CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. A01EJHD

      Install the cooler condenser assembly with the 4 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Tech Tips

      If the condenser is replaced with a new one, add compressor oil to the new condenser.

      Capacity
      40 cc (1.35 fl.oz.)
      Compressor oil
      ND-OIL 8 or equivalent

  2. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the attached vinyl tape from the tube 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
      ND-OIL 8 or equivalent

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

      Note

      Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.

    4. A01EKUG

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

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

  3. CONNECT COOLER REFRIGERANT DISCHARGE HOSE


    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 discharge hose.

      Note

      Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.

    4. A01EKQB

      Install the discharge hose on the cooler condenser assembly with the bolt.

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

  4. INSTALL UPPER RADIATOR SUPPORT


    1. A01EMP3

      Install the upper radiator support with the 4 bolts and connect the hood lock control cable clamp to the upper radiator support.

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

  5. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A01EM5H

      Install the hood lock support sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01ELA9

      Engage each clamp.

  6. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch)


    1. A01ELDL

      Apply MP grease to the sliding areas of the lock.

    2. Connect the hood lock control cable.

    3. A01EL24E01

      Install the hood lock assembly with the 3 bolts.

      Torque:
      <A> Centering Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Torque:
      <A> Standard Bolt
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
      Torque:
      <B>
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A01EJ4W

      Install a new hood lock nut cap.

  7. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch)


    1. A01ELDL

      Apply MP grease to the sliding areas of the lock.

    2. Connect the hood lock control cable.

    3. A01EJFGE01

      Install the hood lock assembly with the 3 bolts.

      Torque:
      <A> Centering Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Torque:
      <A> Standard Bolt
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
      Torque:
      <B>
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Connect the connector.

    5. A01EJ4W

      Install a new hood lock nut cap.

  8. INSTALL LOW PITCHED HORN ASSEMBLY


    1. Install the low pitched horn assembly with the bolt.

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

    2. Connect the connector.

  9. INSTALL HIGH PITCHED HORN ASSEMBLY


    1. Install the high pitched horn assembly with the bolt.

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

    2. Connect the connector.

  10. INSTALL RADIATOR GRILLE


    1. Engage the 6 claws.

    2. Install the 3 clips.

    3. Install the radiator grille with the 2 bolts.

  11. INSTALL INLET AIR CLEANER ASSEMBLY


    1. A01EKOK

      Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  12. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 12 clips.

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  14. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      450 to 550 g (15.9 to 19.4 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 turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      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 A/C system.

  15. WARM UP ENGINE


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

      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.

  16. INSPECT FOR REFRIGERANT LEAK


    1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Turn the ignition switch off.

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

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

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

    3. A01EMP0E29
      Text in Illustration
      *1 Halogen Leak Detector

      Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

    4. A01EJA9E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

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

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand 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 testing.

    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 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.

  17. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas *1 through *4 are within each standard range.

      A01EIQXE01
      Standard Clearance
      Area Measurement Area Measurement
      *1 6.9 to 9.9 mm (0.272 to 0.390 in.) *3 2.8 to 5.8 mm (0.110 to 0.228 in.)
      *2 7.6 to 10.6 mm (0.299 to 0.417 in.) *4 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)

  18. ADJUST HOOD SUB-ASSEMBLY

    Click here