2025-09-12

Chiller (V2) (Remove and Replace)

Correction code 18260100502 FRT 1.08 NOTE: Unless otherwise explicitly stated in the procedure, the correction code and FRT listed above reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. NOTE: See Personal Protection to make sure you are wearing proper PPE when performing the procedure below. NOTE: See Ergonomic Precautions for safe and healthy working practices.

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.

Torque Specifications

Table 1. Torque Specifications: Chiller (V2) (Remove and Replace)
Description Torque Value Recommended Tools Reuse/Replace Notes
Bolt that attaches the supermanifold-to-compressor A/C line to the supermanifold
22 Nm (16.2 lbs-ft)
  • 13 mm socket
Reuse
Bolts (x3) that attach the supermanifold harness bracket to the supermanifold
8 Nm (5.9 lbs-ft)
  • 8 mm deep socket
 Reuse
Nut (x4) that attach the chiller to the supermanifold
6.3 Nm (4.6 lbs-ft)
  • 8 mm deep socket
 Reuse

Remove

  1. Set up the AC machine.
  2. Unlock the vehicle gateway. See Gateway (Unlock).
  3. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_START-THERMAL-FILL-DRAINvia Service Mode:
    • Thermal ➜ Actions ➜ Start Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Start Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Start Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Start Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Start Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Start Coolant Fill/Drain
    via Toolbox:(link)
  4. Power off the vehicle from the center display.
    Informational PurposesAn informational icon, calling your attention
    Note
    On the touchscreen, touch Controls > Safety > Power Off > Power Off.
  5. Remove the HEPA filter assembly. See HEPA Filter Assembly (Remove and Replace).
  6. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  7. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  8. Remove the front aero shield. See Aero Shield - Front (Remove and Replace).
  9. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge) (Restore).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Make sure there is no overpressure in the A/C system before performing the following steps. Failure to do so may result in damage to components and/or personal injury.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    HFO-R1234yf and R134a are considered hazardous and, if handled incorrectly, can cause serious injury. Suitable personal protective equipment, consisting of face and eye protection, safety glasses, face shield, heat-proof gloves, chemical resistant gloves, rubber boots and apron or waterproof overall must be worn when carrying out operations on the air conditioning system.
  10. Remove A/C machine hoses from the vehicle.
  11. Carefully depress the Schrader valves (x2) to level out any pressure difference between the A/C system pressure and the actual ambient atmospheric pressure.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure to depress both Schrader valves. Failure to do so may result in injury.
  12. Remove the frunk reinforcement beam. See Beam - Reinforcement - Frunk (Remove and Replace).
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to separate the isolation brackets from the frunk reinforcement beam.
  13. Position a fluid catcher underneath front of the vehicle.
  14. Remove the coolant bottle cap.
  15. Release the spring clip, disconnect the radiator inlet hose from the supermanifold, and then plug the hose and supermanifold.
  16. Release the spring clip, disconnect the radiator outlet hose from the supermanifold, and then plug the hose and supermanifold.
  17. Release the spring clip, disconnect the front drive unit return hose from the supermanifold, and then plug the hose and supermanifold.
  18. Remove the bolt that attaches the supermanifold-to-compressor A/C line to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  19. Remove the supermanifold-to-compressor A/C line from the supermanifold, and move it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    Carefully position the line so that oil does not drip out.
  20. Disconnect the pressure and temperature sensor connectors (x3).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    DO NOT push down on the red locking tab. Pull the tab away from the connector until the connector is unlocked, and then continue pulling the main body of the connector to fully disconnect it.
  21. Remove the bolts (x3) that attach the supermanifold harness bracket to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm deep socket
  22. Grip the bottom of the coils, and pull the supermanifold harness bracket and the valve coils evenly outward to disengage them from the supermanifold.
  23. Remove the seals from the coils, and then install them to the expansion valve cores.
    Informational PurposesAn informational icon, calling your attention
    Note
    This is to aid valve coil installation.
  24. Remove the nuts (x4) that attach the chiller to the supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm deep socket
  25. Slightly release the RH side of the chiller from supermanifold and allow excess coolant to drain, and then remove the chiller from the vehicle.
    Informational PurposesAn informational icon, calling your attention
    Note
    Leave the AC ports of LCCR intact to supermanifold to avoid any cross contamination.
  26. Remove and discard the chiller gasket from supermanifold.

Install

  1. Install a new chiller gasket into supermanifold.
  2. Lubricate both O-rings on the chiller with the appropriate A/C oil. See for A/C oil specifications.
  3. Hand-tighten the bolts (x4) that attach the cooled condenser to Supermanifold.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure the LCCR is fully seated on Supermanifold before installing the bolts.
  4. Install the nuts (x4) that attach the chiller to the supermanifold.
    6.3 Nm (4.6 lbs-ft)
    • 8 mm deep socket
  5. Install the supermanifold harness bracket and the valve coils to the supermanifold.
  6. Connect the pressure and temperature sensor connectors (x3).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Push the red locking tab towards the connector to engage the locking mechanism. DO NOT push down or pull up on the red locking tab.
  7. Install the bolts (x3) that attach the supermanifold harness bracket to the supermanifold.
    8 Nm (5.9 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 8 mm deep socket
  8. Install new seal washers on the supermanifold side of the supermanifold-to-compressor A/C line, and then lubricate the washers with a small amount of the appropriate A/C oil. See Fluids and Capacities for A/C oil specifications.
  9. Position the supermanifold to compressor A/C line onto the supermanifold, and then hand-tighten the bolt that attaches the A/C line to the supermanifold.
  10. Tighten the bolt that attaches the supermanifold to compressor A/C line to the supermanifold.
    22 Nm (16.2 lbs-ft)
    Informational PurposesAn informational icon, calling your attention
    Note
    Use of the following tool(s) is recommended:
    • 13 mm socket
  11. Remove the plugs, immediately connect the front drive unit powertrain return hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull test to verify that the hose is fully seated.
  12. Remove the plugs from the supermanifold and radiator outlet hose, immediately connect the radiator outlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  13. Remove the plugs from the supermanifold and radiator inlet hose, immediately connect the radiator inlet hose to the supermanifold, and then fasten the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Perform a push-pull-push test on the fittings to make sure that they are secure.
  14. Install the frunk reinforcement beam, See Beam - Reinforcement - Frunk (Remove and Replace).
  15. Perform the vacuum leak test and oil injection, and A/C refrigerant recharge. See A/C Refrigerant (Recovery and Recharge) (Restore).
  16. Perform a cooling system vacuum refill. See Cooling System - Vacuum Refill (Test/Adjust).
  17. Remove the fluid catcher from underneath the front of the vehicle.
  18. Unlock the vehicle gateway. See Gateway (Unlock).
  19. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): PROC_VCFRONT_X_STOP-THERMAL-FILL-DRAINvia Service Mode:
    • Thermal ➜ Actions ➜ Stop Thermal Fill/Drain
    • Thermal ➜ Coolant System ➜ Stop Coolant Fill/Drain
    • Thermal ➜ Refrigerant System ➜ Stop Refrigerant Fill/Drain
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Stop Fluid Fill/Drain
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Stop Coolant Fill/Drain
    via Toolbox:(link)
  20. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): Run ODIN routine TEST_VCFRONT_X_THERMAL-COOLANT-AIR-PURGEvia Service Mode:
    • Thermal ➜ Actions ➜ Coolant Purge Stop or Coolant Purge Start
    • Thermal ➜ Coolant System ➜ Coolant Purge Start
    via Service Mode Plus:
    • Drive Inverter ➜ Front Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Left Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Inverter ➜ Rear Right Drive Inverter Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Front Drive Unit Replacement ➜ Coolant Air Purge
    • Drive Unit ➜ Rear Drive Unit Replacement ➜ Coolant Air Purge
    via Toolbox:(link)
  21. Install the front aero shield. See Aero Shield - Front (Remove and Replace).
  22. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  23. Inspect the coolant level and top off as necessary, and then install the coolant bottle cap.
    Informational PurposesAn informational icon, calling your attention
    Note
    Ensure that the coolant level is at the "Max" line. Vacuum fill required if greater than 1L lost during repair。
  24. Perform the following routine using Service Mode or Toolbox (see 0005 - Service Modes): TEST-SELF_VCFRONT_X_HEAT-PUMP-COMMISSIONINGvia Service Mode:Thermal ➜ Refrigerant System ➜ Commission Heat Pumpvia Service Mode Plus:Drive Inverter ➜ Front Drive Inverter Replacement ➜ Heatpump commissioningvia Toolbox:(link)
  25. Exit Service Mode. See Service Mode.
  26. Remove the air intake duct. See Duct - Air Intake (Remove and Replace).
  27. Install the HEPA filter assembly. See HEPA And Carbon Filters (Remove and Replace).
  28. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).