Toyota Highlander Hybrid 6 2005-06

Removal & Installation

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2.4L Engines




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.

  1. Discharge the A/C refrigerant, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the alternator, as outlined in the Engine Electrical Section.
  6.  
  7. Disconnect the cooler refrigerant discharge hose, as follows:
    1. Remove the nut and disconnect the cooler refrigerant discharge hose.
    2.  
    3. Remove the o-ring from the cooler refrigerant discharge hose.
      NOTE
      Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the lines and ports while they are disconnected.



      Click image to see an enlarged view

      Fig. Disconnect the cooler refrigerant discharge hose

    4.  

  8.  
  9. Disconnect the cooler refrigerant suction hose, as follows:
    1. Remove the bolt and disconnect the cooler refrigerant suction hose.
    2.  
    3. Remove the o-ring from the cooler refrigerant suction hose.
      NOTE
      Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the lines and ports while they are disconnected.



      Click image to see an enlarged view

      Fig. Disconnect the cooler refrigerant suction hose

    4.  

  10.  
  11. Remove the compressor and magnetic clutch, as follows:
    1. Detach the electrical connector.
    2.  
    3. Remove the nut.
    4.  
    5. Using an E8 torque socket wrench, remove the stud bolt.
    6.  
    7. Remove the 3 bolts and compressor and magnetic clutch.

      Click image to see an enlarged view

      Fig. Remove the 3 mounting bolts, then remove the compressor and clutch assembly

    8.  

  12.  
  13. Check the compressor oil, as follows:
    1. When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard:(oil capacity inside new cooler compressor assembly: 120 - 135 ml.) - (remaining oil amount in the removed cooler compressor assembly) = (oil amount to be removed when replacing)
      NOTE
      When checking the compressor oil level, observe the precautions on the cooler removal/installation. Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. If the remaining oil in the removed cooler compressor assembly is too small in volume, check for oil leakage. Be sure to use ND-OIL8 compressor oil.

    2.  

  14.  

To install:

  1. Install the compressor and magnetic clutch, as follows:
    1. Install the 3 bolts, nut, stud bolt and compressor and magnetic clutch. Tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Attach the connector.
    4.  

  2.  
  3. Install the cooler refrigerant suction hose, as follows:
    1. Remove the attached vinyl tape from the hose and port.
    2.  
    3. Install a new o-ring to the cooler refrigerant suction hose.
    4.  
    5. Apply clean ND-OIL8 or equivalent compressor oil to the o-ring and fit surface f the compressor and magnetic clutch.
    6.  
    7. Install the cooler refrigerant suction hose to the compressor and magnetic clutch with the nut. Tighten to 87 inch lbs. (9.8 Nm).
    8.  

  4.  
  5. Attach the cooler refrigerant discharge hose, as follows:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Install a new o-ring to the cooler refrigerant discharge hose.
    4.  
    5. Apply clean ND-OIL8 or equivalent compressor oil to the o-ring and fit surface f the compressor and magnetic clutch.
    6.  
    7. Install the cooler refrigerant discharge hose to the compressor and magnetic clutch with the nut and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  6.  
  7. Install the alternator, as outlined in the Engine Electrical Section.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Charge refrigerant, as outlined earlier in this section.
  12.  
  13. Start and warm up the engine
  14.  
  15. Leak test the refrigerant, as outlined in this section.
  16.  

3.0L And 3.3L Engines




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.

  1. Discharge the A/C refrigerant, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the v (cooler compressor to crankshaft pulley) belt, as outlined in the Engine Mechanical Section.
  6.  
  7. Separate the cooler refrigerant suction hose, as follows:
    1. Remove the bolt and disconnect the cooler refrigerant suction hose.
    2.  
    3. Remove the o-ring from the cooler refrigerant suction hose.
      NOTE
      Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the lines and ports while they are disconnected.



      Click image to see an enlarged view

      Fig. Disconnect the suction hose

    4.  

  8.  
  9. Separate the cooler refrigerant discharge hose, as follows:
    1. Remove the nut and disconnect the cooler refrigerant discharge hose.
    2.  
    3. Remove the o-ring from the cooler refrigerant discharge hose,
      NOTE
      Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering the lines and ports while they are disconnected.



      Click image to see an enlarged view

      Fig. Disconnect the discharge hose

    4.  

  10.  
  11. Remove engine under cover.
  12.  
  13. Remove compressor and magnetic clutch assembly, as follows:
    1. Disconnect the connector and clamp.
    2.  
    3. Remove the 2 bolts, nut and cooler compressor bracket.
    4.  
    5. Remove the 3 bolts and compressor and magnetic clutch assembly.

      Click image to see an enlarged view

      Fig. Remove the 2 bolts, nut and cooler compressor bracket

    6.  

  14.  
  15. Check the compressor oil, as follows:
    1. When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (oil capacity inside new cooler compressor assembly: 120 - 135 ml.) - (remaining oil amount in the Removed cooler compressor assembly) = (oil amount to be removed when replacing)
      NOTE
      When checking the compressor oil level, observe the precautions on the cooler removal/installation. Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure. If the remaining oil in the removed cooler compressor assembly is too small in volume, check for oil leakage. Be sure to use ND_OIL8 compressor oil.

    2.  

  16.  

To install:

  1. Install the compressor and magnetic clutch assembly:
    1. Install the compressor and magnetic clutch and 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Install the cooler compressor bracket, 2 bolts and nut.
    4.  
    5. Install the connector and clamp.
    6.  

  2.  
  3. Install the discharge hose, as follows:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Install a new o-ring to the cooler refrigerant discharge hose.
    4.  
    5. Apply clean ND-OIL8 or equivalent compressor oil to the o-ring and fit surface f the compressor and magnetic clutch.
    6.  
    7. Install the cooler refrigerant discharge hose to the compressor and magnetic clutch with the nut. Tighten to 87 inch lbs. (9.8 Nm).
    8.  

  4.  
  5. Install the suction hose, as follows:
    1. Remove the attached vinyl tape from the hose.
    2.  
    3. Install a new o-ring to the cooler refrigerant suction hose.
    4.  
    5. Apply clean ND-OIL8 or equivalent compressor oil to the o-ring and fit surface f the compressor and magnetic clutch.
    6.  
    7. Install the cooler refrigerant suction hose to the compressor and magnetic clutch with the bolt and tighten to 87 inch lbs. (9.8 Nm).
    8.  

  6.  
  7. Install and adjust the compressor to crankshaft pulley belt, as outlined in the Engine Mechanical Section. Fully tighten the belt.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Charge refrigerant, as outlined earlier in this section.
  12.  
  13. Start and warm up the engine
  14.  
  15. Leak test the refrigerant, as outlined in this section.
  16.  

Hybrid




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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