    1x hose clamp
  334. Install wiper drain hose to one-way valve
    Informational PurposesAn informational icon, calling your attention
    Note
    1x washer hose
  335. Install HEPA filter housing
  336. Install underhood storage unit
    Informational PurposesAn informational icon, calling your attention
    Note
    10x bolts, 10mm, 4 Nm, 10x bolts, 10mm, 7 Nm
  337. Install frunk carpet
    Informational PurposesAn informational icon, calling your attention
    Note
    2x connectors
  338. Install front underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    12x clips
  339. Install RH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  340. Install LH underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    10x clips
  341. Leak test overlap
  342. Perform A/C refrigerant refill
    Informational PurposesAn informational icon, calling your attention
    Note
    Run time, per fluid capacity spec
  343. Remove A/C hoses from vehicle
  344. Install rear underhood apron
    Informational PurposesAn informational icon, calling your attention
    Note
    11x clips
  345. Close hood
  346. Click finish when routine is complete
  347. Disconnect laptop from vehicle and reinstall storage cubby
    Informational PurposesAn informational icon, calling your attention
    Note
    1x connect, 2x clips
  348. Remove vehicle from lift
    Informational PurposesAn informational icon, calling your attention
    Note
    Lower rack arms fully and move them from under vehicle, Remove air suspension from "Jack Mode"
  349. Calibrate falcon doors using MCU
    Informational PurposesAn informational icon, calling your attention
    Note
    Required after 12V and FRL disconnect
  350. Close LH front door