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

Set up A/C machine and perform hose flush

Note

Touch time only

Set up A/C machine with flush kit

Note

Attach the flush kit to the Waeco AC machine. Use 2x 8 mm bolts with Nyloc nut

Open all four doors

Lower all 4 windows

Raise and support vehicle

Note

Set air suspension to "Jack Mode" if equipped Via Controls > ''Service''

Connect a laptop with Toolbox 3 to the vehicle.

In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain.

Under Action, select Start to open the valves before the service procedure.

Under Fluid Fill Target, select Refrigerant to activate refrigerant valves.

Click Run, and allow the routine to complete.

Move both front seats fully forward

Open hood

Note

Using MCU touchscreen > Controls > Frunk Trunk

Remove rear underhood apron

Note

8x clips

Remove RH underhood apron

Note

9x clips

Remove LH underhood apron

Note

9x clips

Remove front underhood apron

Note

7x clips

Release drainage hoses from HEPA filter inlet duct

Note

2x hoses

Remove clips securing HEPA filter inlet duct to cowl panel

Note

3x push clips

Remove HEPA filter inlet duct

Note

2x clips on HEPA filter

Remove dust caps from high-side and low-side service ports

Note

2x caps

Connect hoses to vehicle and perform A/C recovery

Note

Touch time only, Ensure quick connects are fully engaged, Turn the connector dials clockwise to fully connect to A/C service ports

Check if the internal A/C Machine cylinder is filled at least with 5 KG

Note

Fill the intern refrigerant tank

Remove HEPA filter outlet duct from vehicle

Note

Lift up, pull towards front of vehicle, then rotate clockwise

Disconnect light and release switch connectors and remove underhood storage carpet

Note

2x connectors, Release edge of carpet from underneath underhood storage unit seal

Remove underhood storage unit

Note

2x bolts, 10mm, 7 Nm, 2x push clips

Push wiring harness grommet through underhood storage unit and remove

Note

1x grommet

Power down vehicle using MCU

Note

Controls > Safety&Security > Power Off > ''POWER OFF''

Disconnect 12V negative terminal and First Responder Loop

Note

1x nut, 10mm, 5 Nm, 1x connector, Wait at least 2 minutes before disconnecting modules or HV components

Remove 2nd row seat bottom cushion

Note

2x clips, 7x connectors, Number of connectors may vary based on configuration, Release the leading edge of the seat on either side

Remove NVH padding from underneath 2nd row seat cushion

Note

If equipped

Remove bolts securing seat bottom frame

Note

8x bolts, 11mm, 26 Nm

Lift up and support seat bottom frame

Note

Release harness clips if necessary

Remove warranty label from charger cover panel

Remove all items from pockets and ensure not wearing metal items

Inspect HV insulating gloves

Note

Check gloves for damage prior to use, Refer to service document TN-15-92-003, for information on inspecting HV gloves. https://service.teslamotors.com/documents?model=&keys=TN-15-92-003&vehicle_system=&sort_by=field_date_submitted&sort_order=DESC

Put on HV insulating gloves and leather over gloves

Remove the charger HV access panel cover and discard fasteners

Note

11x bolts, T20, 2 Nm, Discard after removal

Release tabs and open both access doors

Note

4x tabs, Make sure to wear proper PPE

Verify no high voltage

Note

Measure B+ to B-, B+ to ground, and B- to ground, Make sure to wear proper PPE, If voltage is greater than 10V, pack contactors are not open or welded, Stop work and reach out to Service Engineering

Install charger cover panel and torque screws

Note

11x bolts, T20, 2 Nm, Install new patch bolts

Install new warranty label onto charger cover panel

Note

Wipe charger with IPA prior to installation

Remove HV insulating gloves

Lower seat frame into position and secure harness clips to frame

Note

8x clips

Install and torque bolts securing seat frame to vehicle

Note

8x bolts, 11mm, 26 Nm

Place NVH padding onto seat frame

Reinstall seat bottom cushion

Note

2x clips, 7x connectors if equipped, Replace clips if necessary

Remove LH shock tower cover

Note

4x push clips

Remove RH shock tower cover

Note

4x push clips

Remove LH side wiper arm

Note

1x nut, 17mm, 31 Nm

Remove RH side wiper arm

Note

1x nut, 17mm, 31 Nm

Remove cowl screen panel

Note

4x push clips, 2x end tabs

Disconnect high side and low side hoses from vehicle

Remove fuse box cover

Note

2x clips

Remove 12V supply cable to DCDC

Note

1x nyloc nut, 13mm, 12 Nm, 1x clip, Discard nyloc nut

Release clips securing 12V battery supply cable to fuse box and strut tower cross beam

Note

3x clips

Disconnect pyrotechnic fuse connector

Note

1x connector, Gently lift up orange lock tab to release connector

Remove bolts securing fuse box to body

Note

2x bolts, 10mm, 6 Nm

Release fuse box from body

Note

2x tabs, Slide fuse box to RH side to release tabs and then lift

Disconnect remaining connectors from bottom of fuse box

Note

3x connectors, Depress locking tabs on sides of flip type connector and flip lever on connector to reseal

Remove clip securing harness to LH shock tower brace

Remove wiper motor fastener mounted to LH shock brace

Note

1x bolt, 10mm, 6 Nm

Remove LH air suspension reservoir bracket from LH shock brace

Note

2x bolts, 10mm, 6 Nm

Remove AC line bracket bolt on RH shock brace

Note

1x bolt, 10mm, 6 Nm

Remove air reservoir bracket mounting bolts from RH shock brace

Note

2x bolts, 10mm, 6 Nm

Remove LH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Remove RH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Remove wiper motor

Note

3x bolts, 10mm, 6 Nm, 1x connector

Remove screws securing air suspension reservoir to bracket

Note

2x screws, T25, 2.5 Nm

Set air suspension reservoir aside for access

Note

Maneuver below AC line

Remove 12V positive terminal cover

Note

2x tabs

Disconnect 12V positive terminal

Note

1x nut, 10mm, 6 Nm

Remove fasteners securing 12V battery bracket to shock tower cross member and the battery beam

Note

2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm

Remove the 12V battery bracket assembly from vehicle

Remove fastener securing coolant hose to battery beam

Note

1x bolt, T30, 5 Nm

Remove fasteners securing the battery beam to the LH and RH body beams

Note

2x bolts, T30, 3.5 Nm, 1x edge clip

Remove the battery beam

Remove fasteners securing coolant reservoir to shock tower cross member

Note

4x bolts, 10mm, 6 Nm, This will allow room for reservoir to move to make room during front trunk harness removal

Shift coolant reservoir to give access to components behind

Note

Use bungee or rag to hold out of place

Disconnect the coolant bottle level sensor

Note

1x connector

Disconnect A/C compressor logic connector

Note

1x connector

Release ground connection at the A/C compressor mount bracket

Note

1x bolt, T25, 7 Nm

Raise vehicle partially and lower onto locks

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

Remove screw securing front fascia to RH fender bracket

Note

1x screw, T25, 1.5 Nm

Raise vehicle fully and lower lift onto locks

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

Remove bolt and clips securing RH side of fascia to front aero shield

Note

full aero shield does not need to come off - 1x bolt, 10mm, 3 Nm, 2x push clips_x000A_

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Pull RH side of fascia away from bracket and headlamp

Note

Pull to release clips

Raise vehicle fully and lower lift onto locks

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

Remove cap from condenser

Note

1x cap, 10mm hex, 12 Nm

Remove filter screen from condenser

Remove desiccant bag from condenser

Install cap into condenser

Note

1x cap, 10mm hex, 12 Nm

Lower vehicle until tires are touching the ground

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Release PTC - Battery Heater - DC-DC HV connector from FJB to gain access to release A/C compressor HV connector from FJB

Note

4x locking tab, 4x connector

Remove A/C lines from compressor

Note

2x nuts, 10mm, 10 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Remove A/C compressor assembly from vehicle

Note

3x Torx bolts, T40, torque 20 Nm

Unplug TXV connector

Note

1x connector

Remove fasteners securing TXV to evaporator

Note

2x bolts, T30, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Remove TXV from A/C lines

Note

1x bolt, 5mm hex, 20 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Release connector lock and disconnect the connector on EXV

Note

1x connector, locking tab

Remove nut securing AC lines to EXV

Note

1x nut, 10mm, 12 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Remove EXV from chiller

Note

2x bolts, 3mm hex, 6 Nm, Inspect o-rings for damage if flushing, Discard o-rings and replace on install

Secure flush adapter to low side compressor line

Note

1x nut, 10mm, 10 Nm, Low side hose is big, O-ring OK to reuse if not damaged

Blue line nipple, Ensure gasket is in place and in good condition

Note

be careful while installing to not damage the gasket

Connect the blue line nipple to the adapter block marked with "Inlet" Low pressure

Note

Wear appropriate PPE, do not over tight the nipple, gasket can damage. Tight ONLY with hands

Apply sealer to High pressure adapter threads

Note

Seal the connection with PTFE / Teflon tape

Thread on quick connect fitting to high pressure adapter

Note

Wear appropriate PPE, do not over tighten fitting

Secure flush adapter to high side compressor line

Note

1x nut, 10mm, 10 Nm, High side hose is small, O-ring OK to reuse if not damaged

Secure EXV adapter to chiller

Note

2x bolts, 3mm hex, 6 Nm, O-rings OK to reuse if not damaged

Secure AC lines to EXV adapter

Note

1x nut, 10mm, 12 Nm, O-rings OK to reuse if not damaged

Secure TXV adapter to AC lines

Note

1x bolt, 5mm hex, 6 Nm, O-rings OK to reuse if not damaged

Secure AC lines/TXV adapter to evaporator

Note

2x bolts, T30, 6 Nm, O-rings OK to reuse if not damaged

Remove the liquid inline filter drier

Note

Remove the filter from the container (the gray filter attached to the flush unit) PR052FM

Remove nipple from filter

Note

1x fitting, 17mm, 1x filter, 12mm, Discard filter

Remove old Teflon tape from the container thread

Note

Old Teflon tape must be removed completely.

Wrap Teflon tape on the Container thread

Note

Use Teflon tape. Make sure that enough tape is applied

Wrap the filter nipple in Teflon tape

Note

Use Teflon tape. Make sure that enough tape is applied

Place 1 copper sealing ring on place. Low pressure nipple

Note

Good to use the old copper ring.

Installed Low pressure nipple on filter

Note

1x filter, 12mm, 1x fitting, 17mm, Make sure that enough tape is applied and 1 copper sealing ring in on place, Do not over tighten

Place 1 copper sealing ring on place. Inside the filter.

Note

Good to use the old copper ring.

attach the filter to the container

Note

Do not over torque while installing.

Connect the blue line 1 from the flush unit to the adapter 2 block marked with "Inlet"

Note

Wear appropriate PPE, Ensure gasket is on place between 1 hose connector and 2 nipple , Tighten with hands, do not over tighten

Connect the blue line from the AC machine to the flush unit quick connector (on the liquid line filter drier)

Note

Wear appropriate PPE, Ensure gasket is on place, Do not over tighten

Connect the machine High pressure RED connector to adapter block OUTLET

Note

Wear appropriate PPE, Ensure gasket is on place, Do not over tighten

flush 1. clamp off the TXV

Note

Clamp off at the Low pressure big hose

On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter

Note

Wear appropriate PPE

Flush will take 2 hours

Note

Monitor flush frequently

When the flush 1 program is finished, unclamp the TXV line

Clamp off EXV line at the big hose Low pressure

On the Waeco AC machine select Menu> Other selections > flushing> input vehicle details > Full flushing > enter

Note

Wear appropriate PPE

Flush will take 2 hours

Note

Monitor flush frequently

When the flush 2 program is finished, unclamp the EXV

Note

Remove clamp

Remove machine hoses from adapter

Note

1x quick release fitting, 1x union fitting, Wear appropriate PPE

Remove adapter from low side AC line

Note

1x nut, 10mm, 10 Nm, Low side hose is big, Discard o-ring, Wear appropriate PPE

Remove adapter from high side AC line

Note

1x nut, 10mm, 10 Nm, High side hose is small, Discard o-ring, Wear appropriate PPE

Remove fasteners securing TXV adapter to evaporator

Note

2x bolts, T30, 6 Nm, Discard o-rings, Wear appropriate PPE

Remove TXV adapter from AC lines

Note

1x bolt, 5mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE

Secure AC lines to TXV

Note

1x bolt, 5mm hex, 20 Nm, Install new o-rings

Install bolts securing TXV to evaporator

Note

2x bolts, T30, 6 Nm, Install new o-rings

Make connection at TXV

Note

1x connector

Remove nut securing AC lines to EXV adapter

Note

1x nut, 10mm, 12 Nm, Discard o-rings, Wear appropriate PPE

Remove EXV adapter from chiller

Note

2x bolts, 3mm hex, 6 Nm, Discard o-rings, Wear appropriate PPE

Secure EXV to chiller

Note

2x bolts, 3mm hex, 6 Nm, Install new o-rings

Secure AC lines to EXV

Note

1x nut, 10mm, 12 Nm, Install new o-rings_x000A_

Connect EXV coil and secure lock

Note

1x connector, 1x locking tab

Remove compressor NVH cover

Note

1x velcro strap

Install compressor NVH cover to new compressor

Note

1x velcro strap, Do not drain oil

install the new A/C compressor

Note

3x Torx bolts, T40, torque 20 Nm

Secure A/C lines to compressor

Note

2x nuts, 10mm, 10 Nm, Install new o-rings

Install from above A/C compressor - DC-DC HV - Battery Heater - PTC - connector to the FJB

Note

4x locking tab, 4x connector_x000A_

Connect A/C compressor connector

Note

1x connector

Secure ground strap to A/C compressor

Note

1x bolt, T25, 7 Nm

Connect coolant bottle level sensor

Note

1x connector

Remove bungee cord and place coolant reservoir into position for installation

Re-position coolant bottle and install the fasteners securing the coolant bottle to the shock tower cross member

Note

4x bolts, 10mm, 6 Nm

Install 12V battery beam

Note

2x bolts, T30, 3.5 Nm, 1x edge clip

Position 12V battery bracket assembly onto battery beam for installation

Install fasteners securing 12V battery bracket to shock tower cross member and the battery beam

Note

2x bolts, T30, 5 Nm, 2x bolts, 13mm, 15 Nm

Connect 12V positive terminal

Note

1x nut, 10mm, 6 Nm

Install 12V positive terminal cover

Raise vehicle fully and lower lift onto locks

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

Remove cap from condenser

Note

1x cap, 10mm hex, 12 Nm

Install new desiccant bag into condenser

Install filter / cap into condenser

Note

1x cap, 10mm hex, 12 Nm

Lower vehicle partially and set lift onto locks

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height

Secure RH side of fascia to headlight and fender

Reinstall screw securing RH side of fascia to fender

Note

1x screw, T25, 1.5 Nm, Adjust fascia to fender flushness as necessary

Raise vehicle fully and lower lift onto locks

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

Install hardware securing RH side of fascia to vehicle

Note

1x bolt, 10mm, 3 Nm, 2x push clips

Lower vehicle until tires are touching the ground

Note

Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered

Place air suspension reservoir into position

Loosely install air suspension reservoir brackets

Note

2x screws, T25, 2.5 Nm

Install LH shock tower brace

Note

1x bolt, 13mm, 30 Nm, 2x bolts, 13mm, 20 Nm

Install RH shock tower brace

Note

2x bolts, 13mm, 20 Nm, 1x bolt, 13mm, 30 Nm

Install wiper motor

Note

3x bolts, 10mm, 6 Nm, 1x connector

Install air suspension reservoir bracket mounting fasteners to RH shock brace

Note

2x bolts, 10mm, 6 Nm

Install AC line bracket bolt on RH shock brace

Note

1x bolts, 10mm, 6 Nm

Install wiper motor fastener mounted to LH shock brace

Note

1x bolt, 10mm, 6 Nm

Install air suspension reservoir bracket mounting fasteners to LH shock brace

Note

2x bolts, 10mm, 6 Nm

Clip wire harness to LH shock brace

Note

1x fir tree clip

Secure air suspension reservoir brackets

Note

2x screws, T25, 2.5 Nm

Place fuse box into vehicle and reconnect harness connectors

Note

3x connectors

Position fuse box onto body

Note

2x tabs, Slide the fuse box to LH to attach the tabs into crossbar

Install bolts securing fuse box to body

Note

2x bolts, 10mm, 6 Nm

Reconnect pyrotechnic fuse connector

Note

1x connector, Be sure to secure locking clip

Secure clips holding 12V battery supply cable to fuse box and strut tower beam

Note

3x clips

Install new nut securing 12V supply cable to DCDC

Note

1x nyloc nut, 13mm, 12 Nm, Install new nyloc nut

Reinstall fuse box cover

Note

2x clips

Install 12V negative terminal and first responder loop

Note

1x nut, 10mm, 10 Nm, 1x connector

Connect high side (red) and low side (blue) hoses from AC machine to service ports

Note

2x connections

In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain.

Under Action, select Start.

Under Fluid Fill Target, select Refrigerant, click Run, and allow the routine to complete.

Perform A/C vacuum and leak test

Note

Green check mark approves, Red X declines, 30 minute vacuum and leak test, Touch time only

Leak test overlap

Install cowl screen

Note

4x push clips, 2x end tabs

Install LH side wiper arm

Note

1x nut, 17mm, 31 Nm

Install RH side wiper arm

Note

1x nut, 17mm, 31 Nm

Install LH shock tower cover

Note

4x push clips

Install RH shock tower cover

Note

4x push clips

Install underhood storage unit

Note

Install harness and grommet

Install bolts and clips securing underhood storage unit

Note

2x bolts, 10mm, 7 Nm, 2x push clips

Install underhood storage carpet and reconnect light and release switch connectors

Note

2x connectors, Secure edges of carpet underneath underhood storage unit seal

Install HEPA filter outlet duct

Install front underhood apron

Note

7x clips

Perform A/C refrigerant refill

Note

Green check mark approves, Red X declines, Run time only

After the refrigerant refill is complete, perform the following:

In Toolbox 3, click the Actions tab, type "Fluid fill drain" into the search field, and click PROC_THC_X_FLUID-FILL-DRAINvia Toolbox: (link)via Service Mode: Thermal ➜ Actions ➜ Stop Fluid Fill/Drain.
Under Action, select Stop.
Under Fluid Fill Target, select Refrigerant, click Run, and allow the routine to complete.