19/12/2024 06:59:46

Compressor (Remove and Replace)

Correction Code 18203902

  • 2024-12-19: Added Note on separately adding correction code 18200102.
  • 2024-09-17: Added some missing steps in line with procedure validation.
Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Only technicians who have been trained in High Voltage (HV) Awareness and have completed all required certification courses (if applicable) are permitted to perform this procedure. Proper Personal Protective Equipment (PPE) and insulating HV gloves with a minimum rating of class 0 (1000V) must be worn any time a high voltage cable is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.
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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 activity to the Service Visit.

Removal

  1. Remove the underhood storage unit. See .
  2. Recover the A/C refrigerant. See A/C Refrigerant Recovery and Recharge (Remove and Replace) .
  3. Remove the cowl screen panel. See .
  4. Remove the HEPA filter duct. See .
  5. Perform the electrical isolation procedure. See GUID-FE56114D-662F-41B2-B2B4-F00B5068C5D1.html
  6. Remove the 12V battery bracket. See .
  7. Remove the wiper module. See .
  8. Move the coolant reservoir out of the working area:
    1. Remove the coolant reservoir cap.
    2. Use a fluid evacuation tool to remove the coolant from the reservoir.
    3. Install the coolant reservoir cap.
    4. Release the 12V harness clip from the coolant reservoir.
    5. Disconnect the coolant fluid level sensor electrical connector.
    6. Remove the bolts (x4) that attach the coolant reservoir to the front crossmember (torque 6 Nm).
    7. Clamp the coolant hose at the rear of the coolant reservoir.
    8. Release the locking ring that attaches the hose to the coolant reservoir. Release the coolant hose from the nipple on the reservoir.
    9. Plug the coolant hole, then carefully move the reservoir to the LH side of the front trunk.
  9. Disconnect the A/C recovery hoses from the A/C service ports.
  10. Move the air suspension reservoir out of the working area.
    1. Remove the clip that attaches the electrical harness to the wiper mount bracket.
    2. Remove the bolts (x2) that attach the wiper mount bracket to the crossmember (torque 20 Nm).
    3. Remove the nuts (x2) that attach the wiper mount bracket to the studs on the bulkhead (torque 20 Nm), and then remove the bracket from the vehicle.
    4. Remove the clips (x2) that attach the air suspension reservoir air line to the reservoir brackets.
    5. Remove the bolts (x4) that attach the air suspension reservoir brackets to the crossmember (torque 6 Nm).
    6. Carefully move the air suspension reservoir aside.
  11. Disconnect the pressure sensor from the LH side of the compressor.
  12. Release the ground strap from the compressor (torque 7 Nm).
  13. Disconnect the low voltage connector from the compressor.
  14. Release the clip that attaches the low voltage harness to the compressor mount.
  15. Release the nuts that attach the A/C lines to the compressor (torque 10 Nm).
  16. Disconnect the compressor HV harness from the forward junction box.
  17. Release the clip that attaches the HV harness to the front drive unit.
  18. Have an assistant support the compressor. Remove the bolts (x3) that attach the A/C compressor bracket to the front drive unit (torque 10 Nm).
  19. Remove the compressor and bracket from the vehicle as an assembly.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not spill oil from the compressor when removing it. The amount of oil remaining in the old compressor needs to be measured when the new compressor is installed.
  20. Remove the bolts (x3) that attach the compressor to the bracket (torque 20 Nm).
    Informational PurposesAn informational icon, calling your attention
    Note
    Retain the bracket.
  21. Release the compressor from the bracket.
  22. Remove the NVH padding.

Installation

Installation procedure is the reverse of removal, except for the following:

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CAUTION
The new A/C compressor is pre-filled with the total amount of oil used in the A/C system. Oil needs to be removed so that the amount of oil in the new A/C compressor equals the amount of oil in the old one. To do this, use a digital scale to weigh both the old and new A/C compressors. Turn the new one upside down to drain a small amount of oil, then re-weigh it. Repeat this process until the new A/C compressor weighs the same as the old one.
  • Replace the O-rings on the A/C lines.
  • Recharge the A/C system.