Removal And Installation

ELECTRIC COMPRESSOR

Removal and Installation

WARNING:
- Because EV (electric vehicle) and HEV (hybrid vehicle) contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons never touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.

CAUTION:
- There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore never change the vehicle to READY status unless instructed to do so in the Service Manual.
- Perform lubricant return operation before each refrigeration system disassembly. However, if a large amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA34, "Perform Lubricant Return Operation".

REMOVAL

WARNING:
Disconnect high voltage circuit. Refer to "How to Disconnect High Voltage" Service and Repair.
1.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Lift up the vehicle, and then remove Li-ion battery under covers.
- Refer to "Exploded View" Service and Repair. (Type 1: Without Li-ion battery heater)
- Refer to "Exploded View" Service and Repair. (Type 2: With Li-ion battery heater)
b.Disconnect high voltage connector from front side of Li-ion battery.
- Refer to "Removal and Installation" Service and Repair. (Type 1: Without Li-ion battery heater)
- Refer to "Removal and Installation" Service and Repair. (Type 2: With Li-ion battery heater)

c.Measure voltage between high voltage harness terminals.
DANGER:

Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less

CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
2.Use the refrigerant recovery equipment (for HFC-134a) and recover the refrigerant. {LINK_TO:0000000007635500}, "Recycle
Refrigerant".
3.Remove radiator upper grille. Refer to "RADIATOR UPPER GRILLE : Removal and Installation" Radiator Upper Grille.

4.Remove mounting nut (A), and then disconnect low-pressure flexible hose (1) from electric compressor.

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

CAUTION:
- Cover the low pressure port of the electric compressor with a cap to prevent oil from spilling.
- To prevent the inclusion of foreign matter, use a cap or vinyl tape to seal off the pipe connection port from the atmosphere.

5.Remove mounting nut (A), and then disconnect high-pressure flexible hose (1) from electric compressor.

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

CAUTION:
- Cover the high pressure port of the electric compressor with a cap to prevent oil from spilling.
- To prevent the inclusion of foreign matter, use a cap or vinyl tape to seal off the pipe connection port from the atmosphere.

6.Disconnect quick charge port connectors (1) inside motor room.

7.Disconnect normal charge port connector (1) inside motor room.

WARNING:
- To prevent electric shock hazards, be sure to wear protective gear.
- To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
8.Move water hose to secure work space.
9.Remove front under cover. Refer to "FRONT UNDER COVER : Removal and Installation" Front Under Cover.
10.Remove front tire RH. Refer to "Removal and Installation" Removal And Installation.
11.Remove fender protector. Refer to "FENDER PROTECTOR : Removal and Installation" Removal And Installation.

12.Remove mounting bolts (A), and then remove compressor stay (1).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

13.Disconnect high voltage harness connector (A).

WARNING:
- To prevent electric shock hazards, be sure to wear protective gear.
- To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
- Follow the procedure below and disconnect high voltage harness connector.

14.Disconnect low voltage harness connector (A).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

15.Remove mounting bolts (A) from electric compressor (1).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

16.Remove electric compressor (1) from the vehicle.

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

17.Remove mounting bolts (A), and then remove compressor bracket (1).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

INSTALLATION

Note the following items, and then install in the reverse order of removal.

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

CAUTION:
- Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.
- Before installing the new compressor, adjust the compressor oil level. Refer to "Lubricant Adjusting Procedure for Compressor Replacement" Lubricant Adjusting Procedure For Compressor Replacement.
- To prevent degradation in insulation performance, use special electric compressor oil as the compressor oil.
- In order to prevent conventional PAG oil from becoming mixed in, never reuse recovered compressor oil and instead always use new oil. The use of oil including the conventional PAG oil may degrade the performance of insulation.
- To prevent performance degradation, never use a fluorescent agent in order to detect refrigerant leakage. Also be careful that a fluorescent agent never enter the oil.
- To prevent leakage of refrigerant, replace the O-ring with a new one. Apply a coat of compressor oil to the O-ring prior to installation.
- Perform a check for refrigerant leakage when charging with refrigerant. Refer to "Check Refrigerant Leakage" Check Refrigerant Leakage.
- Set the vehicle to READY and operate the air conditioner for 1 minute or more with the vehicle parked to perform a break-in.

- If the compressor stay was replaced, first check that there is no dust or dirt on the surface of the compressor stay, then apply the new high voltage warning label at position (A), with the direction indicated by the arrow facing up.

- Follow the procedure below and connect the high voltage harness connector.

- After all parts are installed, be sure to check the equipotential. Refer to "Inspection" Electric Compressor Inspection.