CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. A01CI1BE01
      Text in Illustration
      *1 Guide

      Insert the 2 guides.

    2. Temporarily tighten the cooler condenser assembly with the 2 bolts (A) and 2 nuts.

    3. Temporarily tighten the 2 bolts (B).

    4. Install the cooler condenser assembly with the 2 bolts (A) and the 2 bolts (B).

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf, for bolt A }
      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf, for bolt B }

    5. Connect the connector and clamp.

  2. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose and the connecting part of the cooler condenser.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose joint.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring to the air conditioning tube.

    4. Install the No. 1 cooler refrigerant discharge hose to the cooler condenser with the bolt.

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

  3. CONNECT LIQUID HOSE A


    1. Remove the attached vinyl tape from the liquid hose A and the connecting part of the cooler condenser.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the liquid hose A joint.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring onto the liquid hose A.

    4. Install the liquid hose A to the cooler condenser with the bolt.

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

  4. INSTALL FRONT STEP RETAINER RH


    1. Install the front step retainer RH with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  5. INSTALL STEP SUB-ASSEMBLY RH

    Click here

    Tech Tips

    Use the same procedure as for the LH side.

  6. CHARGE REFRIGERANT

    A01CH9RE02

    Tech Tips

    Charge refrigerant in accordance with the equipment manual.


    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
      Standard charge amount
      350 to 450 g (12.3 to 15.9 oz.)

      Note

      Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.

      A01CJ4EE01
      Text in Illustration
      *a High Pressure *b Charge Amount
      *c Regulation amount *d Bubble disappearing point in sight glass.
      *e Refrigerant margin *f Low charge
      *g Proper amount *h High charge

      Tech Tips


      • The relationship between the refrigerant charge amount and the pressure is as follows.

      • High Charge Range:

        If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.

      • Low Charge Range:

        A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.


      1. Install the caps onto the service valves on the refrigerant line.

  7. WARM UP ENGINE

    Note

    Warm up the engine at less than 2000 rpm for 1 minute or more after charging it with refrigerant.

  8. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation as follows:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        When the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

      Tech Tips

      It is impossible for the above pressure to be maintained if there is leakage.

    3. A01CH55E36
      Text in Illustration
      *1 Halogen Leak Detector

      Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.

    4. A01CH32E05
      Text in Illustration
      *1 Drain Hose
      *2 Halogen Leak Detector

      Bring the halogen leak detector close to the drain hose before performing the test.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for at least 15 minutes.

      • Place the halogen leak detector sensor under the drain hose.

      • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to other volatile gases.

      If such a reaction is unavoidable, the vehicle must be lifted up.

    5. If no gas leakage is detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.