Tesla Model S: Air Conditioning System Precautions - General
The air conditioning system contains fluids and components which could
be potentially hazardous to the technician or the environment if not
serviced and handled correctly. The following guidelines are intended to
alert the technician to potential sources of danger and emphasize the
importance of ensuring the integrity of the air conditioning operating
conditions and components fitted to the vehicle.
Where necessary,
additional specific precautions are detailed in the relevant sections of
this Manual which should be referred to prior to commencing repair
operations.
The refrigerant used in the air conditioning system is R134a or
R1234yf.
Warning: Servicing must only be carried out by personnel
familiar with both the vehicle system and the charging and testing
equipment. All operations must be carried out in a well-ventilated
area away from open flame and heat sources.
Warning: Refrigerant is a hazardous liquid and when handled
incorrectly can cause serious injury. Suitable protective clothing,
consisting of face protection, heat-proof gloves, rubber boots and
apron or waterproof overalls, must be worn when carrying out
operations on the air conditioning system.
Remedial actions
Warning: Due to its low evaporating temperature,
refrigerant must be handled with care. Refirgerant splashed on any
part of the body will cause immediate freezing of that area.
If an accident involving refrigerant should occur, conduct the
following remedial actions:
- If liquid refrigerant enters the eye, do not rub it. Gently run
large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean water may
be used to flush the eye. After rinsing, cover the eye with a clean
pad and seek immediate medical attention.
- If liquid refrigerant is splashed onto the skin, run large
quantities of water over the affected area to raise the temperature.
Implement the same action if the skin comes in contact with
discharging cylinders. Wrap the contaminated body parts in blankets
(or similar materials) and seek immediate medical attention.
Service precautions
Observe the following precautions when handling components used in the
air conditioning system:
- Air conditioning units must not be lifted by their hoses, pipes
or capillary lines.
- Hoses and lines must not be subjected to any twist or stress;
the efficiency of the system will be impaired by kinks or
restrictions. Ensure that hoses are correctly positioned before
tightening couplings, and ensure that all clips and supports are
utilized.
- Completed assemblies must be checked for refrigeration lines
touching metal panels. Any direct contact of components and panels
may transmit noise and so must be eliminated.
- The appropriate torque wrench must be used when tightening
refrigerant connections to the stipulated value. An additional
wrench must be used to hold the union to prevent twisting of the
pipe when tightening connections.
- All protective plugs must remain in place to seal the component
until immediately prior to connection.
- Ensure components are at room temperature before uncapping, to
prevent condensation of moisture from the air that enters it.
- Components must not remain uncapped for longer than 15 minutes.
In the event of a delay, the caps must be fitted.
- When disconnecting, immediately cap all air conditioning pipes
to prevent ingress of dirt and moisture into the system.
- The receiver/drier contains desiccant which absorbs moisture. It
must be positively sealed at all times. A receiver/drier that has
been left uncapped must not be used.
- The receiver/drier should be the last component connected to the
system to ensure optimum dehydration and maximum moisture protection
of the system.
- Use alcohol and a clean, lint-free cloth to clean dirty
connections.
- Ensure that all new parts fitted are suitable for use with the
specified refrigerant.
HVAC line installation
Always carry out the following procedure before connecting any hose
or pipe:
- All refrigeration fittings require oiling with the
recommended refrigerant oil before installation. Refer to
General Information > Fluids and Capacities > Fluids.
- When connecting refrigeration fittings, ensure that the
O-ring is positioned correctly. Push the joint together until
the O-ring disappears before attempting to tighten the nut. The
nut should start by hand; if a wrench is required then the joint
is misaligned. Tighten the joint to the torque shown.
- The refrigeration system must be kept clean and capped at
all stages. At no time must any hoses be left open to atmosphere
as the oil in the system is hygroscopic (absorbs moisture). The
connection to the drier should only be completed just prior to
commissioning (or at least the system should be vacuumed to keep
the system dry so any moisture generally in the pipe work does
not affect the oil or 'wet' the receiver drier).
- Keep the lid on oil containers such that a small amount can
be dispensed at any time and then at the end of the week, the
whole can is disposed of to avoid using contaminated oil. Oil
containers kept to lubricate O-rings should not be used to top
up oil in systems due to potential contamination.
Use the HVAC machine to perform a leak test after a major repair
has been completed.
Refrigerant oil
The compressor contains a lubricant, which has greater electrical
insulating properties than the A/C lubrication oil normally used for
standard mechanical belt driven A/C pumps. It is important that the
compressor is kept upright at all times to retain the lubricant in
the compressor's sump.
Caution: Use of the incorrect oil may affect the
dielectric strength of the motor and potentially cause an
internal short circuit as well potentially affecting the bearing
life.
Caution: Refrigerant oil easily absorbs water and must not
be stored for long periods. Do not pour unused refrigerant oil
back into the container.
Compressor
A new compressor is sealed. Ensure that no foreign material is
allowed to enter the compressor.
Caution: Do not remove the cap(s) until immediately prior
to connecting the air conditioning pipes to the compressor.
Foreign material entering the compressor is likely to cause
significant damage requiring replacement.
Rapid refrigerant discharge
If the air conditioning system is involved in accident damage and
the system is punctured, the refrigerant will discharge rapidly. The
rapid discharge of refrigerant will also result in the loss of most
of the oil from the system. The compressor must be removed and all
the remaining oil in the compressor drained and refilled as
instructed in the air conditioning section of this manual.
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The HVAC and battery coolant circuits are sealed to prevent the
discharge of refrigerant. The refrigerant must be recovered before any
removal of system components using the recommended equipmen
Internally or externally damaged components can cause debris and
moisture to enter the A/C system. Perform the following procedures if
debris or excessive moisture ingress is suspected.
Cau
General
The Tesla Model S is an electrically powered vehicle. Energy is stored in
the battery, which is a sealed unit containing Lithium-ion cells producing
up to 1500 A of energy at up to 400V.
SEE MORE:
Removal
Remove front windshield (refer to procedure)
Lower headlining for access (refer to procedure)
With assistance remove headlining through front windshield
opening.
Remove rear map lamps from headlining.
Warning: Before disconnecting the 12 volt power supply,
ensure that driver's door window is fully open. Failure to follow
this instruction could result in vehicle lockout.
Warning: If the 12 volt power supply is disconnected, do
not attempt to open any doors with door glass in closed