CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. A01HQ66

      Engage the 2 guides as shown in the illustration.

    2. 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-OIL 8 or equivalent

  2. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape from the tube and the connecting part of the cooler condenser assembly.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.

    4. Install the air conditioning tube and accessory assembly to the cooler condenser assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  3. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the vinyl tape from the pipe and the connecting part of the cooler condenser assembly.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

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

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  4. INSTALL RADIATOR SIDE DEFLECTOR LH


    1. Engage the guide and 3 claws to install the radiator side deflector LH.

  5. INSTALL RADIATOR SIDE DEFLECTOR RH


    1. Engage the guide and 3 claws to install the radiator side deflector RH.

  6. INSTALL UPPER RADIATOR SUPPORT (for 2AR-FE)


    1. Install the 2 radiator support cushions to the radiator assembly.

    2. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the 2 connectors.

  7. INSTALL UPPER RADIATOR SUPPORT (for 2GR-FE)


    1. Install the 2 radiator support cushions to the radiator assembly.

    2. Install the upper radiator support with the 5 bolts and connect the hood lock control cable clamp to the upper radiator support.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the 2 connectors.

  8. INSTALL HOOD LOCK ASSEMBLY


    1. A01HP78

      Apply MP grease to the sliding areas of the lock.

    2. Connect the hood lock control cable assembly.

    3. Install the hood lock assembly with the 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    4. w/ Engine Hood Courtesy Switch:


      1. Connect the connector.

  9. INSTALL RADIATOR RESERVE TANK ASSEMBLY (for 2AR-FE)


    1. Install the radiator reserve tank with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the radiator reserve tank hose.

  10. INSTALL RADIATOR RESERVE TANK ASSEMBLY (for 2GR-FE)


    1. Install the radiator reserve tank with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the radiator reserve tank hose.

  11. INSTALL INLET AIR CLEANER ASSEMBLY (for 2AR-FE)


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  12. INSTALL INLET NO. 1 AIR CLEANER (for 2GR-FE)


    1. A01HPT1

      Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.

    2. Engage the pin to the radiator support.

  13. INSTALL INLET NO. 2 AIR CLEANER (for 2GR-FE)


    1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 2 wire harness clamps and vacuum hose clamp.

  14. INSTALL BATTERY (for 2GR-FE)


    1. Install the battery and battery tray.

    2. Install the battery clamp with the bolt and nut.

      Torque:
      Bolt
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Connect the cable to the positive (+) battery terminal.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

  15. INSTALL FRONT BUMPER ASSEMBLY

    Click here

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  17. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A01HOLNE11
      Text in Illustration
      *a Sub-cool System *b High Pressure
      *c Refrigerant Amount *d Standard charge amount
      *e Charge additional 100g (3.5oz.) *f Point where bubbles disappear
      *g Mean value in proper range *h Overcharged
      Standard charge amount
      480 to 580g (16.9 to 20.4oz.)
      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 turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      • The graph above is shown for reference only. This vehicle is not equipped with a sight glass.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an air conditioning system.

  18. WARM UP ENGINE


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

  19. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Ignition switch off.

      • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

      • Repeat the inspection 2 or 3 times.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

        Pressure when the compressor is off: approx. 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi)

    3. A01HQV0E40
      Text in Illustration
      *1 Halogen Leak Detector
      *a Inspect for Leak

      Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

    4. A01HN5YE08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

      • Bring 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 volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks.

    5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

    6. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

  20. ADJUST HOOD SUB-ASSEMBLY

    Click here