CONDENSER INSTALLATION

INSTALL COOLER DRYER
1. Using pliers, install the cooler dryer.
2. Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap.
  
  Compressor
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the cap.
4. Using a 14 mm socket hexagon wrench, install the cap to the modulator.
  
  Torque:
  
  2.9 N*m { 30 kgf*cm, 26 in.*lbf }
INSTALL COOLER CONDENSER ASSEMBLY
1. Install the cooler condenser with the 3 bolts as shown in the illustration.
  
  Torque:
  
  for bolt A
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
  
  for bolt B
  
  4.4 N*m { 44 kgf*cm, 39 in.*lbf }
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
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 discharge hose joint.
  
  Compressor
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the discharge hose.
4. Connect the discharge hose to the cooler condenser with the bolt.
  
  Torque:
  
  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.
CONNECT NO. 2 COOLER CONDENSER BRACKET
1. Install the 2 bolts and No. 2 cooler condenser bracket.
CONNECT NO. 1 COOLER CONDENSER BRACKET
1. Install the 2 bolts and No. 1 cooler condenser bracket.
INSTALL AIR CONDITIONING TUBE ASSEMBLY
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 air conditioning tube assembly joint.
  
  Compressor
  
  ND-OIL 8 or equivalent
3. Install the O-ring to the air conditioning tube assembly.
4. Connect the air conditioning tube assembly to the cooler condenser with the bolt.
  
  Torque:
  
  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.

Compressor
ND-OIL 8 or equivalent

Compressor
ND-OIL 8 or equivalent

Compressor
ND-OIL 8 or equivalent

CHARGE REFRIGERANT

SST: 09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard
Model Code	Air Conditioning Type	Cool Box	Refrigerant Charging Amount
Except the model codes below	w/o Rear Cooler	w/ Cool Box	600 +/-30 g (21.2 +/-1.1 oz.)
	w/o Rear Cooler	w/o Cool Box	550 +/-30 g (19.3 +/-1.1 oz.)
	w/ Rear Cooler	w/ Cool Box	800 +/-30 g (28.2 +/-1.1 oz.)
	w/ Rear Cooler	w/o Cool Box	770 +/-30 g (27.2 +/-1.1 oz.)
	w/ Rear Cooler for Cold Area Specification Vehicles	w/o Cool Box	720 +/-30 g (25.3 +/-1.1 oz.)
TRJ150L-GKMEKV TRJ150L-GKPEKV TRJ155L-GJPEKV GRJ150L-GKFEKV GRJ150L-GKAEKV KDJ150L-GKFEYV KDJ150L-GKAEYV	w/o Rear Cooler	w/ Cool Box	600 +/-30 g (21.2 +/-1.1 oz.)
	w/o Rear Cooler	w/o Cool Box	550 +/-30 g (19.3 +/-1.1 oz.) or 600 +/-30 g (21.2 +/-1.1 oz.) *1
	w/ Rear Cooler	w/ Cool Box	800 +/-30 g (28.2 +/-1.1 oz.)
	w/ Rear Cooler	w/o Cool Box	770 +/-30 g (27.2 +/-1.1 oz.)

*1: For vehicles with the 2TR-FE engine which have neither the rear cooler nor cool box, the refrigerant charging amount changes based on region.

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.

INSTALL RADIATOR ASSEMBLY
1. for 1GR-FE:
  
  Install the radiator assembly Click here.
2. for 2TR-FE:
  
  Install the radiator assembly Click here.
3. for 1KD-FTV, w/ DPF:
  
  Install the radiator assembly Click here.
4. for 1KD-FTV, w/o DPF:
  
  Install the radiator assembly Click here.
5. for 5L-E:
  
  Install the radiator assembly Click here.
ADD ENGINE COOLANT
1. for 1GR-FE:
  
  Add engine coolant Click here.
2. for 2TR-FE:
  
  Add engine coolant Click here.
3. for 1KD-FTV, w/ DPF:
  
  Add engine coolant Click here.
4. for 1KD-FTV, w/o DPF:
  
  Add engine coolant Click here.
5. for 5L-E:
  
  Add engine coolant Click here.
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.
INSPECT FOR ENGINE COOLANT LEAK
1. for 1GR-FE:
  
  Inspect for engine coolant leak Click here.
2. for 2TR-FE:
  
  Inspect for engine coolant leak Click here.
3. for 1KD-FTV:
  
  Inspect for engine coolant leak Click here.
4. for 5L-E:
  
  Inspect for engine coolant leak Click here.

CHECK FOR REFRIGERANT GAS LEAK

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

Text in Illustration
*1	Halogen Leak Detector
*a	Check for Leakage

Using a halogen leak detector, check the refrigerant line for leakage.

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