INSTALL CONSOLE BOX ASSEMBLY
Connect the connector and install the console box assembly.
Sufficiently apply compressor oil to 2 new O-rings.
Compressor oil |
---|
ND-OIL 8 or equivalent |
Install the 2 O-rings to the 2 cooler pipes.
Connect the 2 cooler pipes with the 2 bolts.
Connect the drain cooler hose.
Install the 7 bolts and 2 screws.
Install the clip.
INSTALL CENTER FLOOR CARPET COVER RH
Attach the 3 claws to install the center floor carpet cover RH.
INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY
Connect the connector and install the rear console end panel sub-assembly.
INSTALL COOLING BOX TRAY
Install the cooling box tray.
INSTALL NO. 1 CONSOLE BOX DUCT (for Single Air Conditioning System)
Install the No. 1 console box duct with the clip.
INSTALL CONSOLE PANEL SUB-ASSEMBLY
for Automatic Transmission:
Install the console panel sub-assembly Click here.
for Manual Transmission:
Install the console panel sub-assembly Click here.
INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
for Automatic Transmission:
Install the shift lever knob sub-assembly Click here.
for Manual Transmission:
Install the shift lever knob sub-assembly Click here.
INSTALL FRONT NO. 2 CONSOLE BOX INSERT
Attach the 2 clips and guide to install the front No. 2 console box insert.
INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
Attach the 3 clips and 2 guides to install the No. 2 instrument panel under cover.
Install the screw.
*A | for LHD | *B | for RHD |
INSTALL FRONT NO. 1 CONSOLE BOX INSERT
Attach the 2 clips and guide to install the front No. 1 console box insert.
INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
for LHD:
Attach the 2 clips and 2 guides to install the No. 1 instrument panel under cover.
Install the screw.
for RHD:
Attach the 3 clips and 2 guides to install the No. 1 instrument panel under cover.
Install the screw.
INSTALL FRONT CONSOLE UPPER PANEL GARNISH
Attach the 5 clips to install the front console upper panel garnish.
INSTALL INSTRUMENT PANEL FINISH PANEL END LH
Attach the 4 clips to install the instrument panel finish panel end.
INSTALL INSTRUMENT PANEL FINISH PANEL END RH
Connect the connector.
Attach the 4 clips to install the instrument panel finish panel end.
INSTALL NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION
Attach the 5 clips to install the No. 2 instrument panel finish panel cushion.
INSTALL NO. 1 INSTRUMENT PANEL FINISH PANEL CUSHION
Tech Tips
Use the same procedure described for the No. 2 instrument panel finish panel cushion.
INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY
Connect the connector.
Attach the 4 clips to install the integration control and panel assembly.
INSTALL FRONT SEAT ASSEMBLY
for Manual Seat:
Install the front seat assembly Click here.
for Power Seat:
Install the front seat assembly Click here.
for Walk in Seat Type:
Install the front seat assembly Click here.
WARM UP ENGINE
Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
Note
Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
CHARGE REFRIGERANT
Perform vacuum purging using a vacuum pump.
Charge refrigerant HFC-134a (R134a).
Model Code | Air Conditioning Type | Cool Box | Refrigerant Charging Amount |
---|---|---|---|
Except the model codes below | w/o Rear Cooler | w/ Cool Box | 600 +/-30 g (21.2 +/-1.1 oz.) |
w/o Cool Box | 550 +/-30 g (19.3 +/-1.1 oz.) | ||
w/ Rear Cooler | w/ Cool Box | 800 +/-30 g (28.2 +/-1.1 oz.) | |
w/o Cool Box | 770 +/-30 g (27.2 +/-1.1 oz.) | ||
w/ Rear Cooler for Cold Area Specification Vehicles |
w/o Cool Box | 720 +/-30 g (25.3 +/-1.1 oz.) | |
TRJ150L-GKMEKV TRJ150L-GKPEKV TRJ155L-GJPEKV GRJ150L-GKFEKV GRJ150L-GKAEKV KDJ150L-GKFEYV KDJ150L-GKAEYV |
w/o Rear Cooler | w/ Cool Box | 600 +/-30 g (21.2 +/-1.1 oz.) |
w/o Cool Box | 550 +/-30 g (19.3 +/-1.1 oz.) or 600 +/-30 g (21.2 +/-1.1 oz.) *1 | ||
w/ Rear Cooler | w/ Cool Box | 800 +/-30 g (28.2 +/-1.1 oz.) | |
w/o Cool Box | 770 +/-30 g (27.2 +/-1.1 oz.) |
*1: For vehicles with the 2TR-FE engine which have neither the rear cooler nor cool box, the refrigerant charging amount changes based on region.
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 measuring its quantity, and not with the sight glass.
CHECK FOR REFRIGERANT GAS LEAK
After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation under these conditions:
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. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).
*1 | Halogen Leak Detector |
*a | Check for Leakage |
Using a halogen leak detector, check the refrigerant line for leakage.
If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.
Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.