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Section 15 (Air Conditioning): Condenser: Installation

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL COOLER DRYER 
    1. Using pliers, install the cooler dryer.
      Fig 1: Installing Cooler Dryer
      G04950715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap.

      Compressor oil: ND-OIL 11 or equivalent 

    3. Install the O-ring to the cap.
      Fig 2: Locating Cap O-Ring
      G04950717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a 14 mm socket hexagon wrench, install the cap to the modulator.

      Torque: 4.1 N*m (42 kgf*cm, 36 in.*lbf) 

      Fig 3: Identifying Modulator Cap
      G04950713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL RADIATOR ASSEMBLY 
    1. Install the radiator with the 4 bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 4: Identifying Radiator Assembly And Bolt
      G05774607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL COOLER CONDENSER ASSEMBLY 
    1. Install the cooler condenser with the 4 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 5: Identifying Cooler Condenser Bolts
      G05774606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL RADIATOR ASSEMBLY 
  5. CONNECT NO. 1 INVERTER COOLING HOSE 
    1. Connect the cooling hose and install the clip.
      Fig 6: Locating No. 1 Inverter Cooling Hose Clip
      G05773390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT NO. 2 INVERTER COOLING HOSE 
    1. Connect the cooling hose and install the clip.
      Fig 7: Locating No. 2 Inverter Cooling Hose Clip
      G05773391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT LIQUID TUBE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser.
    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 to the liquid tube.
    4. Install the liquid tube to the cooler condenser with the bolt

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

      Fig 8: Locating Liquid Tube Bolt
      G05774603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When tightening the bolt, do not allow any tools to contact the pipe.
      • When tightening the bolt, hold a part of the pipe near the connector.
  8. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser.
    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 to the discharge hose.
    4. Install the discharge hose to the cooler condenser with the bolt.

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

      Fig 9: Locating Discharge Hose Bolt
      G05774602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When tightening the bolt, do not allow any tools to contact the pipe.
      • When tightening the bolt, hold a part of the pipe near the connector.
  9. INSTALL UPPER RADIATOR SUPPORT 
    1. Attach the wire harness to the upper support with the 5 clamps.
      Fig 10: Locating Upper Radiator Support Wire Harness Clamps
      G04948232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the upper support with the 5 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 11: Identifying Upper Support And Bolts
      G04948226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the 2 clamps to the radiator support LH and RH side.
    4. Connect the 3 connectors.
  10. INSTALL HOOD LOCK ASSEMBLY  (See INSTALLATION )
    Fig 12: Locating Upper Radiator Support Connectors And Clamps
    G05774599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL HOOD LOCK CONTROL CABLE COVER 
    1. Install the cover with the 3 screws and attach the claw
      Fig 13: Locating Hood Lock Control Cable Cover Screws And Claw
      G04948223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY 
    1. Install the sensor with the 3 bolts

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 14: Locating Millimeter Wave Radar Sensor Connector And Bolts
      G04948222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
  13. INSTALL RADIATOR GRILLE ASSEMBLY  (See INSTALLATION )
  14. INSTALL RADIATOR RESERVOIR ASSEMBLY  (See INSTALLATION )
  15. INSTALL INLET OIL COOLER HOSE 
  16. INSTALL OUTLET OIL COOLER HOSE 
  17. INSTALL NO. 1 RADIATOR HOSE  (See INSTALLATION )
  18. INSTALL NO. 2 RADIATOR HOSE  (See INSTALLATION )
  19. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  20. INSTALL RADIATOR SUPPORT OPENING COVER  (See INSTALLATION )
  21. INSTALL FRONT LOWER SUSPENSION CROSSMEMBER  (See INSTALLATION )
  22. INSTALL FRONT LOWER BUMPER ABSORBER  (See INSTALLATION )
  23. INSTALL FRONT BUMPER REINFORCEMENT  (See INSTALLATION )
  24. INSTALL FRONT BUMPER ENERGY ABSORBER  (See INSTALLATION )
  25. INSTALL FRONT BUMPER COVER 
    1. w/ Intuitive Parking Assist system.

      Connect the No. 4 engine room main wire connector.

    2. Connect the 2 fog light connectors and install the front bumper.
    3. Attach the 5 claws and connect the front bumper as shown in the illustration.

      HINT:

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

      Fig 15: Identifying Front Bumper Claws
      G04950727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bumper seal bracket.

      HINT:

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

      Fig 16: Identifying Bumper Seal Bracket Clips
      G04950703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the bolt and 8 screws.
      Fig 17: Identifying Front Bumper Cover Bolts And Screws
      G04950702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT FENDER LINER LH 
    1. Install the 2 clips
  27. INSTALL FRONT FENDER LINER RH 

    HINT:

    Use the same procedures described for the LH side

    Fig 18: Identifying Front Fender Liner RH Clip
    G04950730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH  (See INSTALLATION )
  29. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH  (See INSTALLATION )
  30. INSTALL RADIATOR GRILLE ASSEMBLY  (See INSTALLATION )
  31. INSTALL FRONT FENDER WHEEL OPENING MOULDING LH  (See INSTALLATION )
  32. INSTALL FRONT FENDER WHEEL OPENING MOULDING RH  (See INSTALLATION )
  33. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  34. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY  (See INSTALLATION )
  35. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
  36. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  37. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  38. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  40. INSTALL BATTERY SERVICE HOLE COVER LH  (See INSTALLATION )
  41. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See INSTALLATION )
  42. ADD COMPRESSOR OIL  (See REPLACEMENT  )
  43. CHARGE REFRIGERANT  (See REPLACEMENT  )
  44. WARM UP ENGINE  (See REPLACEMENT  )
  45. CHECK FOR REFRIGERANT GAS LEAK  (See REPLACEMENT  )
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