CONDENSER INSTALLATION

INSTALL COOLER DRYER
1. Using pliers, install the cooler dryer to the modulator.
2. Sufficiently apply compressor oil to an O-ring and cap fitting surface.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Using a 14 mm straight hexagon wrench, install the cap to the cooler condenser core.
  
  Torque:
  
  2.9 N*m { 30 kgf*cm, 26 in.*lbf }
INSTALL COOLER CONDENSER ASSEMBLY
1. Install the cooler condenser assembly with the 4 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Tech Tips
  
  If the condenser is replaced with a new one, add compressor oil to the new condenser.
  
  Capacity
  
  40 cc (1.4 fl.oz.)
  
  Compressor oil
  
  ND-8 or equivalent
INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
1. Remove the attached vinyl tape from the hose 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
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the No. 1 cooler refrigerant discharge hose.
4. Install the No. 1 cooler refrigerant discharge hose on the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL LIQUID PIPE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the pipe 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 pipe joint.
  
  Compressor oil
  
  ND-OIL 8 or equivalent
3. Install the O-ring on the liquid pipe sub-assembly.
4. Install the liquid pipe sub-assembly on the cooler condenser assembly with the 2 bolts.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL OIL COOLER BRACKET
1. Install the oil cooler bracket with the 4 bolts.
  
  Torque:
  
  5.5 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL UPPER RADIATOR SUPPORT
1. Install the 5 bolts and the upper radiator support.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the 2 cooling fan ECM connectors.
3. Install the 3 clamps and the wire harness to the fan shroud.
4. Install the 2 clamps and the wire harness to the upper radiator support.
5. Install the 5 clamps and the wire harness to the upper radiator support.
6. Connect the 2 horn connectors.
7. Connect the smog ventilation sensor connector.
INSTALL HOOD LOCK ASSEMBLY
1. Apply MP grease to the sliding areas of the hood lock assembly.
2. Connect the hood lock control cable assembly and connector.
3. Install the hood lock assembly with the 2 bolts and hood lock nut.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL HOOD LOCK NUT CAP
1. Install a new hood lock nut cap.
INSTALL HOOD LOCK CONTROL CABLE COVER
1. Engage the clamp.
2. Install the hood lock control cable cover with the 3 screws.
INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)
1. Install the millimeter wave radar sensor with the 3 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Connect the connector.
INSTALL RADIATOR SUPPORT OPENING COVER
1. Engage the 4 clips and install the radiator support opening cover.
2. Install the 2 screws.
INSTALL FRONT BUMPER ENERGY ABSORBER
1. Install the front bumper energy absorber.
INSTALL FRONT BUMPER ASSEMBLY
1. Connect the 2 fog light connectors.
2. Connect the headlight cleaner hose to the windshield washer jar and pump assembly.
3. w/ LEXUS Parking Assist-Sensor system:
  1. Connect the ultrasonic sensor connector.
4. Engage the 10 claws and install the front bumper assembly.
5. Install the 2 clips and screw.
6. Install the 8 screws.
7. Install the screw.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
8. Install the 2 pin hold clips.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
INSTALL RADIATOR GRILLE PROTECTOR
1. Install the 2 radiator grille protectors.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly with air cleaner hose and lock the 2 clamps.
  
  Tech Tips
  
  Tightening torque for the hose clamp located between the air cleaner cap sub-assembly and air cleaner hose assembly is as follows.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Connect the air cleaner hose to the throttle body with the hose clamp.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Connect the 2 ventilation hoses with the 2 hose clamps.
4. Connect the mass air flow meter connector and wire harness clamp.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the No. 1 air cleaner inlet with the bolt and clip.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
CHARGE REFRIGERANT
1. Perform vacuum purging using a vacuum pump.
2. Charge refrigerant HFC-134a (R134a).
  
  Standard
  
  400 to 500g (14.10 to 17.63 oz.)
  
  SST
  
  09985-20010 ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
  Note
  
  Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
  
  Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
WARM UP ENGINE
1. Warm up the engine at less than 1570 rpm for 2 minutes or more after charging the refrigerant.
  
  Note
  
  Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
INSPECT FOR REFRIGERANT LEAK
1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
2. Perform the operation under the following conditions:
  - Stop the engine.
  - Secure good ventilation (the gas 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 compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
3. Using a gas leak detector, check the refrigerant line for leakage.
4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.
5. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Engage the 4 clips to install the V-bank cover sub-assembly.
  Note
  
  Be sure to engage the clips securely.
  
  Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
INSTALL ENGINE ROOM SIDE COVER LH (for LHD)
1. Install the engine room side cover LH with the 5 clips.
INSTALL ENGINE ROOM SIDE COVER LH (for RHD)
1. Install the engine room side cover LH with the 4 clips.
INSTALL ENGINE ROOM SIDE COVER RH (for LHD)
1. Install the engine room side cover RH with the 3 clips.
INSTALL ENGINE ROOM SIDE COVER RH (for RHD)
1. Install the engine room side cover RH with the 4 clips.
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 9 clips.
ADD WASHER FLUID
1. Add washer fluid to the washer jar.

Compressor oil
ND-OIL 8 or equivalent

Capacity
40 cc (1.4 fl.oz.)

Compressor oil
ND-8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

Compressor oil
ND-OIL 8 or equivalent

Standard
400 to 500g (14.10 to 17.63 oz.)

ADJUST MILLIMETER WAVE RADAR SENSOR (w/ Dynamic Radar Cruise Control System)

CAUTION:

Exposure to radio frequency emissions is hazardous to your health. It is hazardous to your health to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

Note

This device complies with FCC radio frequency emission regulations.
Perform measurements on a level surface.
Make sure that no large pieces of metal are within a 10 m (32.81 ft.) x 14 m (45.93 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.

Before adjusting the radar beam axis, prepare the vehicle as follows:
1. Check the tire pressure and adjust it if necessary.
2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

Check and adjust the vertical direction of the radar sensor.

Remove dust, oil, and foreign matter from the radar sensor's level rack.
Set a level on the radar sensor's level rack.

Check that the air bubble is within the red frame on the level.

OK
The air bubble is within the red frame on the level.
If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the air bubble is within the red frame.

Tech Tips

The adjustable range within the red frame on the level is +/- 0.2°.
The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Left direction: Turn bolt A to negative (-) side Right direction: Turn bolt A to positive (+) side	For every 8.4 rotations of adjustment bolt, sensor moves about 1°

Adjust the reflector height.
1. Adjust the reflector so that the center of the SST reflector is the same height as the millimeter wave radar sensor.
  
  SST
  
  09870-60000 ( 09870-60010 )
  
  09870-60040
  
  Tech Tips
  
  Prepare a 10 m (32.81 ft.) string, a string with a sharp-pointed weight (plumb bob), and a 5 m (16.41 ft.) tape measure.
Place the reflector.
1. Hang the string (with a weight) from the center of the vehicle rear emblem. Mark the vehicle rear center point on the ground. Repeat the same procedure for the front of the vehicle.
2. Set one end of the 10 m (32.82 ft.) string on the vehicle rear center point. Run the string over the vehicle front center point to a position 5 m (16.41 ft.) beyond the vehicle front center point, as shown in the illustration. Mark the 5 m (16.41 ft.) position.
3. Using the tape measure, measure 12 mm (0.47 in.) to the left of the 5 m (16.41 ft.) position. Place the reflector at that position.
  
  Note
  
  Perform the operation as precisely as possible.
Adjust the radar beam axis.
1. Connect the intelligent tester to the DLC3.
2. Turn the engine switch on (IG).
3. Turn the intelligent tester main switch on, and turn the cruise control main switch on.
  
  Tech Tips
  
  If an error message is displayed on the screen, initialization of the distance control ECU may not be completed. Initialize the distance control ECU Click here.

Check and adjust the horizontal direction of the radar sensor.

Check that the divergence of the radar beam axis is 0° .

Standard
0° (Both right and left)
If the divergence is not as specified, use a screwdriver to adjust bolt B until the divergence of the radar beam axis is 0°.

Based on the measured divergence of the beam axis, turn and adjust bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Horizontal adjustment	Right direction: Turn bolt B to positive (+) side Left direction: Turn bolt B to negative (-) side	For every 18.6 rotations of adjustment bolt, sensor moves about 1°

Tech Tips

If "LEFT SIDE: 1.0°" is displayed, the divergence is 1.0° to the left . Turn bolt B approximately 3 turns to the negative (-) side.
If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.

Reset the radar sensor's driving learning values. Prepare a piece of metal that can block radio waves, such as aluminum foil. Cover the radar sensor's right half with the aluminum foil for 10 seconds.

Note

Be sure to keep the reflector in place and make sure that there is nothing between the sensor's left half and the reflector.

Tech Tips

When the reset is completed, the buzzer sounds for 10 seconds.
Disconnect the intelligent tester from the DLC3.

Recheck and readjust the vertical direction of the radar sensor.

Set a level on the radar sensor's level rack.

Check that the air bubble is within the red frame on the level.

OK
The air bubble is within the red frame on the level.
If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the air bubble is within the red frame.

Tech Tips

The adjustable range within the red frame on the level is +/- 0.2°.
The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Left direction: Turn bolt A to negative (-) side Right direction: Turn bolt A to positive (+) side	For every 8.4 rotations of adjustment bolt, sensor moves about 1°

VEHICLE PREPARATION FOR FOG LIGHT AIMING
1. Prepare the vehicle:
  - Ensure that that there is no damage or deformation to the body around the fog lights.
  - Fill the fuel tank.
  - Make sure that the oil is filled to the specified level.
  - Make sure that the engine coolant is filled to the specified level.
  - Inflate the tires to the appropriate pressure.
  - Unload the trunk and vehicle, ensuring that the spare tire, tools, and jack are in their original positions.
  - Sit a person of average weight (75 kg, 165 lb) in the driver's seat.
  - Vehicles with height adjustable suspension should set the vehicle height to the lowest setting prior to adjusting the fog light aim.
PREPARATION FOR FOG LIGHT AIMING
1. Prepare the vehicle:
  - Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.
  - Place the vehicle at a 90° angle to the wall.
  - Create a 25 m (82 ft.) distance between the vehicle (fog light bulb center) and the wall.
  - Make sure that the vehicle is on a level surface.
  - Position the front wheels straight ahead.
  - Bounce the vehicle up and down several times to settle the suspension.
    
    Note
    
    A distance of 25 m (82 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)
2. Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.
3. Draw a vertical line down the center of the screen (V line).
4. Set the screen as shown in the illustration.
  Tech Tips
  
  Stand the screen perpendicular to the ground.
  
  Align the V line on the screen with the center of the vehicle.
5. Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.
  
  Tech Tips
  
  Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.
  1. H Line (Fog light height):
    
    Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights.
  2. V LH Line, V RH Line (Center mark positions of left-hand (LH) and right-hand (RH) fog lights):
    
    Draw two vertical lines so that they intersect the H line at each center mark aligned with the center of the fog light bulbs.
INSPECT FOG LIGHT AIMING
1. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection.
  
  Note
  
  Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat.
2. Start the engine.
3. Turn on the fog light and check if the cutoff line falls within the specified area in the following illustration.
ADJUST FOG LIGHT AIMING
1. Adjust the aim vertically:
  
  Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.
  
  Note
  
  The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it so that the final turn of the screw is in the clockwise direction.
  
  Tech Tips
  
  If it is not possible to correctly adjust the fog light aim, check bulb, fog light unit, and fog light unit reflector installation.