CONDENSER INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY


    1. A019OFS

      Install the cooler condenser assembly as shown in the illustration.

      Note


      • Due to the potential of damaging the brackets, do not allow the brackets to touch the vehicle body etc. while installing the condenser.

      • Do not allow the condenser to contact the vehicle body or radiator while installing the condenser.

      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 8 or equivalent
    2. A019P2X

      Install the 2 cooler brackets with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  2. INSTALL UPPER RADIATOR SUPPORT

    for 2GR-FE: Click here

    for 1AR-FE: Click here

  3. CONNECT DISCHARGE TUBE SUB-ASSEMBLY


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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring on the discharge tube sub-assembly.

      Note

      Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.

    4. A019OAT

      Install the discharge tube sub-assembly on the cooler condenser assembly with the bolt.

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

  4. 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 8 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.

    4. A019OYB

      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 }

  5. INSTALL NO. 1 AIR CLEANER INLET

    for 2GR-FE: Click here

    for 1AR-FE: Click here

  6. INSTALL NO. 2 AIR CLEANER INLET

    for 2GR-FE: Click here

    for 1AR-FE: Click here

  7. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY


    1. A019KL0

      Install the hood lock support sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 8 ft.*lbf }

    2. Engage each clamp.

  8. INSTALL SMOG VENTILATION SENSOR (w/ Smog Ventilation Sensor)


    1. A019LDV

      Engage the guide.

    2. Install the smog ventilation sensor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the connector.

  9. INSTALL HIGH PITCHED HORN ASSEMBLY


    1. A019LXM

      Install the high pitched horn assembly with the bolt.

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

    2. Connect the connector.

  10. INSTALL HOOD LOCK ASSEMBLY (for LHD)


    1. A019JXY

      Apply MP grease to the sliding areas of the lock.

    2. A019K84

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A019OVS

      Install the hood lock assembly with the 2 bolts and hood lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A019K2X

      Install a new hood lock nut cap.

  11. INSTALL HOOD LOCK ASSEMBLY (for RHD)


    1. A019NVN

      Apply MP grease to the sliding areas of the lock.

    2. A019JRS

      Connect the hood lock control cable assembly.

    3. Connect the connector.

    4. A019O9S

      Install the hood lock assembly with the 2 bolts and hood lock nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  12. INSTALL HOOD LOCK CONTROL CABLE COVER (for LHD)


    1. A019P5I

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  13. INSTALL HOOD LOCK CONTROL CABLE COVER (for RHD)


    1. A019PAW

      Engage the clamp.

    2. Install the hood lock control cable cover with the 3 screws.

  14. INSTALL LOW PITCHED HORN ASSEMBLY


    1. A019OJ0

      Install the low pitched horn assembly with the bolt.

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

    2. Connect the connector.

  15. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)


    1. A019LF9E01

      Tighten the 3 bolts on the millimeter wave radar sensor assembly.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Tech Tips

      Tighten the bolts in the order indicated in the illustration.

    2. Connect the connector.

  16. INSTALL FRONT BUMPER ASSEMBLY

    for Standard: Click here

    for Sport Package: Click here

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  18. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

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

      A019MUNE05
      Standard (for Suction Pipe Separate Type)
      450 to 550 g (15.9 to 19.4 oz.)
      Standard (except Suction Pipe Separate Type)
      500 to 600 g (17.6 to 21.2 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 switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      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.

  19. WARM UP ENGINE


    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 switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  20. 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 engine 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 (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A019KMKE31
      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. A019MG9E08
      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.

  21. INSPECT HOOD SUB-ASSEMBLY


    1. Inspect the hood sub-assembly Click here.

  22. ADJUST HOOD SUB-ASSEMBLY


    1. Adjust the hood sub-assembly Click here.