HEATING / AIR CONDITIONING CONDENSER INSTALLATION

Hide Display 1.INSTALL NO. 1 COOLER CONDENSER CUSHION (for 7GR-FKS)

a.

0,0 0,0 false

Install in this Direction

Install each No. 1 cooler condenser cushion.

Hide Display 2.INSTALL COOLER CONDENSER ASSEMBLY (for 7GR-FKS)

a.

except Wagon:

i.

0,0 0,0 false

Install in this Direction

Insert the cooler condenser assembly from the top as shown in the illustration.

NOTICE:: Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

HINT:: If the cooler condenser assembly is replaced with a new one, add compressor oil to the new cooler condenser assembly.

Capacity:: 40 cc (1.35 fl.oz)

Compressor oil:: ND-OIL 8 or equivalent

b.

for Wagon:

i.

0,0 0,0 false

Install in this Direction

Insert the cooler condenser assembly from the top as shown in the illustration.

NOTICE:: Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

HINT:: If the cooler condenser assembly is replaced with a new one, add compressor oil to the new cooler condenser assembly.

Capacity:: 40 cc (1.35 fl.oz)

Compressor oil:: ND-OIL 8 or equivalent

Hide Display 3.INSTALL COOLER BRACKET (for 7GR-FKS)

a.

except Wagon:

i.

0.531,2.729 0.531,3 true 0.917,2.844 0.531,2.844 true 0.469,3 0.719,3.188 0.25,0.188 10 true *a

*a

Clamp

Attach the guide to install each cooler bracket with the 2 bolts.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Attach the clamp.

b.

for Wagon:

i.

0.396,2.729 0.396,3.073 true 0.813,3 0.396,3 true 0.292,3.083 0.542,3.271 0.25,0.188 10 true *a

*a

Clamp

Attach the guide to install each cooler bracket with the 2 bolts.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Attach the clamp.

Hide Display 51466 4.INSTALL UPPER RADIATOR SUPPORT BRACE LH (for Wagon, 7GR-FKS)

a.

Install the upper radiator support brace LH with the 2 bolts.

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display 51465 5.INSTALL UPPER RADIATOR SUPPORT BRACE RH (for Wagon, 7GR-FKS)

a.

Install the upper radiator support brace LH with the 2 bolts.

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display 52139E 6.INSTALL FRONT BUMPER CENTER BRACE (for 7GR-FKS)

a.

except Wagon:

i.

0,0 0,0 false

Install the front bumper center brace with the 2 bolts.

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)

b.

for Wagon:

i.

Install the front bumper center brace with the 2 bolts.

Torque:: 15 N*m (153 kgf*cm, 11 ft.*lbf)

Hide Display 7.INSTALL NO. 1 COOLER CONDENSER CUSHION (for 1GD-FTV)

a.

0,0 0,0 false

Install in this Direction

Install each No. 1 cooler condenser cushion.

Hide Display 88716B 8.INSTALL COOLER REFRIGERANT LIQUID PIPE B (for 1GD-FTV)

a.

Install the cooler refrigerant liquid pipe B with the bolt.

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Hide Display 9.INSTALL COOLER CONDENSER ASSEMBLY (for 1GD-FTV)

a.

except Wagon:

i.

0,0 0,0 false

Install in this Direction

Insert the cooler condenser assembly from the top as shown in the illustration.

NOTICE:: Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

HINT:: If the cooler condenser assembly is replaced with a new one, add compressor oil to the new cooler condenser assembly.

Capacity:: 40 cc (1.35 fl.oz)

Compressor oil:: ND-OIL 8 or equivalent

b.

for Wagon:

i.

0,0 0,0 false

Install in this Direction

Insert the cooler condenser assembly from the top as shown in the illustration.

NOTICE:: Do not damage the cooler condenser assembly or radiator assembly when installing the cooler condenser assembly.

HINT:: If the cooler condenser assembly is replaced with a new one, add compressor oil to the new cooler condenser assembly.

Capacity:: 40 cc (1.35 fl.oz)

Compressor oil:: ND-OIL 8 or equivalent

Hide Display 10.INSTALL COOLER BRACKET (for 1GD-FTV)

a.

except Wagon:

i.

0.552,2.802 0.552,3.042 true 0.875,2.969 0.552,2.969 true 0.479,3.052 0.76,3.208 0.281,0.156 10 true *a

*a

Clamp

Attach the guide to install each cooler bracket with the 2 bolts.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Attach the clamp.

b.

for Wagon:

i.

0.406,2.698 0.406,3.031 true 0.833,2.99 0.417,2.99 true 0.313,3.052 0.594,3.208 0.281,0.156 10 true *a

*a

Clamp

Attach the guide to install each cooler bracket with the 2 bolts.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Attach the clamp.

Hide Display 53205 11.INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY (for 1GD-FTV)

Click hereEngine / Hybrid System>1GD-FTV (COOLING)>RADIATOR>INSTALLATION201906,202005,_51,_079309,_0386771,RM100000001IZPZ_01_0049,202005,999999,_51,_079309,_0386771,RM100000001LT60_01_0049,

Hide Display 44360 12.CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY (for 1GD-FTV)

Click hereEngine / Hybrid System>1GD-FTV (COOLING)>RADIATOR>INSTALLATION201906,202005,_51,_079309,_0386771,RM100000001IZPZ_01_0063,202005,999999,_51,_079309,_0386771,RM100000001LT60_01_0063,

Hide Display 17751 13.INSTALL NO. 1 AIR CLEANER INLET (for 1GD-FTV)

Click hereEngine / Hybrid System>1GD-FTV (COOLING)>RADIATOR>INSTALLATION201906,202005,_51,_079309,_0386771,RM100000001IZPZ_01_0064,202005,999999,_51,_079309,_0386771,RM100000001LT60_01_0064,

Hide Display 53209B 14.INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY

·

for 7GR-FKS:

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>INSTALLATION201906,999999,_51,_079310,_0386774,RM100000001IZPW_01_0148,

·

for 1GD-FTV:

Click hereEngine / Hybrid System>1GD-FTV (COOLING)>RADIATOR>INSTALLATION201906,202005,_51,_079309,_0386771,RM100000001IZPZ_01_0053,202005,999999,_51,_079309,_0386771,RM100000001LT60_01_0053,

Hide Display 53510 15.INSTALL HOOD LOCK ASSEMBLY (for RHD)

Click hereVehicle Exterior>DOOR / HATCH>HOOD LOCK CONTROL CABLE ASSEMBLY (for RHD)>INSTALLATION201906,999999,_59,_078503,_0385650,RM100000001JOQE_01_0008,

Hide Display 53510 16.INSTALL HOOD LOCK ASSEMBLY (for LHD)

Click hereVehicle Exterior>DOOR / HATCH>HOOD LOCK CONTROL CABLE ASSEMBLY (for LHD)>INSTALLATION201906,999999,_59,_078503,_0385649,RM100000001JOQ8_01_0008,

Hide Display 51466 17.INSTALL UPPER RADIATOR SUPPORT BRACE LH (for Wagon, 1GD-FTV)

a.

Install the upper radiator support brace LH with the 2 bolts.

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display 51465 18.INSTALL UPPER RADIATOR SUPPORT BRACE RH (for Wagon, 1GD-FTV)

a.

Install the upper radiator support brace LH with the 2 bolts.

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display 88710 19.CONNECT AIR CONDITIONING TUBE ASSEMBLY (for 7GR-FKS)

a.

except Wagon:

i.

Remove the vinyl tape from the air conditioning tube assembly and the connecting part of the cooler condenser assembly.

ii.

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

Compressor oil:: ND-OIL 8 or equivalent

iii.

Install the O-ring to the air conditioning tube assembly.

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the air conditioning tube assembly to the cooler condenser assembly with the bolt.

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

b.

for Wagon:

i.

Remove the vinyl tape from the air conditioning tube assembly and the connecting part of the cooler condenser assembly.

ii.

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

Compressor oil:: ND-OIL 8 or equivalent

iii.

Install the O-ring to the air conditioning tube assembly.

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the air conditioning tube assembly to the cooler condenser assembly with the bolt.

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Hide Display 88703 20.CONNECT DISCHARGE HOSE SUB-ASSEMBLY (for 7GR-FKS)

a.

except Wagon:

i.

Remove the vinyl tape from the discharge hose sub-assembly and the connecting part of the cooler condenser assembly.

ii.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

Compressor oil:: ND-OIL 8 or equivalent

iii.

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

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the discharge hose sub-assembly to the condenser assembly with the bolt.

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

b.

for Wagon:

i.

Remove the vinyl tape from the discharge hose sub-assembly and the connecting part of the cooler condenser assembly.

ii.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

Compressor oil:: ND-OIL 8 or equivalent

iii.

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

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the discharge hose sub-assembly to the condenser assembly with the bolt.

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Hide Display 88710 21.CONNECT AIR CONDITIONING TUBE ASSEMBLY (for 1GD-FTV)

a.

except Wagon:

i.

Remove the vinyl tape from the air conditioning tube assembly and the connecting part of the cooler condenser assembly.

ii.

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

Compressor oil:: ND-OIL 8 or equivalent

iii.

Install the O-ring to the air conditioning tube assembly.

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the air conditioning tube assembly to the cooler condenser assembly with the union nut using a double wrench.

Torque:: 13.7 N*m (140 kgf*cm, 10 ft.*lbf)

b.

for Wagon:

i.

Remove the vinyl tape from the air conditioning tube assembly and the connecting part of the cooler condenser assembly.

ii.

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

Compressor oil:: ND-OIL 8 or equivalent

iii.

Install the O-ring to the air conditioning tube assembly.

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

Connect the air conditioning tube assembly to the cooler condenser assembly with the union nut using a double wrench.

Torque:: 13.7 N*m (140 kgf*cm, 10 ft.*lbf)

Hide Display 88703 22.CONNECT DISCHARGE HOSE SUB-ASSEMBLY (for 1GD-FTV)

a.

except Wagon:

i.

Remove the vinyl tape from the discharge hose sub-assembly and the connecting part of the cooler condenser assembly.

ii.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

Compressor oil:: ND-OIL 8 or equivalent

iii.

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

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

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

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

b.

for Wagon:

i.

Remove the vinyl tape from the discharge hose sub-assembly and the connecting part of the cooler condenser assembly.

ii.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the discharge hose sub-assembly.

Compressor oil:: ND-OIL 8 or equivalent

iii.

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

NOTICE:: Keep the O-rings and O-ring fitting surfaces free of foreign matter.

iv.

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

Torque:: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Hide Display 53286F 23.INSTALL RADIATOR SIDE AIR SEAL LH (w/o Condenser fan)

a.

except Wagon:

i.

0,0 0,0 false

Install in this Direction

Attach the clip and claw to install the radiator side air seal LH as shown in the illustration.

b.

for Wagon, for 1GD-FTV:

i.

0,0 0,0 false

Install in this Direction

Attach the clip and claw to install the radiator side air seal LH as shown in the illustration.

c.

for Wagon, for 7GR-FKS:

i.

0,0 0,0 false

Install in this Direction

Attach the clip and claw to install the radiator side air seal LH as shown in the illustration.

Hide Display 53285N 24.INSTALL RADIATOR SIDE AIR SEAL RH (w/o Condenser fan)

a.

0,0 0,0 false

Install in this Direction

except Wagon:

i.

Attach the claw to install the radiator side air seal LH as shown in the illustration.

b.

0,0 0,0 false

Install in this Direction

for Wagon, for 1GD-FTV:

i.

Attach the claw to install the radiator side air seal LH as shown in the illustration.

c.

0,0 0,0 false

Install in this Direction

for Wagon, for 7GR-FKS:

i.

Attach the claw to install the radiator side air seal LH as shown in the illustration.

Hide Display 17311B 25.INSTALL NO. 1 AIR INLET DUCT (for 1GD-FTV, w/o Condenser Fan)

Click hereEngine / Hybrid System>1GD-FTV (COOLING)>RADIATOR>INSTALLATION201906,202005,_51,_079309,_0386771,RM100000001IZPZ_01_0055,202005,999999,_51,_079309,_0386771,RM100000001LT60_01_0055,

Hide Display 26.INSTALL CONDENSER FAN (for 1GD-FTV, w/ Condenser Fan)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>CONDENSER FAN>INSTALLATION201906,999999,_58,_079316,_0384889,RM100000001ISHG,

Hide Display 86520 27.INSTALL LOW PITCHED HORN ASSEMBLY

Click hereVehicle Exterior>HORN>HORN>INSTALLATION201906,999999,_59,_079321,_0385005,RM100000001IHXV_01_0020,

Hide Display 86510 28.INSTALL HIGH PITCHED HORN ASSEMBLY

Click hereVehicle Exterior>HORN>HORN>REMOVAL201906,999999,_59,_079321,_0385005,RM100000001IHXT_01_0007,

Hide Display 29.INSTALL FRONT BUMPER ASSEMBLY

a.

except Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (except Wagon)>INSTALLATION201906,999999,_59,_079322,_0397093,RM100000001IMTG,

b.

for Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for Wagon)>INSTALLATION201906,999999,_59,_079322,_0397092,RM100000001IMTB,

Hide Display 30. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT201906,999999,_58,_079316,_0384872,RM100000001IHVK,

Hide Display 53301 31.INSPECT HOOD SUB-ASSEMBLY

Click hereVehicle Exterior>DOOR / HATCH>HOOD>ON-VEHICLE INSPECTION201902,999999,_59,_078503,_0385648,RM100000001H27U,

Hide Display 53301 32.ADJUST HOOD SUB-ASSEMBLY

Click hereVehicle Exterior>DOOR / HATCH>HOOD>ADJUSTMENT201906,999999,_59,_078503,_0385648,RM100000001JOMV_02_0004,

HEATING / AIR CONDITIONING CONDENSER INSTALLATION

PROCEDURE