INSTALL INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY (for TR Series Engine)
INSTALL FRONT BUMPER REINFORCEMENT EXTENSION LH (for 4WD and Pre-Runner)
INSTALL FRONT BUMPER REINFORCEMENT EXTENSION RH (for 4WD and Pre-Runner)
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH (for 4WD and Pre-Runner)
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for 4WD and Pre-Runner)
INSTALL NO. 1 ENGINE UNDER COVER (except 4WD and Pre-Runner)
Air Conditioning Pressure Sensor -- Installation |
| 1. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY |
Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube and accessory assembly (air conditioning pressure sensor).
- Compressor oil:
- ND-OIL 8 or equivalent
Install the 2 O-rings to the air conditioning tube and accessory assembly (air conditioning pressure sensor).
Install the air conditioning tube and accessory assembly with the 3 bolts.
- Torque:
- 5.4 N*m{55 kgf*cm, 48 in.*lbf}
Connect the connector.
| 2. INSTALL INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY (for TR Series Engine) |
Install the air cleaner and intake air connector assembly with the 4 bolts, and tighten the hose clamp.
- Torque:
- for air cleaner:
- 14 N*m{143 kgf*cm, 10 ft.*lbf}
- for intake air connector:
- 8.0 N*m{82 kgf*cm, 71 in.*lbf}
- for hose clamp:
- 5.0 N*m{51 kgf*cm, 44 in.*lbf}
Connect the mass air flow meter connector and attach the wire harness clamps.
Connect the No. 2 PCV hose.
Connect the vacuum hose.
| 3. INSTALL AIR CLEANER ASSEMBLY (for 1KD-FTV, 2KD-FTV) |
Connect the air cleaner hose.
Install the cleaner with the 2 bolts.
- Torque:
- 14 N*m{143 kgf*cm, 10 ft.*lbf}
Tighten the hose clamp.
Connect the connector to the mass air flow meter connector.
| 4. INSTALL NO. 2 AIR CLEANER HOSE (for 1GR-FE) |
Install the No. 2 air cleaner hose with the 2 bolts.
- Torque:
- 14 N*m{143 kgf*cm, 10 ft.*lbf}
| 5. INSTALL AIR CLEANER ASSEMBLY (for 1GR-FE) |
Install the air cleaner with the 2 bolts.
- Torque:
- 8.0 N*m{82 kgf*cm, 71 in.*lbf}
Tighten the 2 hose clamps.
Attach the 2 wire harness clamps.
Connect the mass air flow meter connector.
Connect the vacuum hose.
| 6. INSTALL V-BANK COVER (for 1GR-FE) |
Install the V-bank cover with the 2 nuts.
- Torque:
- 7.5 N*m{76 kgf*cm, 66 in.*lbf}
| 7. INSTALL RADIATOR SIDE DEFLECTOR RH |
Install the radiator side deflector RH with the 3 clips.
| 8. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY |
Install the front bumper reinforcement with the 4 nuts.
- Torque:
- 67 N*m{683 kgf*cm, 49 ft.*lbf}
| 9. INSTALL FRONT BUMPER REINFORCEMENT EXTENSION LH (for 4WD and Pre-Runner) |
Attach the 2 claws to install the front bumper reinforcement extension.
| 10. INSTALL FRONT BUMPER REINFORCEMENT EXTENSION RH (for 4WD and Pre-Runner) |
- HINT:
- Use the same procedure described for the LH side.
| 11. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH (for 4WD and Pre-Runner) |
Install the engine side cover with the 3 bolts and 2 clips.
- Torque:
- 12 N*m{117 kgf*cm, 8 ft.*lbf}
| 12. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for 4WD and Pre-Runner) |
- HINT:
- Use the same procedure described for the LH side.
| 13. INSTALL NO. 1 ENGINE UNDER COVER (except 4WD and Pre-Runner) |
Install the No. 1 engine under cover with the 5 bolts and 4 clips.
- Torque:
- 12 N*m{117 kgf*cm, 8 ft.*lbf}
| 14. INSTALL FRONT BUMPER COVER |
w/ Fog Light:
Connect the 2 fog light connectors.
Attach the 6 claws to install the front bumper cover.
Install the 5 clips, 2 bolts and 2 screws.
Install the 3 clips and 6 screws.
| 15. INSTALL RADIATOR GRILLE |
Attach the 6 claws to install the radiator grille.
Install the 2 screws and 2 clips.
| 16. ADJUST FOG LIGHT AIMING (w/ Fog Light) |
| 17. CHARGE REFRIGERANT |
- HINT:
- Charge refrigerant in accordance with the equipment manual.
Perform vacuum purging using a vacuum pump.
Charge refrigerant HFC-134a (R134a).
- SST
- 09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)
- Standard:
- 450 +/-30 g (15.9 +/-1.1 oz)
Text in Illustration *a Amount to be charged *b Charge 100 g (3.53 oz) *c Mean value in proper range *d Point where bubbles disappear *e Overcharged *f Pressure *g Sub-cool system *h Refrigerant amount - NOTICE:
- Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
- The system may need to be charged with approximately 100 g (3.53 oz) of refrigerant after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
| 18. WARM UP ENGINE |
Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
- NOTICE:
- Be sure to warm up the compressor by turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.
| 19. CHECK FOR REFRIGERANT GAS LEAK |
After recharging the refrigerant, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation observing the following instructions:
- Stop the engine.
- Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
- Repeat the test 2 or 3 times.
- Make sure that some refrigerant remains in the refrigeration system.
- HINT:
- When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).
- Stop the engine.
Using a halogen leak detector, check the refrigerant line for leakage.
If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.
Text in Illustration *1 Halogen Leak Detector *a Check for Leakage
