Compressor (Remove and Replace)

Correction code 1820370218203702
Warning:

Only technicians who have been trained in High Voltage Awareness 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 at all times a high voltage cable, busbar, or fitting is handled. Refer to Tech Note TN-15-92-003, "High Voltage Awareness Care Points" for additional safety information.

Remove

  1. Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
  2. Remove the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
  3. Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
    Note: Recover the refrigerant while continuing this procedure.
  4. Disconnect 12V power. See 12V Power (Disconnect and Connect).
  5. Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
  6. Remove the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
  7. Remove the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  8. Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  9. Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  10. Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse, and then remove the bracket from the vehicle.
  11. Release the clip that attaches the charge port electrical harness to the vehicle.
  12. Slide the security tab to the unlock position, release the locking handle, and then disconnect the charge port electrical harness from the penthouse DC input connector.
  13. Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  14. Disconnect the compressor HV electrical connector from the HV electrical harness.
  15. Release the clips that attach the compressor HV electrical harness to the bulkhead.
  16. Disconnect the electrical harness from the high pressure transducer connector.
  17. Lower the vehicle.
  18. Disconnect the low voltage electrical connector from the compressor.
  19. Remove the bolt that attaches the ground harness to the compressor.
    Torque 6 Nm
  20. Release the clips that attach the low voltage electrical harness to the compressor and compressor bracket.
  21. Remove the bolt that attaches the suction/liquid line bracket to the shock tower brace, and then separate the bracket from the brace.
  22. Disconnect the electrical harness from the low pressure transducer connector.
1Remove the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
2Remove the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
3Recover the A/C refrigerant. See A/C Refrigerant (Recovery and Recharge).
Note: Recover the refrigerant while continuing this procedure.
4Disconnect 12V power. See 12V Power (Disconnect and Connect).
5Perform the vehicle electrical isolation procedure. See Vehicle Electrical Isolation Procedure.
6Remove the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
7Remove the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
8Remove the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
9Release the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
10Remove the bolts that attach the charge port to HV battery harness bracket at the penthouse, and then remove the bracket from the vehicle.
11Release the clip that attaches the charge port electrical harness to the vehicle.
12Slide the security tab to the unlock position, release the locking handle, and then disconnect the charge port electrical harness from the penthouse DC input connector.
13Remove the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
14Disconnect the compressor HV electrical connector from the HV electrical harness.
15Release the clips that attach the compressor HV electrical harness to the bulkhead.
16Disconnect the electrical harness from the high pressure transducer connector.
17Lower the vehicle.
18Disconnect the low voltage electrical connector from the compressor.
19Remove the bolt that attaches the ground harness to the compressor.
Torque 6 Nm
20Release the clips that attach the low voltage electrical harness to the compressor and compressor bracket.
21Remove the bolt that attaches the suction/liquid line bracket to the shock tower brace, and then separate the bracket from the brace.
22Disconnect the electrical harness from the low pressure transducer connector.

Note: Make sure that the refrigerant has fully recovered before continuing this procedure.

  1. Remove the bolt that attaches the suction/liquid line to the chiller and EXV assembly, and then remove the line from the chiller and EXV assembly.
  2. Remove and discard the o-rings from the suction/liquid line fitting.
  3. Release the clip that attaches the electrical harness to the suction liquid line.
  4. Disconnect the electrical harness from the powertrain coolant pump connector.
  5. Release the clip that attaches the suction/liquid lines to the superbottle.
  6. Remove the nut that attaches the discharge line to the compressor, and then remove the discharge line from the compressor.
  7. Remove and discard the o-ring from the discharge line.
  8. Remove the nut that attaches the suction/liquid line to the compressor, and then remove the suction/liquid line from the compressor.
  9. Remove and discard the o-ring from the suction/liquid line.
  10. Release the clip that attaches the compressor HV electrical harness to the crossbeam.
  11. Move the compressor HV electrical harness forward of the shock tower brace to ease compressor removal.
  12. Remove the bolts that attach the compressor to the shock tower brace, and then lower the compressor and remove it from the vehicle.
    Caution:
    Set the compressor so that the refrigerant fittings are up, and oil will not leak from them. Before the replacement compressor can be installed, the removed compressor and the oil inside must be weighed.
  13. Release the clip that attaches the compressor HV electrical harness to the intermediate bracket.
  14. Remove the bolts that attach the intermediate bracket to the compressor, and then remove the bracket from the compressor.
  15. Release the clips that attach the acoustic cover over to the compressor, and then remove the acoustic cover.
  16. Use a digital scale to weigh the removed compressor and record its weight.
    Note: Do not drain any oil from the removed compressor.
1Remove the bolt that attaches the suction/liquid line to the chiller and EXV assembly, and then remove the line from the chiller and EXV assembly.
2Remove and discard the o-rings from the suction/liquid line fitting.
3Release the clip that attaches the electrical harness to the suction liquid line.
4Disconnect the electrical harness from the powertrain coolant pump connector.
5Release the clip that attaches the suction/liquid lines to the superbottle.
6Remove the nut that attaches the discharge line to the compressor, and then remove the discharge line from the compressor.
7Remove and discard the o-ring from the discharge line.
8Remove the nut that attaches the suction/liquid line to the compressor, and then remove the suction/liquid line from the compressor.
9Remove and discard the o-ring from the suction/liquid line.
10Release the clip that attaches the compressor HV electrical harness to the crossbeam.
11Move the compressor HV electrical harness forward of the shock tower brace to ease compressor removal.
12Remove the bolts that attach the compressor to the shock tower brace, and then lower the compressor and remove it from the vehicle.
Caution:
Set the compressor so that the refrigerant fittings are up, and oil will not leak from them. Before the replacement compressor can be installed, the removed compressor and the oil inside must be weighed.
13Release the clip that attaches the compressor HV electrical harness to the intermediate bracket.
14Remove the bolts that attach the intermediate bracket to the compressor, and then remove the bracket from the compressor.
15Release the clips that attach the acoustic cover over to the compressor, and then remove the acoustic cover.
16Use a digital scale to weigh the removed compressor and record its weight.
Note: Do not drain any oil from the removed compressor.

Install

  1. Remove the port plugs and port nuts from the replacement compressor.
  2. Use the digital scale to weigh the replacement compressor and record its weight.
  3. Subtract the weight of the removed compressor from the weight of the replacement compressor. The difference is the weight of oil to be removed from the replacement compressor.
  4. Turn the replacement compressor upside down to drain a small amount of oil from the suction (large) port into a clean, dry collection container.
    Note: If necessary, the collected oil can be reused later for A/C system recharge.
  5. Repeat step 2 through step 4 until the weight of the replacement compressor is the same as the removed compressor.
  6. Install the acoustic cover over the compressor, and then fasten the clips that attach the cover over the compressor.
  7. Install the intermediate bracket onto the compressor, and then install the bolts that attach the bracket to the compressor.
    Torque 10 Nm
    .
  8. Fasten the clip that attaches the compressor HV electrical harness to the intermediate bracket.
  9. Install the compressor under the shock tower brace, and then install the bolts that attach the compressor to the shock tower brace.
    Torque 10 Nm
  10. Move the compressor HV electrical harness behind the shock tower brace.
  11. Fasten the clip that attaches the compressor HV electrical harness to the body.
  12. Install a new o-ring onto the suction/liquid line, insert the line into the compressor, and then install the nut that attaches the line to the compressor.
    Torque 22 Nm
  13. Install a new o-ring onto the discharge line, insert the line into the compressor, and then install the nut that attaches the line to the compressor.
    Torque 22 Nm
    .
  14. Fasten the clip that attaches the suction/liquid lines to the superbottle.
  15. Connect the electrical harness to the powertrain coolant pump connector.
  16. Fasten the clip that attaches the electrical harness to the suction liquid line.
  17. Install new o-rings onto the suction/liquid line fitting, install the fitting into the chiller and EXV assembly, and then install the bolt that attaches the fitting to the chiller and EXV assembly.
    Torque 5.5 Nm
  18. Connect the electrical harness to the low pressure transducer connector.
  19. Install the suction/liquid line bracket onto the shock tower brace, and then install the bolt that attaches the bracket to the brace.
    Torque 5.5 Nm
  20. Fasten the clips that attach the low voltage electrical harness to the compressor and compressor bracket.
  21. Install the bolt that attaches the ground harness to the compressor.
    Torque 6 Nm
  22. Connect the low voltage electrical harness to the compressor connector.
  23. Raise the vehicle.
  24. Connect the electrical harness to the high pressure transducer connector.
  25. Fasten the clips that attach the compressor HV electrical harness to the bulkhead.
  26. Connect the compressor HV electrical connector to the HV electrical harness.
  27. Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
  28. Connect the red high pressure hose to the vehicle's high pressure port, and the blue low pressure hose to the vehicle's low pressure port.
  29. Start the A/C vacuum and leak test, and continue with this procedure while the tests are running.
  30. Perform the penthouse air leak test. See Penthouse Air Leak Test.
  31. Connect the charge port electrical harness to the penthouse DC input connector. Close the locking handle and slide the security tab to the lock position.
  32. Install the clip that attaches the charge port electrical harness to the vehicle.
  33. Position the charge port to HV battery harness bracket on the body, and then install the bolts that attach the bracket to the body.
    Torque 10 Nm
  34. Install the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
  35. Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
  36. Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
  37. Install the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
  38. Connect 12V power. See 12V Power (Disconnect and Connect).
    Note: Do not install the rear apron at this time.
  39. When the A/C vacuum and leak test is complete, recharge the refrigerant. See A/C Refrigerant (Recovery and Recharge).
  40. Connect a laptop with Toolbox to the vehicle.
  41. Update the vehicle firmware.
  42. After the A/C refrigerant recharge has fully completed, verify the operation of the A/C system.
  43. Connect a charge cable to the vehicle, and then use Toolbox to run the "TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE" test to verify the replacement compressor operation.
  44. Disconnect the charge cable and laptop from the vehicle.
  45. Install the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
  46. Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).
1Remove the port plugs and port nuts from the replacement compressor.
2Use the digital scale to weigh the replacement compressor and record its weight.
3Subtract the weight of the removed compressor from the weight of the replacement compressor. The difference is the weight of oil to be removed from the replacement compressor.
4Turn the replacement compressor upside down to drain a small amount of oil from the suction (large) port into a clean, dry collection container.
Note: If necessary, the collected oil can be reused later for A/C system recharge.
5Repeat step 2 through step 4 until the weight of the replacement compressor is the same as the removed compressor.
6Install the acoustic cover over the compressor, and then fasten the clips that attach the cover over the compressor.
7Install the intermediate bracket onto the compressor, and then install the bolts that attach the bracket to the compressor.
Torque 10 Nm
.
8Fasten the clip that attaches the compressor HV electrical harness to the intermediate bracket.
9Install the compressor under the shock tower brace, and then install the bolts that attach the compressor to the shock tower brace.
Torque 10 Nm
10Move the compressor HV electrical harness behind the shock tower brace.
11Fasten the clip that attaches the compressor HV electrical harness to the body.
12Install a new o-ring onto the suction/liquid line, insert the line into the compressor, and then install the nut that attaches the line to the compressor.
Torque 22 Nm
13Install a new o-ring onto the discharge line, insert the line into the compressor, and then install the nut that attaches the line to the compressor.
Torque 22 Nm
.
14Fasten the clip that attaches the suction/liquid lines to the superbottle.
15Connect the electrical harness to the powertrain coolant pump connector.
16Fasten the clip that attaches the electrical harness to the suction liquid line.
17Install new o-rings onto the suction/liquid line fitting, install the fitting into the chiller and EXV assembly, and then install the bolt that attaches the fitting to the chiller and EXV assembly.
Torque 5.5 Nm
18Connect the electrical harness to the low pressure transducer connector.
19Install the suction/liquid line bracket onto the shock tower brace, and then install the bolt that attaches the bracket to the brace.
Torque 5.5 Nm
20Fasten the clips that attach the low voltage electrical harness to the compressor and compressor bracket.
21Install the bolt that attaches the ground harness to the compressor.
Torque 6 Nm
22Connect the low voltage electrical harness to the compressor connector.
23Raise the vehicle.
24Connect the electrical harness to the high pressure transducer connector.
25Fasten the clips that attach the compressor HV electrical harness to the bulkhead.
26Connect the compressor HV electrical connector to the HV electrical harness.
27Install the front aero shield. See Panel - Aero Shield - Front (Remove and Replace).
28Connect the red high pressure hose to the vehicle's high pressure port, and the blue low pressure hose to the vehicle's low pressure port.
29Start the A/C vacuum and leak test, and continue with this procedure while the tests are running.
30Perform the penthouse air leak test. See Penthouse Air Leak Test.
31Connect the charge port electrical harness to the penthouse DC input connector. Close the locking handle and slide the security tab to the lock position.
32Install the clip that attaches the charge port electrical harness to the vehicle.
33Position the charge port to HV battery harness bracket on the body, and then install the bolts that attach the bracket to the body.
Torque 10 Nm
34Install the clips that attach the low voltage electrical harness to the charge port to HV battery harness bracket at the penthouse.
35Install the LH rear sill panel trim. See Trim - Sill Panel - Rear - LH (Remove and Replace).
36Install the LH 2nd row seat side bolster. See Bolster - Side - Seat - 2nd Row - LH (Remove and Replace).
37Install the penthouse HV cap. See Cap - Penthouse HV (Remove and Replace).
38Connect 12V power. See 12V Power (Disconnect and Connect).
Note: Do not install the rear apron at this time.
39When the A/C vacuum and leak test is complete, recharge the refrigerant. See A/C Refrigerant (Recovery and Recharge).
40Connect a laptop with Toolbox to the vehicle.
41Update the vehicle firmware.
42After the A/C refrigerant recharge has fully completed, verify the operation of the A/C system.
43Connect a charge cable to the vehicle, and then use Toolbox to run the "TEST-SELF_VCFRONT_X_THERMAL-PERFORMANCE" test to verify the replacement compressor operation.
44Disconnect the charge cable and laptop from the vehicle.
45Install the outer HVAC plenum duct. See Duct - HVAC Plenum - Outer (Remove and Replace).
46Install the underhood storage unit. See Underhood Storage Unit (Remove and Replace).