CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY

    Tech Tips

    A 2-bolt type radiator can be used in place of a 4-bolt type radiator.


    1. A01NGKTE01

      Radiator (2-bolt type):


      1. Temporarily tighten the radiator assembly to the cooler condenser assembly with the 2 bolts.

      2. Fully tighten the 2 bolts in the order shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    2. A01NEZFE01

      Radiator (4-bolt type):


      1. Temporarily tighten the radiator assembly to the cooler condenser assembly with the 4 bolts.

      2. Fully tighten the 4 bolts in the order shown in the illustration.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    3. A01NESU

      Install the cooler condenser assembly with the 4 bolts.

      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-OIL 11 or equivalent
      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

  2. CONNECT OUTLET HYBRID RADIATOR HOSE


    1. A01NE7K

      Using pliers, grip the claws of the clip and slide the clip to connect the outlet hybrid radiator hose.

  3. CONNECT INLET HYBRID RADIATOR HOSE


    1. A01ND3G

      Using pliers, grip the claws of the clip and slide the clip to connect the inlet hybrid radiator hose.

  4. CONNECT DISCHARGE TUBE SUB-ASSEMBLY


    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 11 or equivalent

    3. Install the O-ring on the discharge tube sub-assembly.

      Note


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

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. A01NGUX

      Install the discharge tube sub-assembly on the cooler condenser assembly with the bolt.

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

  5. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    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 11 or equivalent

    3. Install the O-ring on the air conditioning tube and accessory assembly.

      Note


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

      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.

    4. A01NH3G

      Install the 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 }

  6. INSTALL UPPER RADIATOR SUPPORT


    1. A01NGA1E01
      Text in Illustration
      *1 Bolt

      Install the upper radiator support with the 5 bolts and connect the 3 clamps of the hood lock control cable to the upper radiator support.

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

  7. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A01NGOX

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

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

    2. Engage each clamp.

  8. INSTALL NO. 3 INVERTER BRACKET


    1. A01NCVA

      Install the No. 6 inverter bracket with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the hose and hose clamp to the No. 3 inverter bracket.

  9. INSTALL NO. 2 AIR CLEANER INLET


    1. A01ND8W

      Install the inlet No. 2 air cleaner with the 2 bolts.

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

  10. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. A01NG9A

      Install the intake air resonator sub-assembly with the 2 bolts.

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

    2. Connect the 3 water hose clamps to the intake air resonator sub-assembly.

  11. INSTALL SMOG VENTILATION SENSOR (w/ Smog Ventilation Sensor)


    1. A01NDOW

      Engage the guide.

    2. Install the smog ventilation sensor with the bolt.

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

    3. Connect the connector.

  12. INSTALL HIGH PITCHED HORN ASSEMBLY


    1. A01NDP3

      Install the high pitched horn assembly with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the connector.

  13. INSTALL HOOD LOCK ASSEMBLY (for LHD)


    1. A01NGOU

      Apply MP grease to the sliding areas of the lock.

    2. A01NHW4

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A01NFDN

      Install the hood lock assembly with the 2 bolts and hood lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01NGTZ

      Install a new hood lock nut cap.

  14. INSTALL HOOD LOCK ASSEMBLY (for RHD)


    1. A01NEBI

      Apply MP grease to the sliding areas of the lock.

    2. A01NH3T

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A01NF9X

      Install the hood lock assembly with the 2 bolts and hood lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01NDDY

      Install a new hood lock nut cap.

  15. INSTALL HOOD LOCK CONTROL CABLE COVER (for LHD)


    1. A01NEIY

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  16. INSTALL HOOD LOCK CONTROL CABLE COVER (for RHD)


    1. A01NDKG

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  17. INSTALL LOW PITCHED HORN ASSEMBLY


    1. A01NG9V

      Install the low pitched horn assembly with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the connector.

  18. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)


    1. A01NFIVE01

      Tighten the 3 bolts on the millimeter wave radar sensor assembly.

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

      Tech Tips

      Tighten the bolts in the order indicated in the illustration.

    2. Connect the connector.

  19. INSTALL FRONT BUMPER ASSEMBLY


    1. Connect the No. 1 clearance sonar connector. (w/ LEXUS Parking Assist-sensor System)

    2. Connect the headlight cleaner hose.

    3. Connect the fog light connector.

    4. A01NI0A

      Engage the 2 claws and install the front bumper assembly as shown in the illustration.

    5. A01NFNZ

      Engage the 4 claws to install the front bumper assembly.

      Tech Tips

      Use the same procedure for the RH side and LH side.

    6. A01NE3M

      Install the 6 clips.

    7. Install the 2 bolts and 2 screws.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    8. A01NDQH

      Install the front bumper seal bracket.

      Tech Tips

      Use the same procedure for the RH side and LH side.

    9. Install the screw.

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

      Tech Tips

      Use the same procedure for the RH side and LH side.

    10. A01NG8UE01

      Install the 2 pin hold clips.

      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 aligned vertically.

      Tech Tips

      Use the same procedure for the RH side and LH side.

  20. INSTALL HOOD CENTER CUSHION


    1. A01NE5D

      Install the 2 hood center cushions.

  21. ADD WINDSHIELD WASHER FLUID (w/ Headlight Cleaner System)


    1. Add washer fluid to the washer jar.

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  23. INSTALL REAR DECK FLOOR BOX


    1. A01NDSY

      Install the rear deck floor box with the 3 clips.

  24. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      A01NEL9E05
      Standard
      550 to 650 g (19.4 to 22.9 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the cooler compressor.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      • Avoid using the gauge manifold set that had been used for vehicles with conventional compressor oil (ND-OIL 8 or equivalent) as much as possible. This will cause compressor oil remaining in the manifold to enter the vehicle, resulting in insulation performance deterioration. A gauge manifold set that had been used 3 times or less can be reused if an appropriate one is not available.

      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. ADD COOLANT (for Inverter)

    Note


    • Do not reuse the drained coolant because it may contain foreign objects.

    • If the vehicle is driven with air in the inverter cooling system, the following DTCs may be set.

      DTC Code Detection Item
      P0A01-726 Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
      P0A04-725 Motor Electronics Coolant Temperature Sensor Circuit Intermittent
      P0A08-264 DC / DC Converter Status Circuit
      P0A78-284 Drive Motor "A" Inverter Performance
      P0A78-286 Drive Motor "A" Inverter Performance
      P0A79-692 Drive Motor "B" Inverter Performance
      P0A79-696 Drive Motor "B" Inverter Performance
      P0A7A-322 Generator Inverter Performance
      P0A7A-324 Generator Inverter Performance
      P0A93-346 Inverter Cooling System Performance
      P0A94-553 DC / DC Converter Performance
      P0A94-557 DC / DC Converter Performance
      P0AEE-277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance
      P0AF1-276 Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic
      P0AF3-676 Sensor of Rear Motor Inverter Temperature
      P0AF6-675 Drive Motor Inverter Temperature Sensor "B" Circuit Intermittent / Erratic
      P0BCD-315 Generator Inverter Temperature Sensor Circuit Range / Performance
      P0BD0-314 Generator Inverter Temperature Sensor Circuit Intermittent / Erratic
      P0C39-626 DC / DC Converter Temperature Sensor "A" Range / Performance
      P0C3C-625 DC / DC Converter Temperature Sensor "A" Intermittent / Erratic
      P0C3E-628 DC / DC Converter Temperature Sensor "B" Range / Performance
      P0C41-627 DC / DC Converter Temperature Sensor "B" Intermittent / Erratic
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance

    1. Add coolant to the reserve tank.

    2. A01NFAW

      Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

      Coolant quantity
      1.9 liter (2.0 US qts, 1.7 Imp. qts.)

    3. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

      3. On the intelligent tester, enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. Keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds.

        Standard
        Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

        Tech Tips

        Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

    4. When not using the intelligent tester:


      1. Turn the power switch on (READY). [*1]

      2. Turn the power switch off and keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds. [*2]

        Note


        • Be sure to turn the power switch off before adding SLLC.

        • Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

      3. Repeat steps [*1] and [*2] until air bleeding from the coolant system is completed.

        Standard
        Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

        Tech Tips

        Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

    5. A01NFAW

      Add coolant to the FULL mark of the reserve tank.

  26. WARM UP COMPRESSOR


    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 on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  27. 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 power 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. A01NDU8E31
      Text in Illustration
      *1 Inspect for Leak
      *2 Halogen Leak Detector

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

    4. A01NDJ6E08
      Text in Illustration
      *1 Halogen Leak Detector
      *2 Drain Hose

      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.

  28. INSPECT FOR COOLANT LEAK (for Inverter)


    1. Remove the reserve tank cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.

    2. A01NFFO

      Install the radiator cap tester.

    3. Pump the radiator cap tester to 118 kPa (1.2 kgf/ cm2, 17 psi), and then check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks.

    4. Reinstall the reserve tank cap.

  29. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A01NDNO

      Install the cool air intake duct seal with the 6 clips.

  30. INSTALL ENGINE ROOM SIDE COVER


    1. A01NHKG

      Install the engine room side cover with the 4 clips.

  31. INSTALL ENGINE ROOM SIDE COVER LH


    1. A01NH7B

      Engage the guide.

    2. Install the engine room side cover LH with the 4 clips.

  32. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT


    1. Prepare the vehicle:


      • Ensure there is no damage or deformation to the body around the fog lights.

      • Fill the fuel tank.

      • Make sure that the oil is filled to the specified level.

      • Make sure that the coolant is filled to the specified level.

      • Inflate the tires to the appropriate pressure.

      • Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions (except Taiwan).

      • Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are also removed (for Taiwan).

      • Sit a person of average weight (75 kg, 165 lb) in the driver's seat (except Taiwan).

      • Sit a person of average weight (55 kg, 121 lb) in the driver's seat (for Taiwan).

      • Vehicles with height adjustable suspension should set the vehicle height to the lowest setting prior to adjusting the headlight aim.

  33. PREPARE FOR FOG LIGHT AIMING


    1. A01NFMHE02

      Prepare the vehicle (except Taiwan and China):


      • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.

      • Place the vehicle at a 90° angle to the wall.

      • Create a 25 m (82 ft.) distance between the vehicle (fog light bulb center) and the wall.

      • Make sure that the vehicle is on a level surface.

      • Position the front wheels straight ahead.

      • Bounce the vehicle up and down to settle the suspension.

        Note

        A distance of 25 m (82 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

    2. A01NFMHE03

      Prepare the vehicle (for Taiwan and China):


      • Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.

      • Place the vehicle at a 90° angle to the wall.

      • Create a 10 m (32.8 ft.) distance between the vehicle (fog light bulb center) and the wall.

      • Make sure that the vehicle is on a level surface.

      • Position the front wheels straight ahead.

      • Bounce the vehicle up and down to settle the suspension.

        Note

        A distance of 10 m (32.8 ft.) between the vehicle (fog light bulb center) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

    3. Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.

    4. Draw a vertical line down the center of the screen (V line).

    5. Set the screen as shown in the illustration (except Taiwan and China).

      A01NHYCE02

      Tech Tips


      • Stand the screen perpendicular to the ground.

      • Align the V line on the screen with the center of the vehicle.

    6. Set the screen as shown in the illustration (for Taiwan and China).

      A01NHYCE03

      Tech Tips


      • Stand the screen perpendicular to the ground.

      • Align the V line on the screen with the center of the vehicle.

    7. A01NDDNE15

      Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.

      Tech Tips

      Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.


      1. H Line (Fog light height):

        Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights.

      2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights):

        Draw two vertical lines so that they intersect the H line at each center mark (Aligned with the center of the fog light bulbs).

  34. INSPECT FOG LIGHT AIMING


    1. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection.

      Note

      Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

    2. Start the engine.

    3. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration (except Taiwan and China).

      A01NCNUE07

      Tech Tips


      • If the alignment distance is 25 m (82 ft.):

        The upper edge of the hot zone for the fog light should be 500 mm (19.7 in.) below the H line.

      • If the alignment distance is 3 m (9.84 ft.):

        The upper edge of the hot zone for the fog light should be 60 mm (2.37 in.) below the H line.

    4. Turn on the fog lights and check if the upper edge of the hot zone for each fog light matches the upper edge as shown in the illustration (for Taiwan and China).

      A01NCNUE08

      Tech Tips


      • If the alignment distance is 10 m (32.8 ft.):

        The upper edge of the hot zone for the fog light should be 200 mm (7.88 in.) below the H line.

      • If the alignment distance is 3 m (9.84 ft.):

        The upper edge of the hot zone for the fog light should be 60 mm (2.37 in.) below the H line.

  35. ADJUST FOG LIGHT AIMING


    1. A01NH2AE01
      Text in Illustration
      *1 Aiming Screw

      Adjust the aim vertically:

      Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.

      Note

      The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

      Tech Tips

      If it is not possible to correctly adjust fog light aim, check bulb, fog light unit and fog light unit reflector installation.

  36. INSPECT HOOD SUB-ASSEMBLY


    1. Inspect the hood sub-assembly Click here.

  37. ADJUST HOOD SUB-ASSEMBLY


    1. Adjust the hood sub-assembly Click here.