Electric A/C Compressor Repair Procedures

Removal

1. 1
   If the compressor is operating at its limit, start the engine and run the A/C for several minutes, then turn the engine off.
2. 2
   Disconnect the high voltage circuit. (Refer to Hybrid System Control - High Voltage Disabling)
3. 3
   Recover the refrigerant using a recovery/recharging station.

   If PVE or POE oil mixes with PAG oil in the system, dielectric breakdown may occur due to reduced volume resistivity, and the air conditioning compressor may be damaged and may not operate.

4. 4
   Loosen the mounting bolts and remove the lower cover (A).

   

5. 5
   Loosen the mounting bolts and clamp, then remove the wheel well cover (A).

   

6. 6
   Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to prevent moisture and dirt from entering.

   

7. 7
   Disconnect the compressor low voltage connector, then remove the 6 mounting bolts and the compressor (A).

   

Installation

1. 1
   Check the length of the compressor mounting bolts, then tighten them in the order A>B>C>D>E>F.

   Tightening torque: 10~15 N·m

   

2. 2
   Install in the reverse order of removal, and pay attention to the following items.

   • If installing a new compressor, drain all refrigerant oil from the removed compressor and measure its volume. Subtract the drained oil volume from 105–125 cm3 (3.7–4.4 oz). The result is the amount of oil to drain from the new compressor (through the suction port).
   • Replace the O-rings with new ones at each fitting and apply a thin coat of refrigerant oil before installation. Be sure to use the correct O-rings for R-134a to prevent leakage.
   • To avoid contamination, do not return spilled oil to the container, and never mix it with other refrigerant oils.
   • Immediately after use, close the container with its cap to prevent moisture absorption.

   If PVE or POE oil mixes with PAG oil in the system, dielectric breakdown may occur due to reduced volume resistivity, and the air conditioning compressor may be damaged and may not operate.

Inspection

Be sure to read and follow the "General Safety Information and Caution" before performing any work on the high voltage system. Failure to follow safety instructions may result in serious electrical injury.

1. 1
   Disconnect the high voltage cable. (Refer to "High Voltage Disconnection Procedure" in this group)
2. 2
   Remove the air cleaner assembly and air duct. (Refer to "Intake and Exhaust System" in Group EM)
3. 3
   Drain the coolant from the hybrid engine cooling system and remove the reservoir installed on the HPCU. (Refer to "Hybrid Engine Cooling System" in Group HM).
4. 4
   Disconnect the coolant inlet hose (A) and outlet hose (B).
5. 5
   Remove the HPCU protective cover (C).

   

6. 6
   Disconnect the power cable (A) from the HPCU.

   1. Pull the lever (B) in the direction of the arrow while pressing the hook (C).
   2. Press the lever (D) and pull out the power cable connector.

      

7. 7
   Disconnect the engine power cable (A) and the HSG power cable (B).

   1. Disconnect the connector by turning the lever (C) after pulling the lever (D).

      

8. 8
   Disconnect the electric A/C compressor power cable (A).

   1. Pull the lever (B) in the direction of the arrow.
   2. Press the hook (C) and pull out the engine power cable connector.

      

9. 9
   Measure the capacitors between the (+) and (-) terminals of the compressor connector.

   Specified value: 98? ±2%