ELECTRIC COMPRESSOR REMOVAL/INSTALLATION

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Oil and chemical type

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

•  If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.

•  Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See HIGH VOLTAGE SERVICE CAUTIONS.) (See HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)

Warning

•  The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.

•  If the cooling system cap is removed while the EV system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the cooling system cap when the EV system is cool.

•  When removing the cooling system cap, cover the cooling system cap with a clean cloth and remove it slowly.

•  The cooling fan may suddenly start operating regardless of the main power switch position. Keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury, or damage to the cooling fan. When servicing the cooling fan or parts near the cooling fan, ensure the following.

―  Do not perform normal charging or quick charging

―  Do not select high voltage battery cooling on center display after EV system stops

―  Do not open/close doors frequently with main power switched OFF

―  Switch to connected vehicle maintenance mode (MyMazda App connected vehicle)

―  Cancel climate control timer

―  Operate center display and turn off battery heater operation

1.  Verify that the READY indicator on the instrument cluster is not illuminated.

•  If the READY indicator is turned on, switch the main power OFF.

2.  Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3.  Partially peel back the cover.

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4.  Remove the service hole cover.

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5.  Wear insulating gloves and remove the service plug using the following procedure.

Warning

[High voltage]

•  Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.

•  Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.

•  Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.

Caution

[High voltage]

•  After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.

•  When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.

•  Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.

(1)  Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)

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(2)  Raise the lever.

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(3)  Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.

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(4)  Hold the lever and pull the service plug straight up.

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6.  After removing the service plug, leave it for 10 min.

7.  Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.

(1)  Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)

Caution

[High voltage]

•  Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.

•  Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.

•  Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.

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(2)  Remove the terminal cover. (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

(3)  Measure the voltage at the high voltage cable connection.

Note

•  Use a tester with a measurement range of 450 V DC or more.

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―  Verify that the tester indicates 0 V and go to the next step.

•  Verify that the waterproof rubber on the terminal cover is securely installed.

•  Be careful not to damage the interlock, and install it securely.

(4)  Install the terminal cover. (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

8.  Collect the refrigerant. (See REFRIGERANT RECOVERY.)

9.  Remove the following parts.

(1)  Flexible hose No.1 (See FLEXIBLE HOSE REMOVAL/INSTALLATION.)

(2)  Flexible hose No.3 (See FLEXIBLE HOSE REMOVAL/INSTALLATION.)

10.  Disconnect the connectors.

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11.  Remove the bolt.

12.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

13.  Remove the bolts.

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Caution

•  If moisture or foreign matter enters the refrigeration cycle, cooling ability will be lowered and abnormal noise or other malfunction could occur. After removing the refrigeration system parts, plug the opening immediately.

14.  Remove the electric compressor being careful not to allow compressor oil to spill. (See Electric Compressor Installation Note.)

15.  Install in the reverse order of removal.

Caution

•  Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.

16.  Wear insulating gloves and install the service plug using the following procedure.

(1)  Insert the service plug as far as it will go.

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(2)  Depress the lever completely.

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(3)  Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.

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17.  Install the service hole cover.

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18.  Close the cover.

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19.  Charge the refrigerant. (See REFRIGERANT CHARGING.)

20.  Perform the air-conditioning system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)

Electric Compressor Installation Note

Caution

•  Compressor oil has high moisture absorbency so if left for a long time, it absorbs moisture, which may lead to a decrease in A/C performance. Drain and refill the compressor oil within 10 min.

1.  While rotating the new electric compressor body, drain the oil into a clean measuring container. Be careful not to allow the oil extracted here to become contaminated, since it will be injected into the compressor again.

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2.  While rotating the old electric compressor body, drain the oil into another clean measuring container.

3.  Compare the quantities of the two oils. The oil quantity drained from the new electric compressor should be more than that from the old electric compressor.

4.  Make the amount of oil extracted in Step 1 equal to the amount of oil extracted from the old electric compressor and pour it into the new electric compressor.

Compressor oil