CONDENSER > INSTALLATION

for Preparation Click here

1. 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 }

2. Install the cooler condenser assembly.
   

   HINT:

   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
   

   NOTICE:

   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.

1. Install the No. 2 fan shroud with the 2 bolts.
   

   Torque:

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

2. Connect the 6 water by-pass hose clamps to the No. 2 fan shroud.
   

3. Connect the water by-pass hose to the radiator assembly.
   

4. Connect the No. 1 water by-pass hose to the radiator assembly.
   

1. Install the upper radiator support with the 4 bolts.
   

   Torque:

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

2. Install the 2 cushions to the radiator support RH and radiator support LH.
   

3. Install the radiator support RH and radiator support LH with the 2 bolts.
   

   Torque:

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

4. Connect the 2 horn connectors.
   

5. Connect the 2 wire harness clamps and connector to the fan shroud and cooling fan motor.
   

6. Connect the connector to the No. 2 cooling fan motor.
   

7. Connect the hood lock connector and hood lock control cable wire.
   

8. Connect the 3 wire harness clamps.
   

9. Connect the water by-pass hose clamp to the radiator support RH.
   

1. 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{ 140 kgf*cm , 10 ft.*lbf }

1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 7 inverter cooling hose.
   

1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 5 inverter cooling hose.
   

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 and accessory assembly.
   

   NOTICE:

   1. Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.
      
   2. 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 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 }

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.
   

   NOTICE:

   1. Keep the O-ring and O-ring fitting surfaces clean from dirt or any foreign objects.
      
   2. 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 the discharge hose sub-assembly on the cooler condenser assembly with the bolt.
   

   Torque:

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

1. w/o Dynamic Radar Cruise Control System:
   
   

   
   
   

   1. Install the millimeter wave radar sensor bracket with the 3 bolts.
      

      Torque:

      6.2 N*m{ 63 kgf*cm , 55 in.*lbf }

      NOTICE:

      Tighten the bolts in the order shown in the illustration to install the millimeter wave radar sensor bracket.

2. w/ Dynamic Radar Cruise Control System:
   
   

   
   
   

   1. Install the millimeter wave radar sensor bracket with the bolt.
      

      Torque:

      6.2 N*m{ 63 kgf*cm , 55 in.*lbf }

1. Tighten the 5 bolts on the millimeter wave radar sensor assembly.
   

   Torque:

   6.2 N*m{ 63 kgf*cm , 55 in.*lbf }

   HINT:

   Tighten the bolts in the order indicated in the illustration.

2. Connect the connector.
   

1. Connect the headlight cleaner hose. (w/ Headlight Cleaner System)
   

2. Connect each connector.
   

3. Install the front bumper assembly as shown in the illustration.
   

4. Engage the 3 claws to install the front bumper assembly.
   

   HINT:

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

5. Engage the 2 guides and install the front spoiler cover. (w/ Front Spoiler)
   

6. Install the 2 clips and 2 screws. (w/ Front Spoiler)
   

7. Install the 7 clips.
   

8. Install the 2 bolts and 4 screws.
   

9. Install the screw.
   

   HINT:

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

10. Install the pin hold clip.
    

    NOTICE:

    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.

    HINT:

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

1. Add washer fluid to the washer jar.
   

NOTICE:

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

1. Engage the 2 guides to install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Engage the 3 guides <A>.
   

2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.
   

1. Perform vacuum purging using a vacuum pump.
   

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

   
   
   
   

   Standard:

   470 g (16.6 oz.)
   

   SST

   09985-20010   (09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150)
   

   NOTICE:

   1. 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.
      
   2. 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.
      
   3. Avoid using the gauge manifold set that had been used for 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.
      

   HINT:

   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.

NOTICE:

1. Do not reuse the drained coolant because it may contain foreign objects.
   
2. If the vehicle is driven with air in the inverter cooling system, damage may occur and the following DTCs may be set.
   
   

   DTC Code	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. 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. On the intelligent tester, 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 water pump becomes smaller and the circulation of coolant in the reserve tank improves.
      

      HINT:

      Loud noise made by the water pump 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]
      

      NOTICE:

      1. Be sure to turn the power switch off before adding SLLC.
         
      2. 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 water pump becomes smaller and the circulation of coolant in the reserve tank improves.
      

      HINT:

      Loud noise made by the water pump 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. Add coolant to the F line of the reserve tank.
   

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
   

   NOTICE:

   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.

1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
   

2. Carry out the test under the following conditions:
   

   1. Turn the power switch off.
      
   2. Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
      
   3. Repeat the test 2 or 3 times.
      
   4. 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. Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.
   

   Text in Illustration 

   *1	Inspect for Leak
   *2	Halogen Leak Detector

4. Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.
   

   Text in Illustration 

   *1	Halogen Leak Detector
   *2	Drain Hose

   HINT:

   1. After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
      
   2. Bring the halogen leak detector sensor under the drain hose.
      
   3. 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.
   

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. 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.
   

   HINT:

   If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks.

4. Reinstall the reserve tank cap.
   

HINT:

Refer to the procedure for Adjust Fog Light Aiming (Click here).

HINT:

Refer to the procedure for Adjust Hood Sub-assembly (Click here).

CAUTION:

Exposure to radio frequency emissions is hazardous to your health. It is hazardous to your health to be within 20 cm (7.87 in.) of the device's radio frequency aperture.

NOTICE:

1. This device complies with FCC radio frequency emission regulations.
   
2. Perform measurements on a level surface.
   
3. Make sure that no large pieces of metal are within a 10 m (32.8 ft.) x 14 m (45.9 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.
   

1. Before adjusting the radar beam axis, prepare the vehicle as follows.
   
   

   1. Check the tire pressure and adjust it if necessary.
      

   2. Remove all excess weight from the vehicle (luggage, heavy objects, etc.).
      

2. Check and adjust the vertical direction of the radar sensor.
   

   Text in Illustration 

   *1

   Level

   
   

   1. Remove dust, oil and foreign matter from the radar sensor's level rack.
      

   2. Set a level on the radar sensor's level rack.
      

   
   
   

   3. Check that the level's air bubble is within the red frame.
      

      Text in Illustration 

      *1	FR
      *2	LH
      *3	Level
      *4	Air Bubble
      *5	Bolt A

      OK:

      Level's air bubble is within the red frame.
      

      If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the air bubble is within the red frame.
      

      HINT:

      1. The adjustable range within the level's red frame is +/-0.2°.
         
      2. The target angle is +0.2° (upward angle of 0.2°).
         

         Result:

         Adjustment Direction	Adjustment Procedure	Adjustment Angle
         Vertical adjustment	Upward direction: Turn bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
         	Downward direction: Turn bolt A to positive (+) side

3. Adjust the reflector height.
   

   Text in Illustration 

   *1	Millimeter Wave Radar Sensor

   
   

   1. Adjust the reflector so that the center of SST reflector is the same height as the millimeter wave radar sensor.
      

      SST

      09870-60000   (09870-60010)
      09870-60040  
      

      HINT:

      Prepare a 10 m (32.8 ft.) string, string with a sharp-pointed weight (plumb bob), and 5 m (16.4 ft.) tape measure.

4. Place the reflector.
   
   

   1. Hang the string (with weight) from the center of the vehicle's rear emblem. Mark the vehicle's rear center point on the ground. Repeat for the front of the vehicle.
      

   
   
   

   2. Set one end of the 10 m (32.8 ft.) string on the vehicle's rear center point. Run the string over the vehicle's front center point to a position 5 m (16.4 ft.) beyond the vehicle's front center point, as shown in the illustration. Mark the 5 m (16.4 ft.) position.
      

   
   
   

   3. Using a tape measure, measure 15.7 mm (0.618 in.) to the right of the 5 m (16.4 ft.) position. Place the reflector at that position.
      

      NOTICE:

      Perform the operation as precisely as possible.

      
      
      
      
      
      
      

      Text in Illustration 

      *1

      Reflector Placement Point

      *2

      Millimeter Wave Radar Sensor Position

5. Check the radar beam axis.
   When using the intelligent tester:
   
   

   1. Connect the intelligent tester to the DLC3.
      

   2. Turn the power switch on (IG).
      

   3. Turn the intelligent tester on, and turn the cruise control main switch on.
      

   4. Select "Auto" from the intelligent tester display screen.
      

   5. Select "Radar Cruise" from the display screen.
      

   6. Select "Utility" from the display screen.
      

   7. Select "Beam Axis Adjustment" from the display screen.
      

   8. Follow the tester display, and select "Next".
      

      CAUTION:

      Do not come within 20 cm (7.87 in.) of the radar sensor.

      NOTICE:

      1. Turn the cruise control main switch on before pressing "Next".
         
      2. Make sure there is at least 20 cm (7.87 in.) between the radar sensor and any nearby individuals.
         

   9. Check the following items on the laser cruise divergence data screen.
      

      NOTICE:

      While using the intelligent tester's beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the intelligent tester's data. In such a case, the deviation is displayed on the combination meter's multi-information display.

      1. Confirm that the distance value is approximately 5 m (16.4 ft.).
         

         HINT:

         1. A value between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.) should be indicated.
            
         2. If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).
            

      2. Confirm that the left/right side value is between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.).
         

         HINT:

         If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).

6. Check and adjust the horizontal direction of the radar sensor.
   
   

   1. Check that the divergence of the radar beam axis is 0°.
      

      Standard:

      0° (Both right and left)
      

      If the axis is not as specified, use a screwdriver to adjust the bolt B until the divergence of the radar beam axis is 0°.
      

   
   
   

   2. Based on the measured divergence of the beam axis, turn and adjust the bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.
      

      Text in Illustration 

      *1

      Bolt B

      Result:

      Adjustment Direction	Adjustment Procedure	Adjustment Angle
      Horizontal adjustment	Right direction: Turn bolt B to positive (+) side.	For every 2.5 rotations of adjustment bolt, sensor moves about 1°
      	Left direction: Turn bolt B to negative (-) side.

      HINT:

      1. If "LEFT SIDE: 1.0°" is displayed, the divergence is 1.0° in the left direction. Turn the bolt B approximately 2.5 turns to the negative (-) side.
         
      2. If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.
         

   3. Select "Next". The driving learning value is automatically reset.
      

      HINT:

      A buzzer will sound for 10 seconds or more.

   4. Disconnect the intelligent tester from the DLC3.
      

7. Recheck and readjust the vertical direction of the radar sensor.
   
   

   
   
   

   1. Set a level on the radar sensor's level rack.
      

      Text in Illustration 

      *1

      Level

   
   
   

   2. Check that the level's air bubble is within the red frame.
      

      Text in Illustration 

      *1	FR
      *2	LH
      *3	Level
      *4	Air Bubble
      *5	Bolt A

      OK:

      Level's air bubble is within the red frame.
      

      If the bubble is not within the red frame, use a screwdriver to adjust the bolt A until the level's air bubble is within the red frame.
      

      HINT:

      1. The adjustable range within the red frame is +/-0.2°.
         
      2. The target angle is +0.2° (upward angle of 0.2°).
         

         Result:

         Adjustment Direction	Adjustment Procedure	Adjustment Angle
         Vertical adjustment	Upward direction: Turn bolt A to negative (-) side	For every 1.4 rotations of adjustment bolt, sensor moves about 1°
         	Downward direction: Turn bolt A to positive (+) side

1. Engage the 2 claws and install the radiator support opening cover.
   

2. Install the 3 clips.