CONDENSER INSTALLATION

INSTALL COOLER CONDENSER ASSEMBLY
1. Install the cooler condenser assembly with the 4 bolts to the hybrid radiator assembly.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Install the cooler condenser 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-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 upper radiator support 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 to the fan shroud and cooling fan motor.
6. Connect the connector to the No. 2 cooling fan motor.
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 { 140 kgf*cm, 10 ft.*lbf }
CONNECT NO. 7 INVERTER COOLING HOSE
1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 7 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.
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. 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 }
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 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 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. Install the discharge hose sub-assembly on the cooler condenser assembly with the bolt.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
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
1. w/ Headlight Cleaner System:
  1. Connect the headlight cleaner hose.
2. Connect the connector.
3. Install the front bumper assembly as shown in the illustration.
4. Engage the 3 claws to install the front bumper assembly.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
5. w/ Front Spoiler:
  1. Engage the 2 guides and install the front spoiler cover.
  2. Install the 2 clips and 2 screws.
6. Install the 7 clips.
7. Install the 2 bolts and 4 screws.
8. Install the screw.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
9. Text in Illustration
  
  *a Correct
  
  *b Incorrect
  
  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 vertical.
  
  Tech Tips
  
  Use the same procedure for the RH side and LH side.
ADD WINDSHIELD WASHER FLUID (w/ Headlight Cleaner System)
1. Add washer fluid to the washer jar.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL REAR NO. 3 FLOOR BOARD
1. Engage the 2 guides to install the rear No. 3 floor board.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box.
INSTALL REAR NO. 2 FLOOR BOARD
1. Engage the 3 guides <A>.
2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.
CHARGE WITH REFRIGERANT
1. Perform vacuum purging using a vacuum pump.
2. Charge with refrigerant HFC-134a (R134a).
  
  Standard
  
  470 g (16.6 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.

Capacity
40 cc (1.35 fl.oz.)

Compressor oil
ND-11 or equivalent

Compressor oil
ND-OIL 11 or equivalent

Compressor oil
ND-OIL 11 or equivalent

Text in Illustration
*a	Correct
*b	Incorrect

Standard
470 g (16.6 oz.)

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, damage may occur and 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
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
P0C73-776	Motor Electronics Coolant Pump "A" Control Performance

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

Coolant quantity

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

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

When using the intelligent tester:

Connect the intelligent tester to the DLC3.
Turn the power switch on (IG).
On the intelligent tester, enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

Keep the coolant at the F 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 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 cooling system.

When not using the intelligent tester:

Turn the power switch on (READY). [*1]
Turn the power switch off and add coolant to the F 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 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 cooling system.

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

INSPECT FOR REFRIGERANT LEAK

After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
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 (3.9 to 5.9 kgf/cm², 57 to 85 psi)

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

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

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.

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.
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.

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 the radiator cap tester.
3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm², 17.7 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.
ADJUST FOG LIGHT AIMING

Tech Tips

Refer to the procedure for Adjust Fog Light Aiming Click here.
ADJUST HOOD SUB-ASSEMBLY

Tech Tips

Refer to the procedure for Adjust Hood Sub-assembly Click here.

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

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

CAUTION:

Exposure to radio frequency emissions is hazardous to your health. It is hazardous to your health to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

Note

This device complies with FCC radio frequency emission regulations.
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. Check the tire pressure and adjust it if necessary.
2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).

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 bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
Vertical adjustment	Downward direction: Turn bolt A 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.
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.

When using the intelligent tester:
1. Connect the intelligent tester to the DLC3.
2. Turn the power switch on (IG).
3. Turn the intelligent tester on, and turn the cruise control main switch on.
4. Select "Auto" from the intelligent tester display screen.
5. Select "Radar Cruise" from the display screen.
6. Select "Utility" from the display screen.
7. Select "Beam Axis Adjustment" from the display screen.
8. Follow the tester display, and select "Next".
  
  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.
9. Check the following items on the laser cruise divergence data screen.
  
  Note
  
  While using the intelligent tester's beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the intelligent tester's 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 bolt B to positive (+) side.	For every 2.5 rotations of adjustment bolt, sensor moves about 1°
Horizontal adjustment	Left direction: Turn bolt B 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 intelligent tester 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 bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
Vertical adjustment	Downward direction: Turn bolt A to positive (+) side

INSTALL RADIATOR SUPPORT OPENING COVER
1. Engage the 2 claws and install the radiator support opening cover.
2. Install the 3 clips.