CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER CUSHION


    1. for LH Side:


      1. A003RHH

        Install the cooler condenser cushion.

    2. for RH Side:


      1. A003TQN

        Install the cooler condenser cushion.

  2. INSTALL COOLER CONDENSER ASSEMBLY


    1. A003TZQ

      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 }

  3. INSTALL CONDENSER ASSEMBLY WITH HYBRID RADIATOR ASSEMBLY


    1. A003UD3

      Install the cooler condenser assembly with hybrid radiator 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.

  4. INSTALL NO. 2 FAN SHROUD


    1. A003TEK

      Install the No. 2 fan shroud with the 2 bolts and 2 claws.

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

  5. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A003RM1

      Connect the 4 clamps and No. 3 water by-pass hose.

  6. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A003U6G

      Install the hood lock support sub-assembly with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003S7S

      Connect the horn connector.

  7. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch)


    1. A003SHY

      Apply MP grease to the sliding areas of the lock.

    2. Install the hood lock assembly with the 3 bolts.

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

    3. Connect the hood lock control cable.

  8. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch)


    1. A003TNW

      Apply MP grease to the sliding areas of the lock.

    2. Install the hood lock assembly with the 3 bolts.

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

    3. Connect the hood lock control cable.

    4. Connect the connector.

  9. 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.

  10. 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.

  11. CONNECT AIR CONDITIONING TUBE 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 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. A003SSP

      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 }

  12. 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. A003SFN

      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 }

  13. INSTALL RADIATOR SUPPORT RH


    1. Install the radiator support cushion to the radiator support RH.

    2. A003UVV

      Install the radiator support RH with the bolt.

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

    3. Connect the No. 2 water by-pass hose clamp to the radiator support RH.

  14. INSTALL RADIATOR SUPPORT LH


    1. Install the radiator support cushion to the radiator support LH.

    2. A003S9K

      Install the radiator support LH with the bolt.

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

  15. INSTALL NO. 1 INVERTER BRACKET


    1. A003USVE01

      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 }

  16. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  17. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  18. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  19. INSTALL FRONT BUMPER ASSEMBLY


    1. Connect the 2 fog light connectors.

    2. w/ Headlight Cleaner System:


      1. Fill up washer jar with washer fluid Click here.

    3. A003S2L

      Engage the 6 claws and install the front bumper assembly.

    4. A003T9S

      Install the 4 bolts and 3 clips.

    5. A003TD1

      Install the 6 screws.

    6. A003T5J

      Install the clip.

      Tech Tips

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

    7. A003U0CE01
      Text in Illustration
      *1 Correct
      *2 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.

    8. Remove the protective tape.

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  21. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      Standard
      440 to 500 g (15.5 to 17.6 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 a gauge manifold set that had been used on 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.

  22. 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 No. 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

    1. A003RO4

      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.)

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

      3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. 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 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.

    3. When not using the intelligent tester:


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

      2. 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.

      3. 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.

    4. After the air is completely bled from the cooling system, tighten the reserve tank cap.

    5. A003RO4

      Add coolant to the F line of the reserve tank.

  23. 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.

  24. 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 (3.9 to 5.9 kgf/cm2, 57 to 85 psi)

    3. A003T91E31
      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. A003U02E08
      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.

  25. 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. A003SWR

      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, inverter water pump assembly, inverter with converter, and hybrid vehicle transaxle assembly for leaks.

    4. Reinstall the reserve tank cap.

  26. ADJUST FOG LIGHT AIMING

    Click here

  27. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas A through F are within each standard range.

      A003S12E01
      Standard Clearance
      Area Measurement Area Measurement
      A 3.1 to 6.1 mm (0.122 to 0.240 in.) D -1.4 to 1.6 mm (-0.0551 to 0.0630 in.)
      B -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) E 2.3 to 5.3 mm (0.0906 to 0.209 in.)
      C 1.7 to 4.7 mm (0.0669 to 0.185 in.) F -1.0 to 1.0 mm (-0.0394 to 0.0394 in.)

  28. ADJUST HOOD SUB-ASSEMBLY


    1. Horizontally and vertically adjust the hood.


      1. A003S9I

        Loosen the 4 hinge bolts of the hood.

      2. Adjust the clearance between the hood and front fender by moving the hood.

      3. Tighten the 4 hinge bolts after the adjustment.

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

    2. Adjust the height of the front end of the hood using the cushion rubber.


      1. A003RIA

        Adjust the 2 cushion rubbers so that the heights of 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. A003TRF

        Loosen the 3 bolts.

      2. Tighten the bolts after the adjustment.

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

      3. Check that the striker can engage with the hood lock smoothly.