GSIC - Global Service Information Center

# CONDENSER (for TR Series Engine) > INSTALLATION

## for Preparation Click here

1. INSTALL COOLER CONDENSER ASSEMBLY

1. Install the cooler condenser.

2. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER

1. Install the radiator support with the 6 bolts.

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

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

3. INSTALL HOOD LOCK ASSEMBLY

1. Install the hood lock with the 3 bolts.

4. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

1. Remove the vinyl tape attached to the pipe and connecting part of the cooler condenser.

1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.

   Compressor oil:
     ND-OIL 8 or equivalent

1. Install the O-ring on the A/C tube.

1. Install the A/C tube on 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 pipe and connecting part of the cooler condenser.

1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

   Compressor oil:
     ND-OIL 8 or equivalent

1. Install the O-ring on the refrigerant discharge hose.

1. Install the refrigerant discharge hose on the cooler condenser with the bolt.

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

6. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

1. Install the reinforcement with the 4 nuts.

   Torque:
     67 N*m{ 683 kgf*cm , 49 ft.*lbf }

7. INSTALL FRONT BUMPER COVER

1. Put protective tape under the front fender.

1. Attach the 4 claws to install the cover.

1. Install the 9 clips.

8. INSTALL RADIATOR GRILLE

1. Push the radiator grille in the direction indicated by the arrow in the illustration. Attach the 5 claws to install the radiator grille.

1. Install the 2 screws and 2 clips.

9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

10. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

11. CHARGE REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

1. Charge refrigerant HFC-134a (R134a).

   Standard:
     450 +- 30 g (15.87 +- 1.05 oz.)
   SST
     07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

   NOTICE:
   1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   1. 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.

12. WARM UP ENGINE

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

   NOTICE:
     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.

13. CHECK FOR LEAKAGE OF REFRIGERANT

1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

1. Perform the operation under these conditions:

   1. Stop the engine.
   1. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   1. Repeat the test 2 or 3 times.
   1. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

1. Using a gas leak detector, check the refrigerant line for leakage.

1. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

1. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.