PRESSURE SWITCH INSTALLATION

INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY
1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube and accessory assembly (pressure switch).
  
  Compressor oil
  
  ND-OIL 8 or equivalent
2. Install the 2 O-rings to the air conditioning tube and accessory assembly (pressure switch).
3. Install the air conditioning tube and accessory assembly (pressure switch) with the 3 bolts.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
4. Connect the connector.
INSTALL AIR CLEANER ASSEMBLY (for 1GR-FE)

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL V-BANK COVER (for 1GR-FE)
1. Remove the 2 nuts and the V-bank cover.
INSTALL AIR CLEANER ASSEMBLY (for 1KD-FTV, 2KD-FTV)
1. Install the air cleaner with the 2 bolts.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
2. w/ Intake Air Temperature Sensor:
  
  Connect the connector to the intake air temperature sensor.
3. w/ Mass Air Flow Meter:
  
  Connect the connector to the mass air flow meter.
4. Tighten the hose clamp.
5. w/o EGR Cooler:
  
  Connect the ventilation hose.
INSTALL INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY (for 2TR-FE)
1. Install the air cleaner and intake air connector assembly with the 4 bolts, and tighten the hose clamp.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf, for air cleaner }
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf, for intake air connector }
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf, for hose clamp }
2. Connect the MAF meter connector and harness clamps.
3. Connect the No. 2 ventilation hose.
4. Connect the vacuum hose.
INSTALL RADIATOR SIDE DEFLECTOR RH
1. Install the radiator side deflector RH with the 3 clips.
INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY
1. Install the front bumper reinforcement with the 4 nuts.
  
  Torque:
  
  67 N*m { 683 kgf*cm, 49 ft.*lbf }
INSTALL FRONT BUMPER REINFORCEMENT EXTENSION LH (for 4WD and Pre-Runner)
1. Attach the claw to install the radiator side deflector.
2. Install the 3 clips.
INSTALL FRONT BUMPER REINFORCEMENT EXTENSION RH (for 4WD and Pre-Runner)

Tech Tips

Use the same procedure described for the LH side.
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH (for 4WD and Pre-Runner)
1. Install the engine side cover with the 3 bolts and 2 clips.
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for 4WD and Pre-Runner)

Tech Tips

Use the same procedure described for the LH side.
INSTALL ENGINE UNDER COVER (except 4WD and Pre-Runner)
1. Install the engine under cover with the 5 bolts and 4 clips.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL FRONT BUMPER COVER
1. w/ Fog Light:
  
  Connect the 2 fog light connectors.
2. w/ Headlight Cleaner System:
  
  Connect the No. 1 headlight cleaner hose.
3. Attach the 6 claws to install the front bumper cover.
4. Install the 5 clips, 2 bolts and 2 screws.
5. Install the 3 clips and 6 screws.
INSTALL RADIATOR GRILLE
1. Attach the 6 claws to install the radiator grille.
2. Install the 2 screws and 2 clips.
CHARGE REFRIGERANT
SST

09985-20010 ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )
1. Perform vacuum purging using a vacuum pump.
2. Charge refrigerant HFC-134a (R134a).
  
  Standard
  
  450 +- 30 g (15.87 +- 1.05 oz.)
  Note
  
  Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
  
  Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.
WARM UP ENGINE
1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.
  
  Note
  
  After removing and installing the cooler refrigerant lines (with the compressor), be sure to warm up the compressor when turning the A/C switch ON. This is done to prevent damage to the compressor.
CHECK FOR REFRIGERANT GAS LEAK
1. After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met.
  - The ignition switch is OFF.
  - The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up.
  - Some refrigerant is remaining in the refrigerant system.
  - The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2).
2. Check for refrigerant gas leakage from the refrigerant line.
  1. After the blower motor stops, wait at least 15 minutes.
  2. Using a gas leak detector, check that gas is not leaking from the refrigerant line. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
3. Check for refrigerant gas leakage from the cooling unit.
  1. Hold the gas leak detector so that the sensor is under the drain hose, as shown in the illustration.
  2. Check that gas is not leaking from the drain hose. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
4. Check for refrigerant gas leakage from the cooling unit.
  1. Remove the blower motor control from the unit. Insert the gas leak detector's sensor into the unit.
  2. Check that gas is not leaking from the unit. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
5. Check for refrigerant gas leakage from the pressure switch.
  1. Disconnect the pressure switch connector and wait approximately 20 minutes.
  2. Using a gas leak detector, check that gas is not leaking from the pressure switch. If leakage is found, tighten parts or replace damaged parts as necessary to stop the leak.
6. Repeat all steps above 2 to 3 times.