COMPRESSOR (for 2ZR-FXE) REMOVAL


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM


    1. Turn the A/C switch on.

    2. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

    3. Turn the power switch off.

    4. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

  3. REMOVE REAR NO. 2 FLOOR BOARD


    1. Remove the rear No. 2 floor board.

  4. REMOVE REAR DECK FLOOR BOX


    1. Remove the rear deck floor box.

  5. REMOVE REAR NO. 3 FLOOR BOARD


    1. Remove the rear No. 3 floor board.

  6. REMOVE DECK FLOOR BOX RH


    1. A003Z5J

      Remove the clip.

    2. Disengage the 6 guides and remove the deck floor box RH.

  7. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. A003VKN

      Disengage the 4 claws and 2 guides, and remove the rear floor board upper No. 3 plate.

  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  9. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003ZJQ

      Remove the 9 clips and radiator support opening cover (for 9 Clip Type).

    2. A003XV0

      Remove the 7 clips and radiator support opening cover (for 7 Clip Type).

  10. REMOVE SERVICE PLUG GRIP

    CAUTION:


    • Wear insulating gloves.

    • Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.

    • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

    • High voltage wiring connectors are orange.


    1. Wear insulated gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.

      A003XIK

      CAUTION:


      • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

      • After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.

      Tech Tips

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  11. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    1. A003WQ2

      Remove the 9 bolts and inverter cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  12. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.

    Note

    Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A003W23

      Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V

      Tech Tips

      Use measuring range of DC 750 V or more on the voltmeter.

  13. INSTALL INVERTER COVER

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A003XT9E01
      Text in Illustration
      *1 Interlock

      Install the inverter cover with the 9 bolts to the inverter with converter assembly.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  14. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A003VRO

      Separate the water hose from the hose clamp.

    2. A003VGC

      Separate the wire harness clamp from the inlet air cleaner assembly.

    3. Remove the 2 bolts, 2 clips and inlet air cleaner assembly.

  15. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE


    1. A003VV2

      Remove the bolt and disconnect the cooler refrigerant discharge hose from the electric inverter compressor.

    2. Remove the O-ring from the cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  16. DISCONNECT COOLER REFRIGERANT SUCTION HOSE


    1. A003V4J

      Remove the bolt and disconnect the cooler refrigerant suction hose from the electric inverter compressor.

    2. Remove the O-ring from the cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  17. REMOVE ELECTRIC INVERTER COMPRESSOR


    1. A003XW5E01
      Text in Illustration
      *1 Green-colored Lock

      Using a screwdriver, slide the green-colored lock of the connector <A> in the direction indicated by the arrow in the illustration to release it and disconnect the connector.

      CAUTION:

      Make sure to wear insulating gloves.

      Note

      Insulate the removed terminals and connector with insulating tape.

    2. Disconnect the connector <B>.

    3. A003V89

      Remove the bolt and 2 nuts.

    4. A003VTO

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts.

    5. Remove the electric inverter compressor