CONDENSER INSTALLATION


  1. INSTALL CONDENSER ASSEMBLY WITH RECEIVER

    A00DTJ8

    1. Install the condenser assembly with receiver 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 (1.4 fl.oz)
      Compressor oil
      ND-OIL 8 or equivalent

  2. CONNECT SUCTION PIPE SUB-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 8 or equivalent

    3. Install the O-ring to the suction pipe sub-assembly.

    4. A00DRY0

      Install the suction pipe sub-assembly to the cooler condenser assembly with the bolt.

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

  3. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the hose 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 hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

    4. A00DSJH

      Install the discharge hose sub-assembly to the cooler condenser assembly with the bolt.

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

  4. INSTALL NO. 2 FAN SHROUD

    A00DUULE01
    Text in Illustration
    *1 except ZR Series Engine
    *2 for ZR Series Engine
    *3 for Automatic Transaxle, CVT

    1. Attach the 2 claws to install the fan shroud.

    2. Install the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. for ZR Series Engine:


      1. for Automatic Transaxle, CVT:

        Attach the clamps to install the No. 3 water by-pass hose.

      2. for Manual Transaxle:

        Attach the clamp to install the No. 3 water by-pass hose.

  5. INSTALL RADIATOR SUPPORT CUSHION

    A00DT0M

    1. Install the 2 cushions.

  6. INSTALL RADIATOR SUPPORT UPPER


    1. Install the radiator support upper with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 9 ft.*lbf }

    2. Attach the 2 clamps to install the No. 2 water by-pass hose.

    3. Connect the 2 horn connectors.

      A00DR8M

  7. INSTALL HOOD LOCK ASSEMBLY

    A00DQBYE01
    Text in Illustration
    *1 w/o Engine Hood Courtesy Switch
    *2 w/ Engine Hood Courtesy Switch

    1. Install the hood lock with the 3 bolts

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

    2. w/ Engine Hood Courtesy Switch:

      Connect the connector.

  8. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    A00DSTM

    1. Install the battery clamp with the bolt.

  9. INSTALL NO. 1 WATER HOSE CLAMP BRACKET

    A00DSJI

    1. Install the hose clamp bracket with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  10. 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
      440 +/-30 g (15.5 +/-1.1 oz)
      A00DTEOE26

      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 200 g (7.05 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  11. INSPECT HOOD SUB-ASSEMBLY


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

      A005UW1E01
      Standard
      Area Specified Condition Area Specified Condition
      A 3.2 to 6.2 mm (0.126 to 0.244 in.) E 4.0 to 7.0 mm (0.158 to 0.276 in.)
      B -0.5 to 2.5 mm (-0.0197 to 0.0984 in.) F -0.9 to 2.1 mm (-0.0354 to 0.0827 in.)
      C 2.7 to 5.7 mm (0.106 to 0.224 in.) G 3.7 to 6.7 mm (0.146 to 0.264 in.)
      D -0.5 to 2.5 mm (-0.0197 to 0.0984 in.) H -0.5 to 2.0 mm (-0.0197 to 0.0787 in.)

  12. ADJUST HOOD SUB-ASSEMBLY


    1. A003EFE

      Adjust the hood position.


      1. Loosen the 4 hinge bolts on the hood.

      2. Move the hood and adjust the clearance between the hood and front fender.

      3. Tighten the 4 hinge bolts on the hood after the adjustment.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003DNO

      Adjust the cushion rubber so that the hood and fender are aligned.

      Tech Tips

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

    3. Adjust the hood lock.


      1. A003D6O

        Loosen the 3 bolts.

      2. Adjust the hood lock position so that the striker can enter it smoothly.

      3. Tighten the 3 bolts after the adjustment.

        Torque:
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  13. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A00OKDO

      Install the radiator support opening cover with the 8 clips.

  14. INSTALL ENGINE ROOM SIDE COVER


    1. A00OJKZ

      Install the engine room side cover with the clip.

  15. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the 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.

  16. 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 observing the following instructions:


      • 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.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A00DTQYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

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

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

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.