CONDENSER (for 1GR-FE) INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY

    A01J62S

    1. Install the cooler condenser assembly.

  2. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

    A01J6HNE01

    1. Install the upper radiator support sub-assembly with the 7 bolts.

      Torque:
      for bolt A
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for bolt B
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      for bolt C
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. INSTALL HOOD LOCK ASSEMBLY


    1. A01J45L

      Apply MP grease to the sliding areas of the lock.

    2. Connect the hood lock control cable.

    3. Install the hood lock with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 78 in.*lbf }

  4. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape attached to the air conditioning tube and accessory assembly and 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 and accessory assembly joint.

      Compressor oil
      ND-OIL 8 or equivalent

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

    4. Install the air conditioning tube and accessory assembly to the cooler condenser with the bolt.

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

  5. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the vinyl tape attached to the No. 1 cooler refrigerant discharge hose and connecting part of the cooler condenser.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

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

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

  6. INSTALL FRONT BUMPER COVER

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  7. CHARGE REFRIGERANT

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

    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      750 +-30 g (26.45 +-1.05 oz.)
      A01J472E02

      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 quantity, and not with the sight glass.

  8. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      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.

  9. CHECK FOR REFRIGERANT GAS LEAK


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

    2. Perform the operation under these conditions:


      • Stop the engine.


      • Secure good ventilation (the gas 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 to 6 kgf/cm2, 57 to 85 psi)

    3. A01J7J3E02

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

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.