CONDENSER REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine speed of approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. REMOVE FRONT BUMPER ASSEMBLY (for ALPHARD)

    Click here

  3. REMOVE FRONT BUMPER ASSEMBLY (for VELLFIRE)

    Click here

  4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for 2AZ-FE)


    1. A01CCQD

      Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the condenser.

    2. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  5. DISCONNECT NO. 3 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (for 2GR-FE)


    1. w/ No. 2 Air Conditioning Tube:


      1. A01CFCB

        Remove the bolt and disconnect the No. 3 air conditioning tube and accessory assembly from the condenser.

    2. w/o No. 2 Air Conditioning Tube:


      1. A01CE6E

        Remove the bolt and disconnect the No. 3 air conditioning tube and accessory assembly from the condenser.

    3. Remove the O-ring from the No. 3 air conditioning tube and accessory assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  6. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A (for 2AZ-FE)


    1. A01CGAK

      Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser.

    2. Remove the O-ring from the cooler refrigerant liquid pipe A.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  7. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A (for 2GR-FE)


    1. w/ No. 2 Air Conditioning Tube:


      1. A01CGAK

        Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser.

    2. w/o No. 2 Air Conditioning Tube:


      1. A01CETP

        Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser.

    3. Remove the O-ring from the cooler refrigerant liquid pipe A.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  8. REMOVE BATTERY CLAMP (for 2AZ-FE)


    1. Disconnect the positive (+) battery terminal from the battery.

    2. A01CDEA

      Remove the bolt and loosen the nut.

    3. Detach the 2 wire harness clamps.

    4. Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.

  9. REMOVE BATTERY CLAMP (for 2GR-FE)


    1. Disconnect the positive battery terminal from the battery.

    2. A01CDEA

      Remove the bolt and loosen the nut.

    3. Detach the 2 wire harness clamps.

    4. Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.

  10. REMOVE HOOD LOCK ASSEMBLY (for LHD)


    1. w/o Engine Hood Courtesy Switch:


      1. A01CBXD

        Remove the 3 bolts.

      2. A01CF0U

        Disconnect the hood lock control cable and remove the hood lock assembly.

    2. w/ Engine Hood Courtesy Switch:


      1. A01CDRQ

        Disconnect the connector.

      2. A01CEIJ

        Remove the 3 bolts.

      3. A01CEXC

        Disconnect the hood lock control cable and remove the hood lock assembly.

  11. REMOVE HOOD LOCK ASSEMBLY (for RHD)


    1. for ALPHARD:


      1. A01CF8O

        Remove the 3 bolts.

      2. A01CCXZ

        Disconnect the hood lock control cable and remove the hood lock assembly.

    2. for VELLFIRE:


      1. A01CATX

        Remove the 3 bolts.

      2. A01CAW6

        Disconnect the hood lock control cable and remove the hood lock assembly.

  12. REMOVE NO. 1 AIR CLEANER INLET (for 2AZ-FE)


    1. A01CBFW

      Remove the bolt and No. 1 air cleaner inlet.

  13. REMOVE NO. 1 AIR CLEANER INLET (for 2GR-FE)


    1. A01CBFW

      Remove the bolt and No. 1 air cleaner inlet.

  14. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH (for 2AZ-FE)


    1. A01CDLA

      Remove the 2 clips and No. 2 front bumper side seal LH.

  15. REMOVE NO. 2 FRONT BUMPER SIDE SEAL LH (for 2GR-FE)

    for ALPHARD: Click here

    for VELLFIRE: Click here

  16. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH (for 2AZ-FE)


    1. A01CFHW

      Remove the 2 clips and No. 2 front bumper side seal RH.

  17. REMOVE NO. 2 FRONT BUMPER SIDE SEAL RH (for 2GR-FE)

    for ALPHARD: Click here

    for VELLFIRE: Click here

  18. REMOVE HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY (for 2AZ-FE)


    1. w/ smog ventilation sensor:


      1. A01CCAK

        Disconnect the 5 wire harness clamps.

      2. Disconnect the 4 connectors.

    2. w/o smog ventilation sensor:


      1. A01CGG7

        Disconnect the 5 wire harness clamps.

      2. Disconnect the 3 connectors.

    3. A01CG3S

      Remove the 2 bolts and hood lock support brace sub-assembly.

  19. REMOVE HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY (for 2GR-FE)


    1. A01CCAK

      Disconnect the 5 wire harness clamps.

    2. Disconnect the 4 connectors.

    3. A01CG3S

      Remove the 2 bolts and hood lock support brace sub-assembly.

  20. DISCONNECT NO. 1 WATER BY-PASS PIPE


    1. A01CF7R

      Remove the bolt and disengage the No. 1 cooler refrigerant suction hose.

    2. A01CAYI

      Remove the 2 bolts and No. 1 water by-pass pipe.

  21. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for 2AZ-FE)


    1. A01CECY

      Disconnect the 6 wire harness clamps.

    2. A01CG8I

      Disconnect the clamp and 2 connectors.

    3. A01CG5M

      Remove the 4 bolts and upper radiator support sub-assembly.

    4. Remove the 2 radiator support cushions.

  22. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for 2GR-FE)


    1. A01CCLE

      Disconnect the 2 clamps and 2 cooling fan ECU connectors.

    2. A01CECY

      Disconnect the 6 wire harness clamps.

    3. A01CG81

      Remove the 4 bolts and upper radiator support sub-assembly.

    4. Remove the 2 radiator support cushions.

  23. REMOVE NO. 2 FAN SHROUD (for 2AZ-FE)


    1. A01CBTP

      Remove the 2 bolts, 2 claws and No. 2 fan shroud.

  24. REMOVE NO. 2 FAN SHROUD (for 2GR-FE)


    1. A01CDKW

      Remove the 2 bolts, 2 claws and the No. 2 fan shroud.

  25. REMOVE COOLER CONDENSER ASSEMBLY


    1. A01CFTT

      Remove the cooler condenser assembly as shown in the illustration.