Toyota 88460-06210
Condenser Assembly

As the first step to remove the HVAC condenser technicians must recover refrigerant from the refrigeration system. The process of condenser replacement starts with removing the V-bank cover sub-assembly together with the cool air intake duct seal and air cleaner cap sub-assembly followed by the air cleaner inlet assembly and No. 1 air cleaner inlet of the 2GR-FE engine. Both the 2AZ-FE engine requires the removal of the air cleaner cap sub-assembly in addition to the air cleaner inlet sub-assembly. The installation procedure begins by taking out the front bumper assembly including or omitting fog lights and the radiator support upper. You need to extract the hood lock support sub-assembly by unbolt the fastener. Remove the bolt securing the air conditioner tube and then take off the condenser air conditioning tube assembly before extracting its O-ring from the assembly. Use vinyl tape to seal the opened sections of parts to avoid both moisture and foreign materials. The cooing refrigerant discharge pipe can be removed from the condenser by dislodging its bolt and pipe. After extracting the O-ring from the pipe finish the sealing process according to prior protocol. To end the process remove the cooler condenser assembly through bolt removal of the four holding bolts and condenser unit followed by a 14 mm straight hexagon wrench to detach the cap from the modulator and then pliers to separate the cooler dryer unit.

The condenser removal procedure starts by discharging refrigerant from the system followed by air cleaner inlet No.2 and air cleaner inlet No.1 removal and hood lock assembly detachment until finally separating the radiator support upper. Before continuing disconnect the bolt holding cooler refrigerant discharge hose No.1 along with its O-ring along with sealing the openings with vinyl tape to stop moisture and foreign matter from entering. The air conditioner tube and accessory should be detached by unbolting them and covering their openings with vinyl tape for sealing. You need to remove the cooler condenser assembly through the removal of its 4 bolts. The installation process starts with fitting the cooler condenser assembly by tightening 4 bolts to 5.0 N.m (51 kgf.cm, 44 in.lbf). Additional 40 cc (1.4 fl. oz.) of ND-8 or equivalent compressor oil should be added when replacing with a new condenser. To install the air conditioner components, start by using ND-OIL 8 or equivalent compressor oil to a new O-ring and the fitting surface before placing the O-ring then fastening the tube with the accessory bolt at 9.8 N.m (100 kgf.cm, 87 in.lbf). After removing the tape from cooler refrigerant discharge hose Number 1 you must apply compressor oil to a new O-ring which you should then install using a torque of 9.8 N.m (100 kgf.cm, 87 in.lbf). The process ends with reinstalling the radiator support upper along with the hood lock assembly before charging the refrigerant and engine warming and leak inspections.

The HVAC condenser needs removal which requires performing refrigerant recovery from the refrigeration system followed by coolant drain of the inverter. The first step requires removal of the air cleaner inlet assembly followed by front bumper assembly and front bumper energy absorber. The work sequence starts with removal of the radiator support upper and subsequent removal of the radiator assembly. You must disconnect the liquid tube sub-assembly through the bolt removal along with O-ring replacement before securing the separated components with vinyl tape for moisture and foreign particles exclusion. Next follow the steps to disconnect the cooler refrigerant discharge pipe after removing its bolt and O-ring while performing vinyl tape seals on all open sections. The final step involves unfastening the 2 bolts holding the condenser before removing the condenser assembly and the cooler dryer through use of a 14 mm straight hexagon wrench to uninstall the modulator cap followed by pliers for removing the coil dryer.

Apply 4 bolts for the cooler condenser assembly installation with 6.0 Nm (61 kgf-cm, 53 in-lbf) torque and add 40 cc (1.35 fl oz.) of ND-OIL 8 or equivalent compressor oil when using a new condenser unit. After removing the vinyl tape from the air conditioning tube and cooler condenser assembly users must apply ND-OIL 8 or equivalent compressor oil to a new O-ring while attaching the tube to the fitting surface with the bolt torqued to 9.8 Nm (100 kgf-cm, 87 in-lbf). Surely for the HVAC discharge hose you should remove the tape, apply compression oil to a new O-ring followed by installation before securing it with a bolt while torquing at 9.8 Nm (100 kgf-cm, 87 in-lbf). Mount the upper radiator support and hood lock support sub-assembly through two bolts before mounting each clamp. The installation sequence includes the hood lock assembly followed by both high-pitched and low-pitched horn assemblies and the three air cleaners and battery before adding the air cleaner case and caps and radiator grille protector and cool air intake duct seal. Attach the cable to the negative terminal while understanding that system initialization might be needed following reinstallation. After charging with refrigerant the technician should warm up the engine before inspecting for refrigerant leaks and conducting checks on the hood sub-assembly followed by necessary adjustments.

Remove the vinyl tape from the pipe and the cooler condenser assembly connection, apply ND-OIL 8 or equivalent compressor oil to a new O-ring and the fitting surface of the pipe joint, install the O-ring, and secure the hose with a torque of 9.8 Nm (100 kgf-cm, 87 in-lbf).

Reinstall the radiator support upper and hood lock assembly.

Install the cooler dryer with pliers, applying sufficient compressor oil to an O-ring and cap fitting surface.

Add coolant for the inverter, inspect for coolant leaks, charge with refrigerant, warm up the engine, and inspect for refrigerant leaks.

Apply ND-OIL 8 or equivalent compressor oil.

Remove the air cleaner inlet assembly.

Remove inlet No. 2 air cleaner, air cleaner cap sub-assembly, air cleaner case, battery, and inlet No. 1 air cleaner.