COMPRESSOR (for 5ZR-FXE) INSTALLATION


  1. ADJUST COMPRESSOR OIL


    1. A003W6T

      When replacing the electric inverter compressor with a new one, gradually discharge the gas from the service valve of the new compressor, and drain the following amount of oil from the new electric inverter compressor before installation.

      Standard
      (Oil capacity inside the new electric inverter compressor: 130 to 145 cc (4.4 to 4.9 fl. oz.)) - (Remaining oil amount in the removed electric inverter compressor) = (Oil amount to be removed from the new compressor when replacing)

      Note


      • When checking the compressor oil level, observe the precautions on the air conditioning Refrigerant-Replacement.

      • If a new compressor is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes refrigeration failure.

      • If the amount of oil remaining in the old compressor is too small, check the air conditioning system for oil leaks.

      • Be sure to use ND-OIL 11 or equivalent for compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

  2. INSTALL ELECTRIC INVERTER COMPRESSOR


    1. Using an E8 "TORX" socket wrench, temporarily install the electric inverter compressor with the 2 stud bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Temporarily install the bolt and 2 nuts.

    3. A003Z6AE01

      Install the electric inverter compressor with the bolt and 2 nuts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the electric inverter compressor.

    4. A003W6QE01
      Text in Illustration
      *1 Green-colored Lock

      Connect the connector <B>.

    5. Connect the connector <A> and slide the green-colored lock in the direction indicated by the arrow in the illustration to lock it securely.

      CAUTION:

      Make sure to wear insulating gloves.

      Note

      Make sure that the connector is connected securely.

  3. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Remove the vinyl tape from the hose.

    2. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surface of the electric inverter compressor.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring onto the No. 1 cooler refrigerant suction hose.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the No. 1 cooler refrigerant suction hose onto the electric inverter compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  4. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Apply a sufficient amount of compressor oil to a new O-ring and the fitting surface of the electric inverter compressor.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring onto the No. 1 cooler refrigerant discharge hose.

      Note


      • Keep the O-ring and O-ring fitting surfaces free from dirt or foreign matter.

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. Install the No. 1 cooler refrigerant discharge hose onto the electric inverter compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  5. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulating gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.


    1. Wear insulated gloves and install the service plug grip in the order shown in the illustration.

      A003X0M

    2. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.

  6. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Install the radiator support opening cover with the 9 clips (for 9 Clip Type).

    2. Install the radiator support opening cover with the 7 clips (for 7 Clip Type).

  7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  8. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

  9. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

    2. Install the deck floor box RH with the clip.

  10. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  11. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  12. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.

  13. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly to the air cleaner case.

    2. Install the inlet air cleaner assembly with the 2 bolts and 2 clips.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. Connect the wire harness clamp to the inlet air cleaner assembly.

    4. Install the water hose to the hose clamp.

  14. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A003ZARE09
      Standard charge amount
      470 g (16.6 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      • The graph above is shown for reference only. This vehicle is not equipped with a sight glass.

      • If at all possible, avoid using a manifold gauge set or recovery and recycling unit that has been used for vehicles with conventional compressor oil (ND-OIL 8 or equivalent). If either of these is used, conventional compressor oil remaining in the equipment will enter the air conditioning system of the vehicle, resulting in electrical insulation performance deterioration. A manifold gauge set that has been used 3 times or less can be used if an appropriate one is not available.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an air conditioning system.

  15. WARM UP COMPRESSOR


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

  16. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Power switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

      • Repeat the inspection 2 or 3 times.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

        Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)

    3. A003W8IE40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

      Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

    4. A003XEEE08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

      • Bring the halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks.

    5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

    6. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.