CONDENSER INSTALLATION

INSTALL CONDENSER WITH RECEIVER ASSEMBLY
1. Install the condenser with receiver assembly to the hybrid radiator assembly with the 4 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Install the condenser with receiver assembly.
  
  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
  
  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.
INSTALL NO. 2 FAN SHROUD
1. Install the No. 2 fan shroud with the 2 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the 6 water by-pass hose clamps to the No. 2 fan shroud.
3. Connect the water by-pass hose to the radiator assembly.
4. Connect the No. 1 water by-pass hose to the radiator assembly.
INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
1. Install the hood lock support sub-assembly with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Install the 2 cushions to the radiator support RH and radiator support LH.
3. Install the radiator support RH and radiator support LH with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
4. Connect the 2 horn connectors.
5. Connect the 2 wire harness clamps and connector.
6. Connect the connector.
7. Connect the hood lock connector and hood lock control cable wire.
8. Connect the 3 wire harness clamps.
9. Connect the water by-pass hose clamp to the radiator support RH.
INSTALL NO. 1 INVERTER BRACKET
1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  14 N*m { 138 kgf*cm, 10 ft.*lbf }
CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Remove the attached vinyl tape from the air conditioning tube and accessory assembly and the connecting part of the condenser with receiver 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 matter.
  - 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. Install the air conditioning tube and accessory assembly on the condenser with receiver assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the attached vinyl tape from the discharge hose sub-assembly and the connecting part of the condenser with receiver assembly.
2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
  
  Compressor oil
  
  ND-OIL 11 or equivalent
3. Install the O-ring on the discharge hose sub-assembly.
  Note
  - Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign matter.
  - 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. Install the discharge hose sub-assembly on the condenser with receiver assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
CONNECT NO. 1 INVERTER COOLING HOSE
1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 1 inverter cooling hose.
CONNECT NO. 5 INVERTER COOLING HOSE
1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 5 inverter cooling hose.
INSTALL MILLIMETER WAVE RADAR SENSOR BRACKET (w/ Dynamic Radar Cruise Control System)
1. Install the millimeter wave radar sensor bracket with the bolt.
  
  Torque:
  
  6.2 N*m { 63 kgf*cm, 55 in.*lbf }
INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)
1. Tighten the 5 bolts on the millimeter wave radar sensor assembly.
  
  Torque:
  
  6.2 N*m { 63 kgf*cm, 55 in.*lbf }
  
  Tech Tips
  
  Tighten the bolts in the order indicated in the illustration.
2. Connect the connector.
INSTALL FRONT BUMPER ASSEMBLY

Click here

Capacity
40 cc (1.35 fl. oz.)

Compressor oil
ND-OIL 11 or equivalent

Compressor oil
ND-OIL 11 or equivalent

Compressor oil
ND-OIL 11 or equivalent

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Perform vacuum purging using a vacuum pump or appropriate equipment.

Charge the air conditioning system with refrigerant.

Refrigerant type
HFC-134a (R134a)

Text in Illustration
*a	Sub-cool System	*b	High Pressure
*c	Refrigerant Amount	*d	Standard charge amount
*e	Charge additional 100 g (3.5 oz.)	*f	Point where bubbles disappear
*g	Mean value in proper range	*h	Overcharged

Standard charge amount
440 to 500g (15.5 to 17.6oz.)

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 switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.
The refrigerant amount should be checked by quantity (weight).

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 air conditioning system.

ADD COOLANT (for Inverter)

Note

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

If the vehicle is driven with air in the inverter cooling system, damage may occur and the following DTCs may be stored.

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
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
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
P1557-887	DC / DC Converter Temperature Sensor Circuit

Slowly pour coolant into the reserve tank until it reaches the full line.

Coolant quantity

2.1 liters (2.2 US qts, 1.8 Imp. qts.)

Note

To prevent foreign matter such as dust or dirt from entering the cooling system, make sure to confirm that the container used to add coolant is clean and free of foreign matter such as dust or dirt.

Coolant quantity
2.1 liters (2.2 US qts, 1.8 Imp. qts.)

When using the GTS:

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

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

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

Tech Tips

If free spinning of the inverter water pump is detected for approximately 5 seconds, fail-safe control will be activated to suspend the operation of the pump for approximately 15 seconds and resume operation for approximately 4 seconds repeatedly. Operation of the inverter water pump will return to normal if coolant is added.
Loud noise made by the inverter water pump assembly and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

When not using the GTS:

Turn the power switch on (READY). [*1]
Turn the power switch off and add coolant to the full line because the coolant level drops as 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.

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

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

Tech Tips

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

After the air is completely bled from the cooling system, tighten the reserve tank cap.
Add coolant to the full line of the reserve tank.

WARM UP COMPRESSOR
1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
  
  Note
  
  To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

INSPECT FOR REFRIGERANT LEAK

After recharging the air conditioning system with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
Carry out the test under the following conditions:
- Power switch off.
- Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).
- Repeat the inspection 2 or 3 times.
- Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.
  
  Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm², 57 to 85 psi)

Text in Illustration
*1	Halogen Leak Detector
*a	Inspect for Leak

Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

Text in Illustration
*1	Halogen Leak Detector
*2	Drain Hose

Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

Tech Tips

After the blower motor has stopped, leave the cooling unit 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 checking for leaks.

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 check for a leak.
Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

Tech Tips

When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

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. Install a radiator cap tester.
3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm², 18 psi), and then check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator, inverter water pump assembly, inverter with converter, and hybrid vehicle transaxle assembly for leaks.
4. Reinstall the reserve tank cap.
ADJUST HOOD SUB-ASSEMBLY

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ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

Text in Illustration
*1	Approx. 10 m
*2	Approx. 14 m

Note

Perform measurements on a level surface.
Make sure that no large pieces of metal are within a 10 m (32.8 ft.) x 14 m (45.9 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.

Before adjusting the radar beam axis, prepare the vehicle as follows.
1. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).
2. Check the tire pressure and adjust it if necessary Click here.

Text in Illustration
*1	Level

Check and adjust the vertical direction of the radar sensor.

Remove dust, oil and foreign matter from the radar sensor's level rack.
Set a level on the radar sensor's level rack.

Text in Illustration
*1	FR
*2	LH
*3	Level
*4	Air Bubble
*5	Bolt A

Check that the level's air bubble is within the red frame.

OK
Level's air bubble is within the red frame.

If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the air bubble is within the red frame.

Tech Tips

The adjustable range within the level's red frame is +/-0.2°.

The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Upward direction: Turn screwdriver to negative (-) side	When screwdriver is turned once, adjustment changes by about 0.12°.
Vertical adjustment	Downward direction: Turn screwdriver to positive (+) side

Text in Illustration

*1 Millimeter Wave Radar Sensor

Adjust the reflector height.
1. Adjust the reflector so that the center of SST reflector is the same height as the millimeter wave radar sensor.
  
  SST
  
  09870-60000 ( 09870-60010 )
  
  09870-60040
  
  Tech Tips
  
  Prepare a 10 m (32.8 ft.) string, string with a sharp-pointed weight (plumb bob), and 5 m (16.4 ft.) tape measure.

Text in Illustration
*1	Millimeter Wave Radar Sensor

Place the reflector.

Hang the string (with weight) from the center of the vehicle's rear emblem. Mark the vehicle's rear center point on the ground. Repeat for the front of the vehicle.

Text in Illustration
*a	Adjust center by moving string to right and left
*b	Extend string through front center mark

Set one end of the 10 m (32.8 ft.) string on the vehicle's rear center point. Run the string over the vehicle's front center point to a position 5 m (16.4 ft.) beyond the vehicle's front center point, as shown in the illustration. Mark the 5 m (16.4 ft.) position.

Using a tape measure, measure 15.7 mm (0.618 in.) to the right of the 5 m (16.4 ft.) position. Place the reflector at that position.

Note

Perform the operation as precisely as possible.

Text in Illustration
*1	Reflector Placement Point	*2	Millimeter Wave Radar Sensor Position

Check the radar beam axis.
1. When using the GTS:
  1. Connect the GTS to the DLC3.
  2. Turn the power switch on (IG).
  3. Turn the GTS on, and turn the cruise control main switch on.
  4. Select "Connect to Vehicle".
  5. Select each item on the display screen and proceed to the next screen.
  6. Under "System Selection Menu", select "Radar Cruise".
  7. Select "Utility".
  8. Select "Beam Axis Adjustment" and proceed to the next screen.
    
    Tech Tips
    
    A buzzer will sound for 1 second.
  9. Follow the GTS display, and continue with the adjustment.
    
    CAUTION:
    
    Do not come within 20 cm (7.87 in.) of the radar sensor.
    Note
    - Turn the cruise control main switch on before pressing "Next".
    - Make sure there is at least 20 cm (7.87 in.) between the radar sensor and any nearby individuals.
2. Check the following items on the laser cruise divergence data screen.
  
  Note
  
  While using the GTS beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the GTS data. In such a case, the deviation is displayed on the combination meter's multi-information display.
  1. Confirm that the distance value is approximately 5 m (16.4 ft.).
    Tech Tips
    - A value between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.) should be indicated.
    - If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).
  2. Confirm that the left/right side value is between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.).
    
    Tech Tips
    
    If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).

Check and adjust the horizontal direction of the radar sensor.

Check that the divergence of the radar beam axis is 0°.

Standard

0° (Both right and left)

If the axis is not as specified, use a screwdriver to adjust the bolt B until the divergence of the radar beam axis is 0°.

Standard
0° (Both right and left)

Text in Illustration
*1	Bolt B

Based on the measured divergence of the beam axis, turn and adjust the bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Horizontal adjustment	Right direction: Turn screwdriver to positive (+) side.	When screwdriver is turned once, adjustment changes by about 0.07°.
Horizontal adjustment	Left direction: Turn screwdriver to negative (-) side.

Tech Tips

If "LEFT SIDE: 1.0°" is displayed, the divergence is 1.0° in the left direction. Turn the bolt B approximately 2.5 turns to the negative (-) side.
If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.

Select "Next". The driving learning value is automatically reset.

Tech Tips

A buzzer will sound for 10 seconds or more.
Disconnect the GTS from the DLC3.

Recheck and readjust the vertical direction of the radar sensor.

Text in Illustration

*1 Level

Set a level on the radar sensor's level rack.

Text in Illustration
*1	FR
*2	LH
*3	Level
*4	Air Bubble
*5	Bolt A

Check that the level's air bubble is within the red frame.

OK
Level's air bubble is within the red frame.

If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the level's air bubble is within the red frame.

Tech Tips

The adjustable range within the red frame is +/-0.2°.

The target angle is +0.2° (upward angle of 0.2°).

Result

Adjustment Direction	Adjustment Procedure	Adjustment Angle
Vertical adjustment	Upward direction: Turn screwdriver to negative (-) side	When screwdriver is turned once, adjustment changes by about 0.12°.
Vertical adjustment	Downward direction: Turn screwdriver to positive (+) side