CONDENSER INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


  • Centering bolts are used to mount the hood hinge to the vehicle body and hood. The hood cannot be adjusted with the centering bolts on. Substitute the centering bolts for standard bolts (with washers) when making adjustments.

  • A bolt without a torque specification is shown in the standard bolt chart.

    Click here

  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

B000WJLC17
*1 Centering Bolt
*2 Standard Bolt

PROCEDURE


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. B000W3S

      Install the sub radiator assembly to the cooler condenser assembly with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    2. B000Z0TC01
      B000WYJ Install in the Direction

      Insert the cooler condenser assembly and sub radiator assembly into the vehicle and into the guide.

      Note

      When inserting the cooler condenser assembly and sub radiator assembly, do not damage the cooler condenser assembly, sub radiator assembly and radiator assembly.

    3. B000VWX

      Attach the claw to install the cooler condenser assembly with sub radiator assembly.

  2. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape from the discharge hose sub-assembly and the connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil
      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. B000TTX

      Connect the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note


      • Do not apply excessive force to the discharge hose sub-assembly.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  3. CONNECT LIQUID TUBE SUB-ASSEMBLY A


    1. Remove the vinyl tape from the liquid tube sub-assembly A and the connecting part of the cooler condenser assembly.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor Oil
      Refrigerant Compressor Oil
      HFC-134a (R134a) ND-OIL 8 or equivalent
      HFO-1234yf (R1234yf) ND-OIL 12 or equivalent

    3. Install the O-ring to the liquid tube sub-assembly A.

      Note

      Keep the O-rings and O-ring fitting surfaces free of foreign matter.

    4. B000WTQ

      Connect the liquid tube sub-assembly A and No. 1 cooler refrigerant hose bracket to the cooler condenser assembly with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note


      • Do not apply excessive force to the liquid tube sub-assembly A.

      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)

  4. CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY


    1. B000WELC01
      *a View A
      *b Marking (Yellow)
      *c Hose Clip Installation Angle (120°)

      Connect the No. 2 radiator hose sub-assembly with its marking aligned with the positioning rib as shown in the illustration and install the hose clips within the range shown in the illustration.

      Note


      • Do not apply excessive force to the sub radiator assembly or No. 2 radiator hose sub-assembly.

      • Make sure the hose is securely inserted to the stopper. However, If the end of the hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

      • Install the hose clips 2 to 5 mm (0.0787 to 0.1969 in.) away from the end of the hose.

  5. CONNECT RADIATOR HOSE SUB-ASSEMBLY


    1. B000XOMC01
      *a View A
      *b Marking (Yellow)
      *c Hose Clip Installation Angle (120°)

      Connect the radiator hose sub-assembly with its marking aligned with the positioning rib as shown in the illustration and install the hose clips within the range shown in the illustration.

      Note


      • Do not apply excessive force to the sub radiator assembly or radiator hose sub-assembly.

      • Make sure the hose is securely inserted to the stopper. However, If the end of the hose is cut diagonally, it is acceptable for the entire circumference of the tip to not contact the stopper.

      • Install the hose clips 2 to 5 mm (0.0787 to 0.1969 in.) away from the end of the hose.

  6. INSTALL UPPER RADIATOR SUPPORT


    1. B000YULC01
      B000XM7 Bolt
      B000TT4 Radiator Support Cushion
      B000WYJ Install in this Direction

      Attach the upper radiator support to the 2 radiator support cushions and install the upper radiator support with the 5 bolts as shown in the illustration.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      When installing the upper radiator support, do not damage the cooler condenser assembly, sub radiator assembly and radiator assembly.

    2. for LHD:


      1. Attach the clamp to connect the engine room main wire.

        B000XTO

    3. for RHD:


      1. B000ZC7

        Attach the clamp to connect the engine room main wire.

  7. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH


    1. B000V6N

      Install the lower arm bracket brace sub-assembly RH with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  8. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH


    1. B000TZY

      Install the lower arm bracket brace sub-assembly LH with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  9. INSTALL LOW PITCHED HORN ASSEMBLY

    Click here

  10. INSTALL HOOD LOCK ASSEMBLY

    Click here

  11. INSTALL HOOD LOCK CONTROL CABLE COVER LH (for LHD)

    Click here

  12. INSTALL HOOD LOCK CONTROL CABLE COVER RH


    1. B000Z1Q

      Attach the clamp and install the hood lock control cable cover RH.

  13. INSTALL AIR (WITH ELEMENT) CLEANER ASSEMBLY WITH AIR CLEANER INLET

    Note

    Check that the air cleaner support is properly installed to the specified position on the air cleaner support bracket and upper radiator support.


    1. Install the air (with element) cleaner assembly with air cleaner inlet to the air cleaner support.

      B000Y94C01
      *1 Air Cleaner Support - -
      *a Clamp *b Protrusion
      *c Cutout - -
      B000XM7 No. 2 Air Cleaner Hose Clamp - -

    2. Attach the clamp as shown in the illustration.

      Installation Position
      Part Length
      A 310 mm (1.02 ft.)
      B 176 to 186 mm (6.9291 to 7.3228 in.)
      C 60.5 to 68.5 mm (2.3819 to 2.6968 in.)

    3. Align the cutout of the No. 2 air cleaner hose with the protrusion of the air (with element) cleaner assembly with air cleaner inlet and connect the air (with element) cleaner assembly with air cleaner inlet as shown in the illustration.

      Note

      Insert the air (with element) cleaner assembly with air cleaner inlet until it hits the stopper.

    4. Tighten the No. 2 air cleaner hose clamp as shown in the illustration.

      Note

      Install the intake No. 2 air cleaner hose clamp so that it contacts the No. 2 air cleaner hose positioning stopper.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      B000YQXC01
      *a View A *b Positioning Stopper
      *c Front of Vehicle *d Top of Vehicle

    5. Connect the connector.

    6. Attach the clamp.

    7. Tighten the No. 2 air cleaner hose clamp as shown in the illustration.

      Note

      Install the intake No. 2 air cleaner hose clamp so that it contacts the No. 2 air cleaner hose positioning stopper.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      B000X3ZC01
      *a View A *b Positioning Stopper
      *c Front of Vehicle *d Top of Vehicle

    8. Connect the 2 connectors.

    9. Attach the clamp.

    10. B000VSGC01
      *a Connector

      Connect the vacuum hose to the connector as shown in the illustration.

      Installation Position
      Part Length
      A 2 mm (0.0787 in.) or less.

    11. Install the vacuum hose to the guide.

  14. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH


    1. B000YOI

      Install the radiator support to crossmember brace sub-assembly RH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  15. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH


    1. B000YXY

      Install the radiator support to crossmember brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  16. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  17. ADD ENGINE COOLANT

    Click here

  18. INSPECT FOR COOLANT LEAK

    Click here

  19. INSTALL FRONT BUMPER ASSEMBLY

    Click here

  20. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

    Click here

  21. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  22. INSPECT FITTING OF HOOD SUB-ASSEMBLY

    Click here

  23. ADJUST HOOD SUB-ASSEMBLY

    Click here

  24. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR

    Click here

  25. WARM UP ENGINE

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  26. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a(R134a):

    Click here

    for HFO-1234yf(R1234yf):

    Click here

  27. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here