CONDENSER (for 1KD-FTV, 2KD-FTV) INSTALLATION


  1. INSTALL COOLER CONDENSER ASSEMBLY

    A01DW3B

    1. Install the cooler condenser assembly.

  2. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

    A01DX99E01

    1. Install the upper radiator support sub-assembly with the 7 bolts.

      Torque:
      for bolt A
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for bolt B
      5.4 N*m  { 55 kgf*cm, 47 in.*lbf }
      for bolt C
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. INSTALL HOOD LOCK ASSEMBLY


    1. for LHD:

      Click here

    2. for RHD:

      Click here

  4. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY


    1. Remove the vinyl tape attached to the air conditioning tube and accessory assembly and connecting part of the cooler condenser.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the air conditioning tube and accessory assembly joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the air conditioning tube and accessory assembly.

    4. Install the air conditioning tube and accessory assembly to the cooler condenser with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 47 in.*lbf }

  5. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the vinyl tape attached to the No. 1 cooler refrigerant discharge hose and connecting part of the cooler condenser.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 1 cooler refrigerant discharge hose joint.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

    4. Install the No. 1 cooler refrigerant discharge hose to the cooler condenser with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 47 in.*lbf }

  6. INSTALL FRONT BUMPER COVER

    Click here

  7. 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
      450 +- 30 g (15.87 +- 1.05 oz.)
      A01DWS4E02

      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 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

  8. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      After removing and installing the cooler refrigerant lines (with the compressor), be sure to warm up the compressor when turning the A/C switch ON. This is done to prevent damage to the compressor.

  9. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.


      • The ignition switch is OFF.

      • The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up.

      • Some refrigerant is remaining in the refrigerant system.

      • The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2).

    2. A01DWJCE03

      Check for refrigerant gas leakage from the refrigerant line.


      1. After the blower motor stops, wait at least 15 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the refrigerant line. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    3. Check for refrigerant gas leakage from the cooling unit.


      1. Hold the gas leak detector so that the sensor is under the drain hose, as shown in the illustration.

      2. Check that gas is not leaking from the drain hose. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    4. Check for refrigerant gas leakage from the cooling unit.


      1. Remove the blower motor control from the unit. Insert the gas leak detector's sensor into the unit.

      2. Check that gas is not leaking from the unit. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    5. Check for refrigerant gas leakage from the pressure switch.


      1. Disconnect the pressure switch connector and wait approximately 20 minutes.

      2. Using a gas leak detector, check that gas is not leaking from the pressure switch. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.

    6. Repeat all steps above 2 to 3 times.