FRONT CONSOLE BOX (w/ Refrigerated Cool Box) INSTALLATION


  1. INSTALL CONSOLE BOX ASSEMBLY


    1. Connect the connector and install the console box assembly.

    2. Sufficiently apply compressor oil to 2 new O-rings.

      Compressor oil
      ND-OIL 8 or equivalent
    3. Install the 2 O-rings to the 2 cooler pipes.

    4. Connect the 2 cooler pipes with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    5. Connect the drain cooler hose.

    6. Install the 7 bolts and 2 screws.

    7. Install the clip.

  2. INSTALL CENTER FLOOR CARPET COVER RH


    1. Attach the 3 claws to install the center floor carpet cover RH.

  3. INSTALL REAR CONSOLE END PANEL SUB-ASSEMBLY


    1. Connect the connector and install the rear console end panel sub-assembly.

  4. INSTALL COOLING BOX TRAY


    1. Install the cooling box tray.

  5. INSTALL NO. 1 CONSOLE BOX DUCT (for Single Air Conditioning System)


    1. Install the No. 1 console box duct with the clip.

  6. INSTALL CONSOLE PANEL SUB-ASSEMBLY


    1. for Automatic Transmission:

      Install the console panel sub-assembly Click here.

    2. for Manual Transmission:

      Install the console panel sub-assembly Click here.

  7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. for Automatic Transmission:

      Install the shift lever knob sub-assembly Click here.

    2. for Manual Transmission:

      Install the shift lever knob sub-assembly Click here.

  8. INSTALL FRONT NO. 2 CONSOLE BOX INSERT


    1. Attach the 2 clips and guide to install the front No. 2 console box insert.

  9. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. Attach the 3 clips and 2 guides to install the No. 2 instrument panel under cover.

    2. Install the screw.

      A00OAYQE01
      Text in Illustration
      *A for LHD *B for RHD
  10. INSTALL FRONT NO. 1 CONSOLE BOX INSERT


    1. Attach the 2 clips and guide to install the front No. 1 console box insert.

  11. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY


    1. for LHD:


      1. Attach the 2 clips and 2 guides to install the No. 1 instrument panel under cover.

      2. Install the screw.

    2. for RHD:


      1. Attach the 3 clips and 2 guides to install the No. 1 instrument panel under cover.

      2. Install the screw.

  12. INSTALL FRONT CONSOLE UPPER PANEL GARNISH


    1. Attach the 5 clips to install the front console upper panel garnish.

  13. INSTALL INSTRUMENT PANEL FINISH PANEL END LH


    1. Attach the 4 clips to install the instrument panel finish panel end.

  14. INSTALL INSTRUMENT PANEL FINISH PANEL END RH


    1. Connect the connector.

    2. Attach the 4 clips to install the instrument panel finish panel end.

  15. INSTALL NO. 2 INSTRUMENT PANEL FINISH PANEL CUSHION


    1. Attach the 5 clips to install the No. 2 instrument panel finish panel cushion.

  16. INSTALL NO. 1 INSTRUMENT PANEL FINISH PANEL CUSHION

    Tech Tips

    Use the same procedure described for the No. 2 instrument panel finish panel cushion.

  17. INSTALL INTEGRATION CONTROL AND PANEL ASSEMBLY

    A0095V3

    1. Connect the connector.

    2. Attach the 4 clips to install the integration control and panel assembly.

  18. INSTALL FRONT SEAT ASSEMBLY


    1. for Manual Seat:

      Install the front seat assembly Click here.

    2. for Power Seat:

      Install the front seat assembly Click here.

    3. for Walk in Seat Type:

      Install the front seat assembly Click here.

  19. WARM UP ENGINE


    1. 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.

  20. 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
      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.

      A00JY00E19

      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.

  21. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. 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).

    3. A00JYOBE34
      Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leakage

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. 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.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.