2025-04-08

Chiller and EXV Assembly (Remove and Replace)

Correction Code 18206202

  • 2025-04-08: Added note on separately adding correction code 18200102.
Equipment:
  • 1120026-05-A - Mastercool 4000 R1234YF AC Machine
  • 1135762-00-A Kit, Svc Plug, Cooling Hose, Model 3
Informational PurposesAn informational icon, calling your attention
Note
This procedure is for vehicles built after April 24, 2019. For vehicles built before April 24, 2019, see EXV - Chiller (Remove and Replace).
Informational PurposesAn informational icon, calling your attention
Note
This procedure requires the A/C Refrigerant (Recovery and Recharge) procedure to be performed. If not already automatically added to the Service Visit, add correction code 18200102 as a separate correction within the same activity to the Service Visit.

Removal

  1. Perform an A/C hose flush.
  2. Open the LH front door and lower the LH front window.
  3. Place the vehicle on a 2-post lift.
    Informational PurposesAn informational icon, calling your attention
    Note
    Raise the lift until the arms contact the lift points.
  4. Place the vehicle in Service Mode. See Service Mode.
  5. Unlock the vehicle gateway. See Gateway Unlock.
  6. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Start Fluid Fill/Drain, tap Run, and allow the routine to complete.
  7. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  8. Remove the dust caps (x2) from vehicle’s high-side and low-side service ports.
  9. Connect hoses to vehicle and perform A/C recovery. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the connects are fully engaged. Turn the connector dials clockwise to fully connect the hoses to A/C service ports.
  10. While the refrigerant is being recovered, remove the HEPA filter. See Filter - HEPA (Remove and Replace).
  11. While the refrigerant is being recovered, disconnect 12V power. See Disconnect 12V Power.
  12. Remove the A/C lines from the vehicle.
  13. Remove the LH front wheel. See Wheel Assembly (Remove and Install).
  14. Remove the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  15. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  16. Position a coolant drain container under the LH front corner of the vehicle to catch the coolant.
  17. 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.
  18. Use a flexible spring band clamp pliers to disconnect the hose that attaches the 4-way valve to chiller from the chiller.
  19. Disconnect the chiller EXV electrical connector.
  20. Remove the nut that attaches the A/C lines to the chiller EXV.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
  21. Use a clip prytool to remove the A/C lines from the chiller EXV.
    Informational PurposesAn informational icon, calling your attention
    Note
    It may be necessary to apply force to free the lines from the EXV.
  22. Remove the bolts (x2) that attach the chiller to the chiller bracket.
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 13 mm 12-point deep socket
  23. Remove the chiller and EXV assembly from the vehicle.

Installation

  1. Install the chiller and EXV assembly to the vehicle.
  2. Install the bolts (x2) that attach the chiller to the chiller bracket.
    12 Nm (8.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    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
  3. Install the A/C lines into the chiller EXV.
  4. Install the nut that attaches the A/C lines to the chiller EXV.
    12 Nm (8.8 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    TIp
    Use of the following tool(s) is recommended:
    • Flex head ratchet/flex head torque wrench
    • 10 mm deep socket
    • Ratchet/torque wrench
  5. Connect the chiller EXV electrical connector.
  6. Use a flexible spring band clamp pliers to connect the hose that attaches the 4-way valve to chiller to the chiller.
  7. 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.
  8. Remove the coolant drain container from under the LH front of the vehicle.
  9. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  10. Install the LH front wheel arch liner. See Wheel Arch Liner - Front - LH (Remove and Replace).
  11. Install the LH front wheel. See Wheel Assembly (Remove and Install).
  12. Inject oil into the system with the amount of being removed during recovery.
  13. Perform a system vacuum leak test and recharge A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace).
  14. Remove the A/C lines from the vehicle.
  15. Install dust caps (x2) onto the vehicle high and low side service ports.
  16. Install the HEPA filter. See Filter - HEPA (Remove and Replace).
  17. Connect 12V power. See Disconnect 12V Power.
  18. On the touchscreen, tap the Service Mode "wrench" (at the bottom of the touchscreen UI), and then tap Thermal > Actions > Stop Fluid Fill/Drain, tap Run, and allow the routine to complete.
  19. Tap Coolant Air Purge > Run, and allow the routine to complete.
  20. Remove the coolant reservoir cap, top off the reservoir, and then install the coolant reservoir cap.
  21. On the touchscreen, tap Thermal Test > Run, and allow the routine to complete.
  22. Exit Service Mode. See Service Mode.
  23. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  24. On the touchscreen, tap Controls > Calibrate to calibrate the falcon doors.
  25. Remove the vehicle from the lift.
  26. Raise the LH front window and close the LH front door.