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CONDENSER INSTALLATION

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  1. Click here

    INSTALL COOLER DRYER


    1. A015629E01

      Using pliers, install the cooler dryer.

    2. A0158HTE01

      Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install O-ring to the cap.

    4. A0158GGE01

      Using a 14 mm socket hexagon wrench, install the cap to the modulator.

      2.9 N*m 30 kgf*cm 26 in.*lbf
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    INSTALL COOLER CONDENSER ASSEMBLY


    1. A015BX3

      Install the cooler condenser as shown in the illustration.

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    INSTALL RADIATOR SUPPORT SUB-ASSEMBLY


    1. Install the radiator support with the 8 bolts.

      21.7 N*m 221 kgf*cm 16 ft.*lbf for bolt A
      9.8 N*m 100 kgf*cm 7 ft.*lbf for bolt B
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    INSTALL HOOD LOCK ASSEMBLY


    1. A01557B

      Apply MP grease to the sliding areas of the lock.

    2. Connect the hood lock control cable.

    3. Install the hood lock.

    4. Install the 2 bolts and nut.

      5.5 N*m 56 kgf*cm 49 in.*lbf

    5. Connect the connector.

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    INSTALL HOOD LOCK CONTROL CABLE COVER


    1. Attach the claw to install the cable cover.

    2. Install the 3 screws.

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    INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY


    1. Install the brace with the 3 bolts and nut.

      21.7 N*m 221 kgf*cm 16 ft.*lbf for bolt
      5.5 N*m 56 kgf*cm 49 in.*lbf for nut

    2. Install the hood lock nut cap.

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    INSTALL OIL COOLER ASSEMBLY (w/ Air Cooled Transmission Oil Cooler)


    1. A015AN3E01

      Temporarily install the oil cooler to the radiator support.

      Note:

      Securely attach the 2 claws of the oil cooler into the hole of the radiator support.

    2. Install the 4 bolts in the sequence shown in the illustration.

      12 N*m 122 kgf*cm 9 ft.*lbf
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    INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)


    1. Install the oil cooler air duct with the 4 bolts in the sequence shown in the illustration.

      4.9 N*m 50 kgf*cm 43 in.*lbf
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    INSTALL SHROUD BLOWER ASSEMBLY (w/ Rear Air Conditioning System)


    1. Install the shroud blower with the bolt.

      9.8 N*m 100 kgf*cm 7 ft.*lbf

    2. Connect the connector.

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    INSTALL LOW PITCHED HORN ASSEMBLY


    1. Connect the horn connector.

    2. A0157OM

      Install the horn with the bolt.

      19 N*m 194 kgf*cm 14 ft.*lbf
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    INSTALL HIGH PITCHED HORN ASSEMBLY


    1. Connect the horn connector.

    2. A0155HM

      Install the horn with the bolt.

      19 N*m 194 kgf*cm 14 ft.*lbf
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    CONNECT COOLER REFRIGERANT LIQUID PIPE A


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

    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 O-ring on the liquid pipe A.

    4. Connect the liquid pipe A to the cooler condenser with the bolt.

      5.4 N*m 55 kgf*cm 48 in.*lbf
      Note:

      • When tightening the bolt, do not allow any tools to contact the pipe.

      • When tightening the bolt, hold a part of the pipe near the connector.

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    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


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

    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 O-ring on the discharge hose.

    4. Connect the discharge hose to the cooler condenser with the 2 bolts.

      5.4 N*m 55 kgf*cm 48 in.*lbf
      Note:

      • When tightening the bolts, do not allow any tools to contact the pipe.

      • When tightening the bolts, hold a part of the pipe near the connector.

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    INSTALL FRONT BUMPER COVER


    1. for Standard:

      (Click here)

    2. w/ Winch:

      (Click here)

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    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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    CHARGE REFRIGERANT

    09985-20010 09985-02130 09985-02150 09985-02090 09985-02110 09985-02010 09985-02050 09985-02060 09985-02070

    1. Perform vacuum purging using a vacuum pump.

    2. A015D7VE19

      Charge refrigerant HFC-134a (R134a).

      Table 1. Standard:
      Condenser Core Thickness Air Conditioning Type Cool Box Refrigerant Charging Amount
      22 mm (0.866 in.) w/o Rear Cooler w/ Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/o Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 1010 +/-30 g (35.6 +/-1.1 oz.)
      w/o Cool Box 960 +/-30 g (33.9 +/-1.1 oz.)
      16 mm (0.630 in.) w/o Rear Cooler w/ Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      w/o Cool Box 920 +/-30 g (32.5 +/-1.1 oz.)
      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 200 g (7.05 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.

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    WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note:

      Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

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    CHECK FOR REFRIGERANT GAS LEAK


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

    2. Perform the operation under these conditions:


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

    3. A015C1XE21

      Using a halogen 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 halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

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    CHECK SRS WARNING LIGHT

    (Click here)

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    INSTALL UPPER RADIATOR SUPPORT SEAL


    1. A015BVKE02

      Install the radiator support seal with the 7 clips.