CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. A01CDWG

      Install the cooler condenser assembly as shown in the illustration.

      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-8 or equivalent

  2. INSTALL NO. 2 FAN SHROUD (for 2AZ-FE)


    1. A01CBTP

      Install the No. 2 fan shroud with the 2 bolts and 2 claws.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  3. INSTALL NO. 2 FAN SHROUD (for 2GR-FE)


    1. A01CDKW

      Install the No. 2 fan shroud with the 2 bolts and 2 claws.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  4. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for 2AZ-FE)


    1. Install the 2 radiator support cushions.

    2. A01CG5M

      Install the upper radiator support sub-assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. A01CECY

      Connect the 6 wire harness clamps.

    4. A01CG8I

      Connect the 2 connectors and clamp.

  5. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for 2GR-FE)


    1. Install the 2 radiator support cushions.

    2. A01CG81

      Install the upper radiator support sub-assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. A01CECY

      Connect the 6 wire harness clamps.

    4. A01CCLE

      Connect the 2 cooling fan ECU connectors and 2 clamps.

  6. CONNECT NO. 1 WATER BY-PASS PIPE


    1. Engage the No. 1 cooler refrigerant suction hose with the bolt.

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

    2. Install the No. 1 water by-pass pipe with the 2 bolts.

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

  7. INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY (for 2AZ-FE)


    1. A01CG3S

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. w/ smog ventilation sensor:


      1. A01CCAK

        Connect the 4 connectors.

      2. Connect the 5 wire harness clamps.

    3. w/o smog ventilation sensor:


      1. A01CGG7

        Connect the 3 connectors.

      2. Connect the 5 wire harness clamps.

  8. INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY (for 2GR-FE)


    1. A01CG3S

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    2. A01CCAK

      Connect the 4 connectors.

    3. Connect the 5 wire harness clamps.

  9. INSTALL NO. 2 FRONT BUMPER SIDE SEAL RH (for 2AZ-FE)


    1. A01CFHW

      Install the No. 2 front bumper side seal RH with the 2 clips.

  10. INSTALL NO. 2 FRONT BUMPER SIDE SEAL RH (for 2GR-FE)

    for ALPHARD: Click here

    for VELLFIRE: Click here

  11. INSTALL NO. 2 FRONT BUMPER SIDE SEAL LH (for 2AZ-FE)


    1. A01CDLA

      Install the No. 2 front bumper side seal LH with the 2 clips.

  12. INSTALL NO. 2 FRONT BUMPER SIDE SEAL LH (for 2GR-FE)

    for ALPHARD: Click here

    for VELLFIRE: Click here

  13. INSTALL NO. 1 AIR CLEANER INLET (for 2AZ-FE)


    1. A01CBFW

      Install the No. 1 air cleaner inlet with the bolt.

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

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


    1. A01CBFW

      Install the No. 1 air cleaner inlet with the bolt.

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

  15. INSTALL HOOD LOCK ASSEMBLY (for LHD)


    1. w/o Engine Hood Courtesy Switch:


      1. A01CAS8

        Apply MP grease to the sliding areas of the lock.

      2. A01CF0U

        Connect the hood lock control cable.

      3. A01CBXD

        Install the hood lock assembly with the 3 bolts.

        Torque:
        7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    2. w/ Engine Hood Courtesy Switch:


      1. A01CEL4

        Apply MP grease to the sliding areas of the lock.

      2. A01CEXC

        Connect the hood lock control cable.

      3. A01CEIJ

        Install the hood lock assembly with the 3 bolts.

        Torque:
        7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
      4. A01CDRQ

        Connect the connector.

  16. INSTALL HOOD LOCK ASSEMBLY (for RHD)


    1. for ALPHARD:


      1. A01CAS8

        Apply MP grease to the sliding areas of the lock.

      2. A01CCXZ

        Connect the hood lock control cable.

      3. A01CF8O

        Install the hood lock assembly with the 3 bolts.

        Torque:
        7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    2. for VELLFIRE:


      1. A01CDC8

        Apply MP grease to the sliding areas of the lock.

      2. A01CAW6

        Connect the hood lock control cable.

      3. A01CATX

        Install the hood lock assembly with the 3 bolts.

        Torque:
        7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

  17. INSTALL BATTERY CLAMP (for 2AZ-FE)


    1. A01CDEA

      Attach the hook of the battery clamp to the front battery bracket.

    2. Temporarily install the nut and bolt.

    3. Adjust the battery clamp position.

    4. Tighten the nut and bolt.

      Torque:
      Nut
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }
      Bolt
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

    5. Attach the 2 wire harness clamps.

    6. Connect the positive (+) battery terminal to the battery.

  18. INSTALL BATTERY CLAMP (for 2GR-FE)


    1. A01CDEA

      Attach the hook of the battery clamp to the front battery bracket.

    2. Temporarily install the nut and bolt.

    3. Adjust the battery clamp position.

    4. Tighten the nut and bolt.

      Torque:
      Nut
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }
      Bolt
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

    5. Attach the 2 wire harness clamps.

    6. Connect the positive battery terminal to the battery.

  19. CONNECT COOLER REFRIGERANT LIQUID PIPE A


    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 cooler refrigerant liquid pipe A.

      Note

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

    4. Install the cooler refrigerant liquid pipe A on the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  20. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (for 2AZ-FE)


    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 No. 1 cooler refrigerant discharge hose.

      Note

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

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

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


    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 No. 3 air conditioning tube and accessory assembly.

      Note

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

    4. Install the No. 3 air conditioning tube and accessory assembly on the cooler condenser assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  22. INSTALL FRONT BUMPER ASSEMBLY (for ALPHARD)

    Click here

  23. INSTALL FRONT BUMPER ASSEMBLY (for VELLFIRE)

    Click here

  24. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      A01CBXEE04
      w/o No. 2 Air Conditioning Tube
      780 to 880 g (27.5 to 31.0 oz.)
      w/ No. 2 Air Conditioning Tube
      700 to 800 g (24.7 to 28.2 oz.)
      SST
      09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02140, 09985-02080 )

      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.

      • Approximately 200 g (7.1 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the 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 A/C system.

  25. 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.

  26. 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 engine 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 to 6 kgf/cm2, 57 to 85 psi)

    3. A01CFS3E26

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

    4. A01CE7VE07

      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.

  27. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas A through H are within each standard range.

      A01CF70E01
      Text in Illustration
      *A for ALPHARD *B for VELLFIRE
      Standard Clearance
      Area Measurement Area Measurement
      A 5.9 to 9.9 mm (0.232 to 0.390 in.) E 2.2 to 6.2 mm (0.0866 to 0.244 in.)
      B 3.4 to 7.4 mm (0.134 to 0.291 in.) F 2.3 to 6.3 mm (0.0906 to 0.248 in.)
      C 2.3 to 5.3 mm (0.0906 to 0.209 in.) G 2.3 to 5.3 mm (0.0906 to 0.209 in.)
      D -1.4 to 1.6 mm (-0.0551 to 0.0630 in.) H -1.4 to 1.6 mm (-0.0551 to 0.0630 in.)

  28. ADJUST HOOD SUB-ASSEMBLY


    1. Horizontally and vertically adjust the hood.


      1. A01CFMK

        Loosen the 4 hinge bolts of the hood.

      2. Adjust the clearance between the hood and front fender by moving the hood.

      3. Tighten the 4 hinge bolts after the adjustment.

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

    2. Adjust the height of the front end of the hood using the cushion rubbers.


      1. A01CD4M

        Adjust the cushion rubbers so that the heights of the hood and fender are aligned.

        Tech Tips

        Raise or lower the front end of the hood by turning the cushion rubbers.

    3. Adjust the hood lock.


      1. A01CGAI

        Loosen the 3 bolts.

      2. Tighten the bolts after the adjustment.

        Torque:
        7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

      3. Check that the striker can engage with the hood lock smoothly.