Tesla Model S: Compressor - 2nd Generation (Remove and Replace)

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 00 (500V) 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.

Removal

1. Recover refrigerant from the vehicle (refer to procedure).
2. Perform the vehicle electrical isolation procedure (refer to procedure).
3. Remove the underhood storage unit for access (refer to procedure).
4. Raise and support the vehicle (refer to procedure). Warning: Do not work on an incorrectly supported vehicle.
5. Remove the front skid plate (refer to procedure).
6. Working beneath the vehicle, remove the nuts (x4) that secure the compressor and bracket assembly to the front subframe (torque 10 Nm).

   

7. Lower the vehicle.
8. Release the compressor harness (#3 in the figure below) from the orange connector on the top of the forward junction box (FJB).

   

   1	HV Battery heater harness
   2	DCDC converter harness
   3	Compressor harness
   4	PTC heater harness

9. Disconnect the compressor logic harness.

   

10. Remove the screw that secures the ground wire to the compressor (torque 7 Nm). Release the ground wire.

    

11. Remove the nuts (x2) that secure the A/C suction and discharge lines to the compressor (torque 10 Nm). Release the lines and remove the seals. Plug the holes.

    Note: The following figure shows the compressor from the rear of the vehicle.

    Caution: The holes must be plugged to prevent contamination.

    Caution: Remove and discard O-rings.

    

12. Remove the compressor and bracket assembly.
13. Remove the screws (x2) that secure the compressor to the inner bracket (torque 24 Nm).

    Caution: The HV cable is connected to the compressor; it cannot be removed.

    

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

Caution: The amount of oil in the new A/C compressor needs to equal the amount of oil from 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 fluid, then re-weigh it. Repeat this process until the new A/C compressor weighs the same as the old one.

• Ensure that the HV cable is routed under the suction and discharge lines and that the clip is installed onto the suction line.

  

• Recharge the A/C system.
• Ensure there is sufficient clearance between the HV connector and the bottom of the underhood storage compartment. If there is contact, adjust the position of the bracket that supports the HV connector.

READ NEXT: