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W/Receiver Condenser ASSY: Overhaul

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

COMPONENTS for condenser assy: See COMPONENTS .

  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE  REPLACEMENT  ) 
    1. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
  2. REMOVE FRONT FENDER LINER LH 
  3. REMOVE FRONT FENDER LINER RH 
  4. REMOVE FRONT BUMPER COVER 
  5. REMOVE INVERTER BRACKET NO.1 (SEE ) 
  6. DISCONNECT DISCHARGE HOSE SUB-ASSY 
    1. Remove the bolt and disconnect the discharge hose sub-assy from the condenser assy (w/ receiver).
    2. Remove the O-ring from the discharge hose sub-assy.
    NOTE: Seal the openings of the disconnected parts of the disconnected parts of the discharge hose and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 1: Disconnecting Discharge Hose Sub Assy.
    G00933590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 
    1. Remove the bolt and disconnect the cooler unit refrigerant liquid pipe E from the condenser assy (w/ receiver).
    2. Remove the O-ring from the cooler refrigerant liquid pipe E.
    NOTE: Seal the openings of the disconnected parts of the cooler unit refrigerant liquid pipe E and the condenser assy using vinyl tape to prevent moisture and foreign matter from entering.
    Fig 2: Disconnecting Cooler Refrigerant Liquid Pipe E
    G00933591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE RADIATOR SUPPORT SUB-ASSY UPPER RH 
    1. Remove the 4 bolts and then the radiator support sub-assy upper RH.
    Fig 3: Removing Radiator Support Sub-Assy Upper RH
    G00933592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE RADIATOR SUPPORT SUB-ASSY UPPER LH 
    1. Remove the 4 bolts and then the radiator support sub-assy upper LH.
    Fig 4: Removing Radiator Support Sub-Assy Upper LH
    G00933593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE W/RECEIVER CONDENSER ASSY 
    1. Remove the 2 angles.
      Fig 5: Removing Angles
      G00933594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and then the condenser assy (w/ receiver).
    Fig 6: Removing Condenser Assy
    G00933595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE COOLER DRYER 
    1. Using the straight hexagon wrench 14mm (0.55 in.), remove the cap from the modulator.
      Fig 7: Removing Cap from Modulator
      G00933596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the cap.
      Fig 8: Removing O-ring from the Cap
      G00933597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using pliers, remove the cooler dryer.
    Fig 9: Removing the Cooler Dryer
    G00933598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COOLER DRYER 
    1. Using pliers, install the cooler dryer to the modulator.
      2. Fig 10: Installing Cooler Dryer into the Modulator
      G00933599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new O-ring to the cap.
    3. Sufficiently apply compressor oil (ND-OIL11) to the O-ring and cap fitting surface.
      1. Compressor oil: ND-OIL 11 or equivalent 
      Fig 11: Installing O-ring on Cap
      G00933600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not use any compressor oil other than ND-OIL11 (see AIR CONDITIONING SYSTEM ).
      • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    4. Using a straight hexagon wrench 14mm (0.55 in.), install the cap to the cooler condenser core.
      1. Torque: 2.9 N.m (30 kgf.cm, 25 in..lbf) 
    Fig 12: Installing Cap to the Cooling Condenser Core
    G00933601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL W/RECEIVER CONDENSER ASSY 
    1. Install the condenser assy (w/ receiver) with 2 bolts.
      1. Torque: 3.9 N.m (40 kgf.cm, 35 in..lbf) 
      Fig 13: Installing Condenser Assy (W/ Receiver)
      G00933602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 angles to the condenser assy (w/ receiver).
    Fig 14: Installing Angles to the Condenser Assy (W/Receiver)
    G00933603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL RADIATOR SUPPORT SUB-ASSY UPPER RH 
    1. Install the radiator support sub-assy upper RH with the 4 bolts.

      Torque: 

      1. Bolt A: 5.0 N.m (51 kgf.cm, 44 in..lbf) 
      2. Bolt B: 3.9 N.m (40 kgf.cm, 35 in..lbf) 
      3. Bolt C: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
    Fig 15: Installing Radiator Support Sub-Assy Upper RH
    G00933604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL RADIATOR SUPPORT SUB-ASSY UPPER LH 
    1. Install the radiator support sub-assy upper LH with the 4 bolts.

      Torque: 

      1. Bolt A: 5.0 N.m (51 kgf.cm, 44 in..lbf) 
      2. Bolt B: 3.9 N.m (40 kgf.cm, 35 in..lbf) 
      3. Bolt C: 7.5 N.m (76 kgf.cm, 66 in..lbf) 
    Fig 16: Installing Radiator Support Sub-Assy Upper LH
    G00933605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 
    1. Remove the attached vinyl tape from the disconnected parts of the cooler refrigerant liquid pipe E and condenser assy (w/ receiver).
    2. Install a new O-ring to the cooler refrigerant liquid pipe E.
    3. Sufficiently apply compressor oil (ND-OIL11) to the O-ring and the cooler refrigerant liquid pipe E fitting surface.
      1. Compressor oil: ND-OIL 11 or equivalent 
      NOTE:
      • Do not use any compressor oil other than ND-OIL11 (see AIR CONDITIONING SYSTEM ).
      • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    4. Install the cooler refrigerant liquid pipe E to the condenser assy (w/ receiver) with the bolt.
      1. Torque: 5.4 N.m (55 kgf.cm, 47 in..lbf) 
    Fig 17: Installing Cooler Liquid Pipe E to the Condenser Assy
    G00933606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL DISCHARGE HOSE SUB-ASSY 
    1. Remove the attached vinyl tape from the disconnected parts of the discharge hose sub-assy and the condenser assy (w/ receiver).
    2. Install a new O-ring to the discharge hose sub-assy.
    3. Sufficiently apply compressor oil (ND-OIL11) to the O-ring and the discharge hose fitting surface.
      1. Compressor oil: ND-OIL 11 or equivalent 
      NOTE:
      • Do not use any compressor oil other than ND-OIL11 (see AIR CONDITIONING SYSTEM ).
      • If any compressor oil other than ND-OIL11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power.
    4. Install the discharge hose to the condenser assy (w/ receiver) with the bolt.
      1. Torque: 5.4 N.m (55 kgf.cm, 47 in..lbf) 
    Fig 18: Installing Discharge Condenser Assy
    G00933607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL INVERTER BRACKET NO.1 (SEE ) 
  19. INSTALL FRONT BUMPER COVER 
  20. INSTALL FRONT FENDER LINER RH 
  21. INSTALL FRONT FENDER LINER LH 
  22. CHARGE REFRIGERANT (SEE  REPLACEMENT  ) 
    1. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
    2. Specified amount: 450 +/- 30 g (15.87 +/- 1.05 oz.) 
  23. WARM UP COMPRESSOR (SEE  REPLACEMENT  ) 
  24. INSPECT LEAKAGE OF REFRIGERANT (SEE  REPLACEMENT  ) 
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