Condenser HVAC: Service and Repair
REMOVAL1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
2. REMOVE V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)
3. REMOVE COOL AIR INTAKE DUCT SEAL (for 2GR-FE)
4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for2AZ-FE)
5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE)
6. REMOVE AIR CLEANER INLET ASSEMBLY (for 2AZ-FE)
7. REMOVE AIR CLEANER INLET SUB-ASSEMBLY (for 2GR-FE)
8. REMOVE NO. 1 AIR CLEANER INLET (for 2GR-FE)
9. REMOVE FRONT BUMPER ASSEMBLY (w/o Fog Light)
10. REMOVE FRONT BUMPER ASSEMBLY (w/ Fog Light)
11. REMOVE RADIATOR SUPPORT UPPER
12. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY
a. Remove the bolt and hood lock support sub-assembly.
13. DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY
a. Remove the bolt and disconnect the air conditioning tube assembly from the condenser.
b. Remove the O-ring from the air conditioning tube assembly.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
14. DISCONNECT COOLER REFRIGERANT DISCHARGE PIPE
a. Remove the bolt and disconnect the cooler refrigerant discharge pipe from the condenser.
b. Remove the O-ring from the cooler refrigerant discharge pipe.
NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
15. REMOVE COOLER CONDENSER ASSEMBLY
a. Remove the 4 bolts and condenser.
16. REMOVE COOLER DRYER
a. Using a 14 mm straight hexagon wrench, remove the cap from the modulator.
b. Using pliers, remove the cooler dryer.
INSTALLATION
1. INSTALL COOLER DRYER
a. Using pliers, install the cooler dryer to the modulator.
b. Apply sufficient compressor oil to an O-ring and cap fitting surface.
Compressor oil: ND-OIL 8 or equivalent
c. Using a straight hexagon wrench 14 mm, install the cap to the cooler condenser core.
Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
2. INSTALL COOLER CONDENSER ASSEMBLY
a. Install the cooler condenser assembly with the 4 bolts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
HINT: If the condenser is replaced with a new one, add compressor oil to the new condenser.
Capacity: 40cc (1.4 fl.oz.)
Compressor oil: ND-8 or equivalent
3. INSTALL COOLER REFRIGERANT DISCHARGE PIPE
a. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the cooler refrigerant discharge pipe.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
4. INSTALL AIR CONDITIONER TUBE AND ACCESSORY
a. Remove the attached vinyl tape from the tube and the connecting part of the cooler condenser assembly.
b. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring on the air conditioning tube assembly.
d. Install the air conditioning tube assembly on the cooler condenser assembly with the bolt.
Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
5. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY
a. Install the hood lock support sub-assembly with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
6. INSTALL RADIATOR SUPPORT UPPER
7. INSTALL FRONT BUMPER ASSEMBLY (w/o Fog Light)
8. INSTALL FRONT BUMPER ASSEMBLY (w/ Fog Light)
9. INSTALL NO. 1 AIR CLEANER INLET (for 2GR-FE)
10. INSTALL AIR CLEANER INLET ASSEMBLY (for 2AZ-FE)
11. INSTALL AIR CLEANER INLET SUB-ASSEMBLY (for 2GR-FE)
12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2AZ-FE)
13. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE)
14. INSTALL COOL AIR INTAKE DUCT SEAL (for 2GR-FE)
15. INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)
16. ADD ENGINE COOLANT (for 2AZ-FE)
17. ADD ENGINE COOLANT (for 2GR-FE)
18. CHECK FOR ENGINE COOLANT LEAKS
19. CHARGE WITH REFRIGERANT
20. WARM UP ENGINE
21. CHECK FOR REFRIGERANT LEAKS