28/11/2023 18:38:41
Chiller and EXV Assembly (Remove and Replace)
Correction Code 18206202
- 1120026-05-A - Mastercool 4000 R1234YF AC Machine
- 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
Note
This procedure is for vehicles built after April 24, 2019. For vehicles built before
April 24, 2019, see Battery Chiller and EXV Assembly (Remove and Replace).
Removal
- Perform an A/C hose flush.
- Open the LH front door and lower the LH front window.
-
Place the vehicle on a 2-post lift.
NoteRaise the lift until the arms contact the lift points.
- Place the vehicle in Service Mode. See Service Mode.
- Unlock the vehicle gateway. See Gateway Unlock.
- On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Run, and allow the routine to complete. , tap
- Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- Remove the dust caps (x2) from vehicle’s high-side and low-side service ports.
-
Connect hoses to vehicle and perform A/C recovery. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
NoteEnsure the connects are fully engaged. Turn the connector dials clockwise to fully connect the hoses to A/C service ports.
- While the refrigerant is being recovered, remove the HEPA filter. See Filter - HEPA (Remove and Replace).
- While the refrigerant is being recovered, disconnect 12V power. See Disconnect 12V Power.
- Remove the A/C lines from the vehicle.
- Remove the LH front wheel. See Wheel Assembly (Remove and Install).
- Remove the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
- Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
- Position a coolant drain container under the LH front corner of the vehicle to catch the coolant.
- Use a flexible spring band clamp pliers to disconnect the chiller to battery pump hose, and plug the ends of fittings as soon as possible to avoid coolant loss.
- Use a flexible spring band clamp pliers to disconnect the hose that attaches the 4-way valve to chiller from the chiller.
- Disconnect the chiller EXV electrical connector.
-
Remove the nut that attaches the A/C lines to the chiller EXV.
Tip: Use of the following tool(s) is recommended:
- Flex head ratchet/flex head torque wrench
- 10 mm deep socket
-
Use a clip prytool to remove the A/C lines from the chiller EXV.
NoteIt may be necessary to apply force to free the lines from the EXV.
-
Remove the bolts (x2) that attach the chiller to the chiller bracket.
Tip: Use of the following tool(s) is recommended:
- Flex head ratchet/flex head torque wrench
- 13 mm 12-point deep socket
- Remove the chiller and EXV assembly from the vehicle.
Installation
- Install the chiller and EXV assembly to the vehicle.
-
Install the bolts (x2) that attach the chiller to the chiller bracket.Tip: Use of the following tool(s) is recommended:
- Flex head ratchet/flex head torque wrench
- 13 mm 12-point deep socket
- Ratchet/torque wrench
- Install the A/C lines into the chiller EXV.
-
Install the nut that attaches the A/C lines to the chiller EXV.Tip: Use of the following tool(s) is recommended:
- Flex head ratchet/flex head torque wrench
- 10 mm deep socket
- Ratchet/torque wrench
- Connect the chiller EXV electrical connector.
- Use a flexible spring band clamp pliers to connect the hose that attaches the 4-way valve to chiller to the chiller.
- Remove the plugs on the ends of fittings, and then use a flexible spring band clamp pliers to connect the chiller to battery pump hose.
- Remove the coolant drain container from under the LH front of the vehicle.
- Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
- Install the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
- Install the LH front wheel. See Wheel Assembly (Remove and Install).
-
Connect the hoses to vehicle and perform A/C vacuum and leak test.
NotePerform a 30-minute vacuum and a 10-minute leak test. Ensure the connects are fully engaged. Turn the connector dials clockwise to fully connect the hoses to A/C service ports.
- While the vacuum and leak test is being performed, install the HEPA filter. See Filter - HEPA (Remove and Replace).
- Inject oil into the system with the amount of being removed during recovery.
- Recharge A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
- Remove the A/C lines from the vehicle.
- Install dust caps (x2) onto the vehicle high and low side service ports.
- Connect 12V power. See Disconnect 12V Power.
- On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Run, and allow the routine to complete. , tap
- Tap , and allow the routine to complete.
- Remove the coolant reservoir cap, top off the reservoir, and then install the coolant reservoir cap.
- On the touchscreen, tap , and allow the routine to complete.
- Exit Service Mode. See Service Mode.
- Perform an A/C hose flush.
- Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
- On the touchscreen, tap to calibrate the falcon doors.
- Remove the vehicle from the lift.
- Raise the LH front window and close the LH front door.