FITTING THE SYSTEM

The new manifold fits between the front evaporator/hoses connection in the engine bay. New hoses, connected to the two stubs, supply the rear system. Inside the cab, the existing cubby box is removed to make space for the air conditioning unit, complete with its own arm rests and storage space. The air-con unit fits neatly in place of the seatbox cover plate, its rear lip engaging under the rear of the seatbox, completely sealing the void. With the manifold mounted, the front hoses are reconnected, and the two hoses for the rear unit are led down off the manifold’s two stubs. The seatbox removable plate under the cubby box is lifted out. This steel finisher is unscrewed at the rear, and the bolt under it is removed. The front edge of the unit is secured to the forward edge of the seatbox with screws that are hidden from view when the cup-holder is fitted. The two hoses for the rear unit are led back under the vehicle, secured out of the way (all hose connector seals lubricated with refrigrerant oil). The vehicle’s diagnostic socket needs to be re-routed through a new hole in the seatbox near the driver’s seat, re-using the grommet. Here, the twin cup-holder insert has been fitted in the front of the unit, and the vehicle’s diagnostic socket is refitted on the front of the seatbox.

Underneath, the new refrigerant hoses are connected to unions on the unit. Harness (left) goes to fuse box. Evaporator drain tube seen top centre. The harness is fed via the existing hole and grommet (arrowed) to the fusebox below the driver’s seat, and connected with an inline fuse. On completion, the system is re-charged with refrigerant and, after a check with the engine running, we’re ready to go.