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Electric Inverter Compressor ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE REAR FLOOR BOARD NO.2 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  2. REMOVE DECK FLOOR BOX REAR (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  3. REMOVE REAR FLOOR BOARD NO.3 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  4. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE  REPLACEMENT  ) 
  5. REMOVE SERVICE PLUG GRIP (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  6. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 
    1. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
  7. DISCONNECT DISCHARGE HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the discharge hose sub-assy.
    2. Remove the O-ring from the discharge hose sub-assy.
    NOTE: Seal the openings of the disconnected parts of the discharge hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 1: Removing O-Ring From Suction Hose Sub-Assy
    G00933578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT SUCTION HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the suction hose sub-assy.
    2. Remove the O-ring from the suction hose sub-assy.
    NOTE: Seal the openings of the disconnected parts of the suction hose and the compressor assy with the electric inverter compressor assy using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 2: Disconnecting Connector
    G00933579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE ELECTRIC INVERTER COMPRESSOR ASSY 
    1. Release the green-colored lock.(1)
    2. Disconnect the connector.(2)
    3. Remove the 3 clamps and disconnect the wire harness.
      Fig 3: Removing Clamps
      G00933580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Wear insulated gloves when performing the procedures.
      • Insulate the connector by sealing it with tape.
    4. Remove the 3 bolts and then the electric inverter compressor assy.
    Fig 4: Removing Electric Inverter Compressor Assy
    G00933581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT COMPRESSOR OIL 
    1. Gradually discharge inert gas (helium) from the service valve when replacing the electric inverter compressor assy with the inverter compressor assy with a new one. Drain the following amount of oil from the new electric inverter compressor before installation.
      1. Standard: (Oil capacity inside new electric inverter compressor 100 (+ 15 mL)) - (Remaining oil amount in the removed compressor assy with the motor (w/ motor compressor assy)) = (Oil amount to be removed before installation) 
    NOTE:
    • Observe the precautions on the cooler removal/installation procedures when checking the amount of compressor oil.
    • Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor assy is installed without removing the oil inside, the amount of oil becomes too great, preventing heat exchange in the refrigerant cycles and causing refrigerant failure and/or abnormal vibration.
    • Check for oil leakage if the remaining oil amount in the removed compressor is too low.
    • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    Fig 5: Identifying Service Valves
    G00933582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. TEMPORARILY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY 
    1. Temporarily tighten the electric inverter compressor assy with the 2 bolts.
    NOTE: Tighten them in the order indicated in Fig 6
    Fig 6: Temporarily Tighten Electric Inverter Compressor Assy Blots
    G00933583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. FULLY TIGHTEN ELECTRIC INVERTER COMPRESSOR ASSY 
    1. Fully tighten the electric inverter compressor assy with the 2 bolts.
      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
      NOTE: Tighten them in the order indicated in Fig 7
      Fig 7: Tightening Electric Inverter Compressor Assy With Bolt
      G00933584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fully tighten the electric inverter compressor assy with the bolt.
      1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 
      Fig 8: Fully Tighten Bolts
      G00933585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the wire harness.
    NOTE: Wear insulated gloves when performing the procedures.
    1. Connect the wire harness 3 clamps.
    2. Connect the connector.(1)
    3. Lock the green-colored lock.(2)
    Fig 9: Locking Green Colored Lock
    G00933586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL SUCTION HOSE SUB-ASSY 
    1. Sufficiently apply compressor oil to a new O-ring and fitting surface of the electric inverter compressor assy.
      1. Compressor oil: ND-OIL 11 or equivalent 
      Fig 10: Installing Discharge Hose Sub-Assy
      G00933587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not use any compressor oil other than ND-OIL11 (see AIR CONDITIONING SYSTEM ).
      • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    2. Install the O-ring to the suction hose sub-assy.
    3. Install the suction hose sub-assy with the bolt.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) 
  14. INSTALL DISCHARGE HOSE SUB-ASSY 
    1. Sufficiently apply compressor oil to a new O-ring and fitting surface of the electric inverter compressor assy.
      1. Compressor oil: ND-OIL 11 or equivalent 
      Fig 11: Installing Discharge Hose Sub-Assy
      G00933588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not use any compressor oil other than ND-OIL11 (see AIR CONDITIONING SYSTEM ).
      • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    2. Install the O-ring to the discharge hose.
    3. Install the discharge hose with the bolt.
      1. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) 
  15. INSTALL SERVICE PLUG GRIP (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REAS  ) 
  16. CONNECT BATTERY NEGATIVE TERMINAL 
  17. INSTALL REAR FLOOR BOARD NO.3 
  18. INSTALL DECK FLOOR BOX REAR 
  19. INSTALL REAR FLOOR BOARD NO.2 
  20. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 
    1. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
    2. Specified amount: 450 +/- 30 g (15.87 +/- 1.05 oz.) 
  21. WARM UP COMPRESSOR (SEE  REPLACEMENT  ) 
  22. INSPECT LEAKAGE OF REFRIGERANT (SEE  REPLACEMENT  ) 
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