CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY

    A0119FU

    1. Engage the 2 claws and install the cooler condenser into the vehicle.

      Note

      Do not damage the condenser or radiator when installing the condenser.

      Tech Tips

      If a new cooler condenser is installed, add compressor oil to the condenser as follows.

      Capacity
      Add 40 cc (1.35 fl. oz.)
      Compressor oil
      ND-OIL8 or equivalent.

  2. INSTALL AIR CONDITIONING TUBE ASSEMBLY


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

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring onto the air conditioning tube.

    4. A011AJT

      Install the air conditioning tube onto the cooler condenser with the bolt.

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

  3. INSTALL COOLER REFRIGERANT DISCHARGE PIPE A


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

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the tube joint.

      Compressor oil
      ND-OIL8 or equivalent

    3. Install the O-ring onto the air conditioning tube.

    4. A0118M6

      Install the air conditioning tube onto the cooler condenser with the bolt.

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

  4. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

    A011AXK

    1. Engage the 2 guides and install the front bumper reinforcement

    2. Tighten the 8 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    3. A0119TQ

      Engage the 5 clamps.

  5. INSTALL WINDSHIELD WASHER JAR ASSEMBLY

    A01182N

    1. Connect the connectors.

    2. Connect the washer hose.

    3. Engage the guide and install the windshield washer jar.

    4. Engage the claw.

    5. Tighten the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  6. INSTALL HEADLIGHT ASSEMBLY RH (for 1ND-TV)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  7. INSTALL RADIATOR SUPPORT EXTENSION LH

    A01172R

    1. Engage the 2 claws and install the radiator support extension.

  8. INSTALL RADIATOR SUPPORT EXTENSION RH

    Tech Tips

    Use the same procedure as for the LH side.

  9. INSTALL NO. 2 RADIATOR SIDE AIR SEAL

    A0117PX

    1. Engage the 2 claws and install the radiator side air seal.

  10. INSTALL NO. 1 RADIATOR SIDE AIR SEAL

    Tech Tips

    Use the same procedure as for the No. 2 side.

  11. INSTALL FRONT BUMPER ENERGY ABSORBER

    A011AT1

    1. Engage the 2 guide and install the front bumper energy absorber.

  12. INSTALL FRONT BUMPER SIDE RETAINER RH (for 1ND-TV)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  13. INSTALL RADIATOR SUPPORT UPPER ABSORBER

    A011BBL

    1. Engage the 7 claws and install the radiator support upper absorber.

  14. INSTALL FRONT BUMPER COVER

    A0117J9

    1. Engage the 6 claws and install the front bumper cover.

    2. A011AST

      Tighten the 4 screws.

    3. A0119NZ

      Install the 5 clips.

    4. A01180SE01

      Install the pin hold clip.

      Note

      Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertically.

      Tech Tips

      Use the same procedure for the RH and LH sides.

  15. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

    A011BPD

    1. Install the front wheel opening extension pad with the 2 screws.

  16. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    Tech Tips

    Use the same procedure as for the LH side.

  17. CHARGE REFRIGERANT

    A011BVPE02

    Tech Tips

    Charge refrigerant in accordance with the equipment manual.


    1. Perform vacuum purging using a vacuum pump.

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

      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )
      Standard
      330 to 390 g (11.6 to 13.8 oz.)

      Note


      • Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear.

        The volume of refrigerant should be measured, not checked with the sight glass.

      Tech Tips


      • The relationship between the refrigerant charge amount and the pressure is as follows.

        A011AJAE01

      • High Charge Range:

        If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.

      • Low Charge Range:

        A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.


      1. Install the caps onto the service valves on the refrigerant line.

  18. WARM UP ENGINE

    Note

    Warm up the engine at less than 2000 rpm for 1 minute or more after charging it with refrigerant.

  19. INSPECT FOR REFRIGERANT LEAK


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

    2. Perform the operation as follows:


      • 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 the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

      Tech Tips

      It is impossible for the above pressure to be maintained if there is leakage.

    3. Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.

    4. A0117AXE04
      Text in illustration
      *1 Drain hose
      *2 Halogen leak detector

      Bring the halogen leak detector close to the drain hose before performing the test.

      Tech Tips


      • After the blower motor has stopped, leave the cooling unit for at least 15 minutes.

      • Place 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 other volatile gases.

      If such a reaction is unavoidable, the vehicle must be lifted up.

    5. If no gas leakage is detected from the drain hose, remove the blower motor 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.