Lexus RX400h, Hybrid 3 2006

Removal & Installation

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CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


CAUTION
Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat. Be careful when connecting service equipment. Do not breathe refrigerant or vapor.

Use only service equipment that is U.L.-listed and is certified to meet the requirements of SAE J2210 to remove HFC-134a (R-134a) from the air conditioning system.

  1. Discharge refrigerant from the A/C system, as outlined earlier in this section.
  2.  
  3. Remove service plug grip, as follows:
    CAUTION
    Remove the service plug to interrupt a high voltage circuit at the time of the check. Keep the removed service plug in your pocket to prevent it from accidentally reconnected while you are servicing the vehicle. All the high voltage wiring connectors are colored in orange.

    1. Remove the 2 clips and door scuff plate LH.
    2.  
    3. Remove the 2 clips and reclining hinge cover.
    4.  
    5. Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.
      CAUTION
      After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.


      WARNING
      After removing the service plug grip, do not operate the ignition switch as it may damage the hybrid vehicle control ECU.



      Click image to see an enlarged view

      Fig. Service plug grip

    6.  

  4.  
  5. Disconnect the negative and positive battery cables, then remove the battery.
  6.  
  7. Remove battery carrier sub-assembly.
  8.  
  9. Disconnect the cooler refrigerant discharge hose no.1:
    1. Remove the bolt and disconnect the cooler refrigerant discharge hose No.1 from the electric inverter compressor.
    2.  
    3. Remove the O-ring from the cooler refrigerant discharge hose No.1.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

    4.  

  10.  
  11. Disconnect cooler refrigerant suction hose no.1:
    1. Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the electric inverter compressor.
    2.  
    3. Remove the O-ring from the cooler refrigerant suction hose No.1.
      NOTE
      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.


      CAUTION
      Wear insulated gloves when performing the procedures.

    4.  

  12.  
  13. Remove the electric inverter A/C compressor, as follows (refer to the accompanying illustration):
    1. Disconnect the connector (A).
    2.  
    3. Release the green-colored lock (B).
    4.  
    5. Disconnect the connector (C).
      NOTE
      Insulate the connector by sealing it with tape.



      Click image to see an enlarged view

      Fig. Disconnect the connector (A). Release the green-colored lock (B), then disconnect the connector (C).

    6.  
    7. Remove the 3 bolt and electric inverter compressor.
    8.  

  14.  
  15. Remove the service valve, as follows:
    1. Remove the bolt and service valve.
    2.  
    3. Remove the O-ring from the service valve.
    4.  

  16.  
  17. Inspect electric inverter compressor:
    1. Disconnect the connector from the electric inverter compressor (A).

      Click image to see an enlarged view

      Fig. Disconnect the connector from the electric inverter compressor (A)

    2.  
    3. Using a megaohm tester, measure the resistance according to the value(s) in the accompanying table.

      Click image to see an enlarged view

      Fig. Using a megaohm tester, measure the resistance and compare with the value(s) in this table



      Click image to see an enlarged view

      Fig. Exploded view of the electric inverter A/C compressor and related component

    4.  

  18.  

To install:

  1. Adjust compressor oil:
    1. When replacing the electric inverter compressor with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new electric inverter compressor before installation.
    2.  
    3. Standard: (Oil capacity inside the new electric inverter compressor: 120 to 135 cc (4.2 to 4.8 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 cooler removal/installation. If a new electric inverter compressor installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and caused refrigerant failure. If the volume of oil remaining in the removed electric inverter compressor is too small, check for oil leakage.


      NOTE
      Be sure to use ND-OIL 11 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.

    4.  

  2.  
  3. Install service valve:
    1. Apply sufficient compressor oil (ND-OIL 11) to a new O-ring and the fitting surface of the electric inverter compressor.
    2.  
    3. Install the O-ring onto the service valve.
    4.  
    5. Install the service valve with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    6.  

  4.  
  5. Install electric inverter compressor:
    1. Install the electric inverter compressor with the 3 bolts and tighten, in the sequence shown, to 18 ft. lbs. (25 Nm).
    2.  
    3. Connect the connector (A).
      CAUTION
      Wear insulated gloves when performing the procedures.

    4.  
    5. Lock the green-colored lock (B).
    6.  
    7. Connect the connector (C).
    8.  

  6.  
  7. Install cooler refrigerant suction hose no.1
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply sufficient compressor oil (ND-OIL 11 or equivalent) to a new O-ring and the fitting surface of the electric inverter compressor.
    4.  
    5. Install the O-ring onto the cooler refrigerant suction hose No.1.
    6.  
    7. Install the cooler refrigerant suction hose No.1 onto the electric inverter compressor with the bolt and tighten to 87 inch lbs. (10 Nm).
    8.  

  8.  
  9. Install cooler refrigerant discharge hose no.1:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Apply sufficient compressor oil (ND-OIL 11or equivalent) to a new O-ring and the fitting surface of the electric inverter compressor.
    4.  
    5. Install the O-ring onto the cooler refrigerant discharge hose No.1.
    6.  
    7. Install the cooler refrigerant discharge hose No.1 onto the electric inverter compressor with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  10.  
  11. Install the battery carrier.
  12.  
  13. Install the battery, then connect the positive and negative cables.
    WARNING
    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.

  14.  
  15. Install the service plug grip:
    1. Wear insulation gloves, then insert the service plug.
    2.  
    3. Push down on the grip to lock.
    4.  
    5. Close the reclining hinge cover.
      NOTE
      Check that the 2 clips are securely connected to the battery carrier bracket (click sound).

    6.  
    7. Close the rear door scuff plate LH.
    8.  

  16.  
  17. Charge the A/C system, as outlined in this section.
  18.  
  19. Warm up the compressor, as outlined under the Charging Procedure.
  20.  
  21. Leak test the A/C system, as outlined in this section.
  22.  
  23. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  24.  

 
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