URBAN CRUISER AIR CONDITIONING (RHD) ENGLISH EUROPE

Transcription

1 URBAN CRUISER (RHD) AIR CONDITIONING ENGLISH EUROPE - 0 -

2 IMPORTANT NOTICE DEFINITION OF TERMS INTRODUCTION This manual has been designed for technicians who are qualified and educated in the proper procedures of vehicle safety, handling and maintenance; experienced in installation of car air conditioning or who are able to carry out installation procedures when given instructions by an experienced technician in a supervisory capacity; and are certified to handling refrigerant. 1. Take special care to ensure that clearance between air conditioning components and other components such as brake parts, fuel system and electric wires as specified in this manual. 2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct the problem(s). 3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without prior notice. Refer to the latest installation manual and service information. Any changes affecting the above items will be given in the form of a Installation instructions for air conditioning (Supplement) (issued by DENSO) or a service bulletin (issued by the manufacturer). WARNING CAUTION NOTE,REAR LEFT,RIGHT :Describes precautions that should be observed in order to prevent injury or death to the user during installation. :Describes precautions that should be observed in order to prevent damage to the vehicle or its components, which may occur during installation if insufficient care is taken. :Provides additional information that facilitates installation work. :Shows the direction when viewed from the driver's seat. FOREWORD This manual has been published to explain how to install the air conditioning for TOYOTA URBAN CRUISER. When installing the air conditioning, installation should be performed as described in this manual. [APPLICATION VEHICLE] VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION URBAN CRUISER CAUTION NLP110R ~ NLP115R ~ 1ND-TV Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation. RHD [DOCUMENT CODE AND DOCUMENT PART NUMBER] MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER GENERAL INFORMATION / E* * AFTER INSTALLATION 2009 DENSO CORPORATION All Rights Reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher.

3 1. INSTALLATION INSIDE PASSENGER COMPARTMENT CAUTION 1. Be sure to use the correct oil, refrigerant and charging/recovery equipment. 2. Before starting installation, read all "PRECAUTIONS FOR SAFETY INSTALLATION" thoroughly and follow the instructions described in it. 3. Before starting installation, remove the negative terminal of the battery and ensure seat/floor covers are in position. 4. Take care not to scratch any parts of the vehicle. 5. Sort removed bolts and tapping screws into groups so that they can be reassembled correctly. VEHICLE HARNESS CAUTION First remove the negative terminal of the battery and the vehicle harness connection before installing the equipment. Disconnect the negative terminal first. BATTERY A (1) REMOVAL OF ORIGINAL PARTS-1 (a) Scuff plate (LH) SCUFF PLATE (LH) A

4 (b) Cowl side panel (LH) COWL SIDE PANEL (LH) A (c) Glove box LEFT SIDE OF THE GLOVE BOX DAMPER PORTION GLOVE BOX LOCK PORTION NOTE Remove the glove box in the following order. 1. Press in the sides of the glove box. 2. Bypass the bosses. 3. Lift. BOSS BOSS NOTE 1, 2 NOTE 1, 2 A GLOVE BOX NOTE 3 SCREW (REUSE) VEHICLE WITH INSTRUMENT PANEL UNDER COVER (LH) ONLY [(d)] (d) Instrument panel under cover (LH) (e) Screw (for instrument panel) GUIDE INSTRUMENT PANEL UNDER COVER (LH) A

5 (f) Bolt (for instrument panel) BOLT (REUSE) A PASSENGER AIRBAG CANCEL SWITCH VEHICLE WITH PASSENGER AIRBAG CAN- CEL SWITCH ONLY [(g)-(h)] (g) Airbag connector clip (h) Disconnect the connection of the airbag connector. AIRBAG CONNECTOR CLIP AIRBAG CONNECTOR A HOOK INSTRUMENT PANEL UNDER COVER (RH) VEHICLE WITH INSTRUMENT PANEL UNDER COVER (RH) ONLY [(i)] (i) Instrument panel under cover (RH) GUIDE A INSTRUMENT PANEL LOWER COVER VEHICLE WITHOUT KNEE AIRBAG ONLY [(j)] (j) Instrument panel lower cover :GUIDE :HOOK A

6 VEHICLE WITH KNEE AIRBAG ONLY [(k)] (k) Instrument panel lower cover CAUTION Wear a pair of Kevlar gloves before starting work. INSTRUMENT PANEL LOWER COVER NOTE 1. To ease work, insert your hand from under the instrument panel lower cover to the other side of the panel and release the projections on the upper part of the bracket from the holes on the panel. 2. Release the projections one by one. :GUIDE :HOOK A CLIPS CENTER CLUSTER PANEL (l) Center cluster panel CLIPS CLIPS A (m) Heater control panel (lift up only) CLIPS CLIPS HEATER CONTROL PANEL A

7 (n) Shift cover SHIFT COVER A (o) Shift panel SHIFT PANEL CLIPS A (p) Console box cover CONSOLE BOX COVER NOTE Disconnect the connector of the console box cover from the vehicle harness. : HOOK A (q) (r) Console box carpet Console box CONSOLE BOX CONSOLE BOX CARPET A

8 CLIP GUIDE (s) Center cluster lower cover GUIDE CENTER CLUSTER LOWER COVER A VEHICLE HARNESS CLAMP (t) (u) Bolt (reuse) Vehicle harness clamp BOLT (REUSE) A (v) Floor carpet (LH) FLOOR CARPET (LH) TURN OVER A (w) Silencer mat (LH) SILENCER MAT (LH) A

9 (x) Weather strip (LH) WEATHER STRIP (LH) A (y) Filter cover FILTER COVER A (z) Filter FILTER A BLOWER MOTOR VEHICLE HARNESS CLAMP (2) REMOVAL OF ORIGINAL PARTS-2 (a) Disconnect the vehicle harness from the blower motor. (b) Disconnect the vehicle harness from the blower resistor. (c) Three vehicle harness clamps (d) Vinyl tape (discard) VEHICLE HARNESS BLOWER RESISTOR VEHICLE HARNESS VINYL TAPE (DISCARD) VEHICLE HARNESS CLAMPS A

10 (e) Original foot air duct (LH) (discard) ORIGINAL FOOT AIR DUCT (LH) (DISCARD) BLOWER UNIT HOOK A (f) Two screws (for blower unit lower case) BLOWER UNIT UPPER CASE BLOWER UNIT LOWER CASE SCREWS (REUSE) A BLOWER UNIT LEG (g) blower unit leg NOTE Pull the blower unit lower case toward the back of the body and remove the blower unit leg. BLOWER UNIT LOWER CASE A SCREW (REUSE) (h) (i) Two screws (for blower unit lower case) Bolt (for blower unit lower case) SCREW (REUSE) BLOWER UNIT LOWER CASE BOLT (REUSE) A

11 BLOWER UNIT LOWER CASE (j) Blower unit lower case CAUTION Be careful not to damage the blower unit lower case when removing the blower unit lower case. [1] [2] [3] BLOWER UNIT LOWER CASE A VEHICLE HARNESS (16-P) VEHICLE HARNESS CLAMP VEHICLE WITHOUT ORIGINAL AMPLIFIER ONLY [(k) ~ (l)] (k) Vinyl tape (discard) (l) Vehicle harness clamp VINYL TAPE (DISCARD) VEHICLE HARNESS A VEHICLE HARNESS (16-P) VEHICLE HARNESS CLAMP VEHICLE WITH ORIGINAL AMPLIFIER ONLY [(m) ~ (n)] (m) Disconnect the vehicle harness from the original amplifier. (n) Vehicle harness clamp ORIGINAL AMPLIFIER A

12 (o) Original amplifier (discard) VIEW:A ORIGINAL AMPLIFIER (DISCARD) VIEW:A ORIGINAL AMPLIFIER (DISCARD) [1] ORIGINAL SCREW (DISCARD) [2] A AIRBAG HARNESS AIRBAG ECU AIRBAG ECU ORIGINAL BOLTS (DISCARD) A (p) Airbag ECU WARNING 1. Before starting work always check the cautions and warnings for the SRS airbag system. 2. Make sure the ignition switch is OFF (LOCK) position. 3. Make sure the negative terminal is removed from the battery. 4. If installing airbag sensor assy CTR without disconnecting the negative terminal of the battery, airbag may open if there is an impact on it. Make sure that the negative terminal of the battery is disconnected before installation. 5. Wait at least 90 seconds after negative terminal is disconnected to start installation. 6. Do not disconnect the airbag harness from the airbag ECU when removing the airbag ECU. 7. Put down the airbag ECU in a way that minimizes the force on the airbag harness. 8. Do not subject the airbag sensor to any shocks or force

13 HEATER UNIT LOWER CASE (q) Two screws (for heater unit lower case) SCREWS (REUSE) A (r) Screw (for heater unit lower case) HEATER UNIT LOWER CASE SCREW (REUSE) A (s) Remove the catch of pawl. [1] CAUTION Unhook the catch of pawl and keep as it is. (Do not pull the pawl forcibly because it is easily damaged.) [1] [2] HEATER UNIT LOWER CASE A

14 (t) Drain hose DRAIN HOSE PULL OUT HEATER UNIT LOWER CASE A (u) Heater unit lower case HEATER UNIT LOWER CASE A HEATER UNIT INNER COVER (DISCARD) (v) Heater unit inner cover (discard) HEATER UNIT LOWER CASE A ORIGINAL PACKING (DISCARD) (w) Remove and discard a packing from the heater unit lower case. (x) Attach a packing (included in A/C kit) to the heater unit lower case. PACKING (INCLUDED IN A/C KIT) HEATER UNIT LOWER CASE A

15 EVAPORATOR (3) THERMISTOR (a) Assemble the evaporator to the heater unit lower case. HEATER UNIT LOWER CASE A HEATER UNIT LOWER CASE (b) Assemble the thermistor to the evaporator. CAUTION 1. It shall be only one time to insert the thermistor into the evaporator. 2. When inserting the thermistor into the evaporator again, shift the thermistor one column from the position where one was inserted previously. THERMISTOR 34mm 50mm EVAPORATOR A (c) Assemble the thermistor connector to the heater unit lower case. THERMISTOR CONNECTOR HEATER UNIT LOWER CASE A

16 INSTRUMENT PANEL (4) REINSTALLATION OF THE HEATER UNIT LOWER CASE (a) Insert the heater unit lower case into the instrument panel. [2] [1] HEATER UNIT LOWER CASE A (b) Insert the heater unit lower case. HEATER UNIT LOWER CASE INSTRUMENT PANEL A

17 (c) Insert A and B and C on the heater unit lower case into A and B and C on the heater unit upper case respectively. NOTE Insert the piping unit of evaporator into the vehicle hole. A B C HEATER UNIT UPPER CASE HEATER UNIT LOWER CASE B C NOTE A A (d) Reinstall the heater unit lower case to the heater unit upper case. HEATER UNIT LOWER CASE NOTE CAUTION Be sure not to damage the evaporator fins. Be careful that the pawl at the vehicle side of a heater unit shall not be locked. NOTE A

18 (e) Reinstall the screw for the heater unit lower case of left side. HEATER UNIT LOWER CASE SCREW (REUSE) A HEATER UNIT LOWER CASE (f) Reinstall two screws for the heater unit lower case of right side. SCREWS (REUSE) A INSTRUMENT PANEL BLOWER UNIT LOWER CASE (5) REINSTALLATION OF THE BLOWER UNIT LOWER CASE (a) Insert the blower unit lower case into the instrument panel. [2] [1] A

19 BLOWER UNIT LOWER CASE (b) Insert A and B on the blower unit lower case into A and B on the blower unit upper case respectively. A B B A BLOWER UNIT UPPER CASE A BLOWER UNIT LOWER CASE (c) Place the right side of the blower unit lower case on the heater unit lower case. HEATER UNIT LOWER CASE [2] [1] BLOWER UNIT LOWER CASE A

20 BLOWER UNIT UPPER CASE (d) Reinstall the blower unit lower case to the blower unit upper case. BLOWER UNIT LOWER CASE SCREWS (REUSE) A SCREW (REUSE) (e) Reinstall the blower unit lower case. SCREW (REUSE) BLOWER UNIT LOWER CASE BOLT (REUSE) A BLOWER UNIT LEG (f) Reinstall the blower unit leg to the blower unit lower case. BLOWER UNIT LOWER CASE A

21 SILENCER 90 DRAIN HOSE CAUTION 1 UP MARK CAUTION 2 BELLOWS SECTION HEATER UNIT LOWER CASE (g) Reinstall the drain hose. CAUTION 1. Install the drain hose with UP MARK set to upper side. 2. Do not install drain hose in twisted status. (Be especially careful at bellows section.) 3. Pass drain hose through the correct route (formed silencer section) and allow no part of the hose to be folded. 4. UP MARK must be positioned in the range shown on the left. 5. After installing the drain hose, confirm that the grommet is securely fitted from the engine room. GROMMET DRAIN HOSE A (6) A/C AMPLIFIER (a) Install the A/C amplifier (included in A/C kit) to the heater unit. VIEW:A A/C AMPLIFIER (INCLUDED IN A/C KIT) VIEW:A A/C AMPLIFIER (INCLUDED IN A/C KIT) [1] SCREW ( 6 15) [2] A

22 (7) REINSTALLATION OF ORIGINAL PARTS-1 (a) Airbag ECU Tightening Torque 17.5 N m (180 kgf cm, 13.0 lbf ft) WARNING Before starting work always check the cautions and warnings for the SRS airbag system. CAUTION A AIRBAG HARNESS AIRBAG ECU AIRBAG ECU BOLTS (M8 20) CAUTION 5 DRIP-PROOF SHEET 1. Do not use a dropped airbag sensor. 2. Do not apply shock or force to the airbag sensor. 3. Check whether the carpet, etc. is not caught between the mounting surfaces. 4. Wobble the airbag sensor to make sure that there is no looseness. 5. Check whether drip-proof sheet is warped or is caught in the connector. 6. After completing the task, use the diagnosis instrument to check the diagnosis code. Also, make sure that there are no error codes displayed, and check that the airbag warning lamp is off. (b) Connect the vehicle harness to the A/C amplifier. VEHICLE HARNESS (16-P) (c) Vehicle harness clamp VEHICLE HARNESS CLAMP A/C AMPLIFIER A (d) Foot air duct (LH) (included in A/C kit) FOOT AIR DUCT (LH) (INCLUDED IN A/C KIT) NOTE Install the foot air duct with R,L mark shown in the left figure. BLOWER UNIT HOOK A

23 BLOWER MOTOR VEHICLE HARNESS CLAMP THERMISTOR CONNECTOR VEHICLE HARNESS (2-P) (e) (f) (g) (h) Three vehicle harness clamps Connect the vehicle harness to the thermistor connector. Reconnect the vehicle harness to the blower resistor. Reconnect the vehicle harness to the blower motor. VEHICLE HARNESS BLOWER RESISTOR VEHICLE HARNESS VEHICLE HARNESS CLAMPS A (i) Filter FILTER A (j) Filter cover FILTER COVER A (k) Silencer mat (LH) SILENCER MAT (LH) A

24 (l) Floor carpet (LH) FLOOR CARPET (LH) A VEHICLE HARNESS CLAMP (m) Vehicle harness clamp (n) Bolt (reuse) BOLT (REUSE) A CLIP GUIDE (o) Center cluster lower cover GUIDE CENTER CLUSTER LOWER COVER A (p) (q) Console box Console box carpet CONSOLE BOX CONSOLE BOX CARPET A

25 (r) Console box cover CONSOLE BOX COVER : HOOK A (s) Shift panel SHIFT PANEL CLIPS A (t) Shift cover SHIFT COVER VEHICLE CLAMP A (8) MODE CONTROL BASE (a) Remove the vehicle clamp A

26 VEHICLE HARNESS (b) (c) Set the mode control dial on the position of FACE mode. Disconnect the vehicle harness from the original mode control base. FACE MODE ORIGINAL MODE CONTROL BASE A MODE DAMPER CONTROL (d) Remove the mode damper control from the original mode control base. HOOK CAUTION Be careful not to bend or twist when removing the mode damper cable. MODE DAMPER CABLE ORIGINAL MODE CONTROL BASE A ORIGINAL MODE CONTROL BASE (DISCARD) (e) Remove and discard the original mode control base from the heater control panel. HOOK HEATER CONTROL PANEL A MODE CONTROL BASE (INCLUDED IN A/C KIT) (f) Assemble the mode control base (included in A/C kit) to the heater control panel. HOOK HEATER CONTROL PANEL A

27 MODE DAMPER CONTROL (g) Reinstall the mode damper control to the mode control base. HOOK CAUTION Be careful not to bend or twist when reinstalling the mode damper cable. MODE DAMPER CABLE MODE CONTROL BASE VEHICLE HARNESS (8-P) A (h) Reconnect the vehicle harness to the mode control base. MODE CONTROL BASE A VEHICLE CLAMP (i) Reinstall the vehicle clamp. A (9) REINSTALLATION OF ORIGINAL PARTS-2 (a) Heater control panel CLIPS CLIPS HEATER CONTROL PANEL A

28 CLIPS CENTER CLUSTER PANEL (b) Center cluster panel CLIPS CLIPS A INSTRUMENT PANEL LOWER COVER VEHICLE WITHOUT KNEE AIRBAG ONLY [(c)] (c) Instrument panel lower cover :GUIDE :HOOK A VEHICLE WITH KNEE AIRBAG ONLY [(d)] (d) Instrument panel lower cover CAUTION Wear a pair of Kevlar gloves before starting work. INSTRUMENT PANEL LOWER COVER :GUIDE :HOOK A

29 HOOK INSTRUMENT PANEL UNDER COVER (RH) VEHICLE WITH INSTRUMENT PANEL UNDER COVER (RH) ONLY [(e)] (e) Instrument panel under cover (RH) GUIDE A PASSENGER AIRBAG CANCEL SWITCH VEHICLE WITH PASSENGER AIRBAG CAN- CEL SWITCH ONLY [(f)~(g)] (f) Disconnect the connection of the airbag connector. (g) Airbag connector clip AIRBAG CONNECTOR CLIP AIRBAG CONNECTOR A (h) Bolt (for instrument panel) BOLT (REUSE) A SCREW (REUSE) (i) Screw (for instrument panel) VEHICLE WITH INSTRUMENT PANEL UNDER COVER (LH) ONLY [(j)] (j) Instrument panel under cover (LH) GUIDE INSTRUMENT PANEL UNDER COVER (LH) A

30 (k) Glove box LEFT SIDE OF THE GLOVE BOX GLOVE BOX DAMPER PORTION LOCK PORTION BOSS BOSS GLOVE BOX A (l) Cowl side panel (LH) COWL SIDE PANEL (LH) A (m) Scuff plate (LH) SCUFF PLATE (LH) A

31 2. INSTALLATION INSIDE ENGINE COMPARTMENT CAUTION 1. Before starting installation, remove the negative terminal of the battery. 2. Before making any hoses and tubes connections, apply a few drops of compressor oil to the seat of O-ring and coupling nuts. 3. When tightening and loosening the fittings, use two wrenches for support. 4. Ensure fender covers are in position. 5. Start the work from the inside passenger compartment side. (1) REMOVAL OF ORIGINAL PARTS-1 (a) Front bumper CLOTH TAPE CLOTH TAPE CAUTION 1. Attach the cloth tape as shown, before removing the front bumper. 2. For the removal steps of clamp, remove the lock portion first before removing the clamp. BUMPER A

32 (b) Absorber ABSORBER A (c) Under cover A UNDER COVER (d) Engine cover ENGINE COVER CLIPS A WIPER ARM (LH) (e) Wiper arm (RH, LH) WIPER ARM (RH) COVER A

33 : HOOK COWL TOP VENTILATOR LOUVER (RH) (f) Cowl top ventilator louver (RH) HOOD COWL TOP SEAL HOOD COWL TOP SEAL CLIPS A : HOOK COWL TOP VENTILATOR LOUVER (LH) (g) Cowl top ventilator louver (LH) A COVER (h) Cover A

34 VEHICLE CONNECTOR (i) Wiper motor and link VEHICLE CLAMPS WIPER MOTOR AND LINK A (j) Cowl top panel COWL TOP PANEL COWL TOP PANEL A

35 (k) Bolt CAUTION HOSE BOLT CAUTION Take care not to damage the hose. A (l) Vehicle bracket No.1 VEHICLE BRACKET No.1 A VEHICLE BRACKET No.2 (m) Vehicle bracket No.2 VEHICLE CONNECTOR A VEHICLE CLAMPS (n) Vehicle bracket No.3 VEHICLE CONNECTOR A VEHICLE BRACKET No

36 HEATER INSULATOR (o) Heater insulator A HORN (p) Disconnect the vehicle harness from the horn. VEHICLE HARNESS A VEHICLE CLAMP (q) Remove the hood lock release wire from the vehicle clamp. HOOD LOCK HOOD LOCK RELEASE WIRE VEHICLE CLAMP A VEHICLE WITH VEHICLE HARNESS ONLY [(r) ~ (s)] (r) Vehicle clamp (s) Vehicle connector VEHICLE CONNECTOR A

37 HOOD LOCK (t) Hood lock A (u) Cover up hood lock with cloth to protect from damage. HOOD LOCK CLOTH A (v) Center brace CENTER BRACE A BOLT (w) Bolt A

38 (x) Radiator upper support RADIATOR UPPER SUPPORT A VINYL BAG (y) Radiator reserve tank (lift up only) CAUTION 1. Do not let the hose bend. 2. Wrap the radiator reserve tank with a vinyl bag to protect the alternator from splashes of coolant. RADIATOR RESERVE TANK (LIFT UP ONLY) HOSE CAUTION1 A (2) REMOVAL OF ORIGINAL PARTS-2 (a) Three vehicle clamps VEHICLE CLAMPS A VEHICLE CLAMPS (b) Four vehicle clamps VEHICLE CLAMPS A

39 (c) Plate (RH) PLATE (RH) A (d) Plate (LH) PLATE (LH) A (e) Reinforcement REINFORCEMENT A

40 SEE UP THE UNDER (f) Turn the auto tensioner counterclockwise and insert an hexagonal wrench (5 mm) in the anchoring hole. HEXAGONAL WRENCH (5 mm) BOX-END COMBINATION WRENCH (14 mm) DRIVE SHAFT AUTO TENSIONER HEXAGONAL WRENCH (5 mm) ALTERNATOR PULLEY WATER PUMP PULLEY BOX-END COMBINATION WRENCH (14 mm) A ALTERNATOR (g) Remove and discard the original belt from the pulleys. ORIGINAL BELT (DISCARD) A SEE UP THE UNDER (h) Remove an hexagonal wrench (5 mm) from the anchoring hole. HEXAGONAL WRENCH (5 mm) BOX-END COMBINATION WRENCH (14 mm) DRIVE SHAFT A

41 (3) COMPRESSOR AND COMPRESSOR DRIVE BELT NOTE The following describes how to install the compressor with schematic diagrams. STUD BOLT (M8 98) ENGINE BLOCK BOLT (M8 81) COMPRESSOR NUT (M8) A COMPRESSOR (i) Install the stud bolts in the compressor. STUD BOLT (M8 98) A

42 SEE UP THE UNDER STUD BOLTS (M8 98) HAND TIGHTEN (j) Loosely install the compressor to the engine with stud bolts and bolts. BOLT (M8 81) HAND TIGHTEN COMPRESSOR A SEE UP THE UNDER (k) Fully tighten the stud bolts. STUD BOLTS (M8 98) FULLY TIGHTEN Tightening Torque 15.0 ± 3.0 N m (153 ± 31 kgf cm, 11.0 ± 2.1 lbf ft) COMPRESSOR SEE UP THE UNDER A NUT (M8) FULLY TIGHTEN (l) Fully secure the compressor with bolts and nuts. CAUTION Tightening order; [1]»[2]»[3]»[4] BOLTS (M8 81) FULLY TIGHTEN Tightening Torque Nut : 24.5 N m (250 kgf cm, 18.1 lbf ft) Bolt : 24.5 N m (250 kgf cm, 18.1 lbf ft) COMPRESSOR COMPRESSOR [3] [1] [4] [2] A

43 SEE UP THE UNDER (m) Turn the auto tensioner counterclockwise and insert an hexagonal wrench (5 mm) in the anchoring hole. HEXAGONAL WRENCH (5 mm) BOX-END COMBINATION WRENCH (14 mm) DRIVE SHAFT HEXAGONAL WRENCH (5 mm) AUTO TENSIONER ALTERNATOR PULLEY WATER PUMP PULLEY BOX-END COMBINATION WRENCH (14 mm) A ALTERNATOR (n) Install the compressor drive belt to the pulleys as shown in the left figure. COMPRESSOR DRIVE BELT BELT LAYOUT COMPRESSOR DRIVE BELT ALTERNATOR PULLEY WATER PUMP PULLEY COMPRESSOR PULLEY CRANKSHAFT PULLEY A

44 SEE UP THE UNDER (o) Remove an hexagonal wrench (5 mm) from the anchoring hole. HEXAGONAL WRENCH (5 mm) BOX-END COMBINATION WRENCH (14 mm) DRIVE SHAFT A TAPING (CUT OFF) (p) Pull the vehicle harness. VEHICLE HARNESS (2-P) A (q) Connect the vehicle harness to the compressor. VEHICLE HARNESS (2-P) COMPRESSOR A

45 RADIATOR (4) CONDENSER (a) Install the condenser to the radiator. NOTE Insert the resin bracket at the lower side of condenser into the lower side of the radiator, and then insert the resin bracket at the upper side of condenser into the upper side of radiator. CONDENSER RADIATOR CONDENSER A

46 PIPING LAYOUT TO PASSENGER COMPARTMENT LIQUID TUBE No.3 LIQUID TUBE No.1 SUCTION TUBE No.1 SUCTION TUBE No.2 LIQUID TUBE No.2 DISCHARGE HOSE COMPRESSOR SUCTION HOSE CONDENSER A RADIATOR (5) PIPING-1 (a) Install the plastic clamp [A] to the radiator. PLASTIC CLAMP [A] A (b) Install two plastic clamps [B] to the vehicle body. PLASTIC CLAMPS [B] WASHER TANK A

47 PLASTIC CLAMP [A] (c) Fasten the liquid tube No.1 to the plastic clamp [A]. LIQUID TUBE No.1 MARKING A (d) Loosely connect the liquid tube No.1 to the vehicle body using a bolt. BOLT (M6 14) HAND TIGHTEN LIQUID TUBE No.1 A LIQUID TUBE No.1 (e) Loosely connect the liquid tube No.1 to the condenser using a bolt. BOLT (M6 25) HAND TIGHTEN CONDENSER A EVAPORATOR ASSEMBLY (f) Remove and discard the cap from the evaporator assembly. CAP (DISCARD) A

48 EXPANSION VALVE (g) Connect the expansion valve to the evaporator assembly using two hexagon socket head bolts. EVAPORATOR ASSEMBLY Tightening Torque 3.4 N m (35 kgf cm, 2.5 lbf ft) HEXAGON SOCKET HEAD BOLTS (M5 40) A EXPANSION VALVE (h) Connect the suction tube No.2 to the expansion valve. SUCTION TUBE No.2 A EXPANSION VALVE (i) Connect the liquid tube No.3 to the expansion valve. LIQUID TUBE No.3 A EXPANSION VALVE (j) Loosely connect the suction tube No.2 to the expansion valve using a bolt. SUCTION TUBE No.2 BOLT (M6 20) HAND TIGHTEN A

49 WASHER TANK (k) Fasten the liquid tube No.2 to two plastic clamps [B]. LIQUID TUBE No.2 PLASTIC CLAMPS [B] A NUT (M6) HAND TIGHTEN (l) Loosely connect the liquid tube No.2 to the liquid tube No.1 using a nut. LIQUID TUBE No.2 LIQUID TUBE No.1 A (m) Connect the liquid tube No.3 to the liquid tube No.2. LIQUID TUBE No.3 Tightening torque 13.7 ± 1.0 N m (140 ± 10 kgf cm, 10.1 ± 0.7 lbf ft) LIQUID TUBE No.2 A BOLT (M5 16) HAND TIGHTEN (n) Loosely install bracket No.1 and bracket No.2 to the suction tube No.1 with a bolt. BRACKET No.1 SUCTION TUBE No.1 BRACKET No.2 A

50 PLASTIC CLAMPS [B] (o) Fasten the suction tube No.1 to two plastic clamps [B]. SUCTION TUBE No.1 A NUT (M6) HAND TIGHTEN (p) Loosely connect the suction tube No.1 to the suction tube No.2 using a nut. SUCTION TUBE No.2 SUCTION TUBE No.1 A SUCTION TUBE No.1 (q) Loosely install the bracket No.2 to the vehicle body using a bolt. BRACKET No.2 BOLT (M6 14) HAND TIGHTEN A DISCHARGE HOSE BOLT (M6 25) (r) Connect the discharge hose to the compressor using a bolt. COMPRESSOR Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) MARKING A

51 COMPRESSOR BOLT (M6 25) (s) Connect the suction hose to the compressor using a bolt. Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) SUCTION HOSE A CONDENSER (t) Connect the discharge hose to the condenser using a bolt. BOLT (M6 25) Tightening torque 9.8 N m (100 kgf cm, 7.2 lbf ft) DISCHARGE HOSE MARKING A BOLT (M6 25) HAND TIGHTEN (u) Loosely connect the suction hose to the suction tube No.1 using a bolt. MARKING SUCTION TUBE No.1 SUCTION HOSE A

52 BRAKE BOOSTER HOSE (v) Fully tighten the bolt. Tightening Torque 10 mm OR MORE 9.8 N m (100 kgf cm, 7.2 lbf ft) CAUTION BOLT (M6 20) FULLY TIGHTEN Keep the distance between suction tube No.2 and brake booster hose 10 mm or more. SUCTION TUBE No.2 A SUCTION TUBE No.1 (w) Fully tighten the bolts. Tightening Torque Bolt [A] : 9.8 N m (100 kgf cm, 7.2 lbf ft) BOLT [A] (M6 14) FULLY TIGHTEN BOLT [B] (M5 16) FULLY TIGHTEN A SUCTION TUBE No.1 BOLT (M6 25) FULLY TIGHTEN (x) Fully tighten the bolt. Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) CAUTION NOTE Keep the distance between suction hose and vehicle body 10 mm or more. SUCTION HOSE NOTE Turn the suction hose counterclockwise. SUCTION HOSE ALTERNATOR 10 mm OR MORE A

53 (y) Fully tighten the nut. 5 mm OR MORE Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) CAUTION Keep the distance between suction tube No.2 and brake booster 5 mm or more. BRAKE BOOSTER SUCTION TUBE No.2 NUT (M6) FULLY TIGHTEN SUCTION TUBE No.1 SUCTION TUBE No.2 A LIQUID TUBE No.1 (6) PIPING-2 (a) Fully tighten the bolt. Tightening Torque 5.4 N m (55 kgf cm, 4.0 lbf ft) BOLT (M6 25) FULLY TIGHTEN CONDENSER A NUT (M6) FULLY TIGHTEN (b) (c) Fully tighten the bolt. Fully tighten the nut. Tightening Torque 5.4 N m (55 kgf cm, 4.0 lbf ft) LIQUID TUBE No.2 LIQUID TUBE No.1 BOLT (M6 14) FULLY TIGHTEN A

54 (d) Pull the vehicle harness. ALTERNATOR VEHICLE HARNESS (3-P) TAPING (CUT OUT) A VEHICLE HARNESS (3-P) (e) Connect the vehicle harness to the pressure sensor. NOTE Reinstall the radiator upper support, then secure it with vehicle clamp. VEHICLE CLAMP NOTE PRESSURE SENSOR A HEAD LAMP (LH) (7) RESISTOR (a) Pull the vehicle harness down. TAPING (CUT OUT) VEHICLE HARNESS (2-P) A HEAD LAMP (LH) (b) Install the resistor to the vehicle body using two bolts. (c) Connect the vehicle harness to the resistor. RESISTOR BOLT (M6 14) VEHICLE HARNESS (2-P) A

55 (8) RELAY (a) Temporarily remove the relay box cover from the relay box. HOOK RELAY BOX COVER A FAN No.2 RELAY (BROWN, 5-P) (b) Install the fan No.2 relay (brown, 5-P) into the relay box. RELAY BOX A CAUTION 1. Be sure to install the relay box by supporting the relay box by hand from the bottom side to prevent a contact defect. 2. If fan No.2 relay is already installed in the relay box, relay installation work is unnecessary. Please discard the relay in the A/C kit. (c) Reinstall the relay box cover to the relay box. HOOK RELAY BOX COVER A ENGINE HOOD (9) CAUTION PLATE (a) Attach the caution plate to the engine hood. CAUTION PLATE NOTE Affix after completely wiping off dust and oil stains from the engine hood. A

56 (10) REINSTALLATION OF ORIGINAL PARTS - 1 (a) Reinforcement Tightening Torque Bolt : 40.0 N m (408 kgf cm, 29.5 lbf ft) Nut : 5.6 N m (57 kgf cm, 4.1 lbf ft) REINFORCEMENT A (b) Plate (RH) PLATE (RH) A (c) Plate (LH) PLATE (LH) A VEHICLE CLAMPS (d) Four vehicle clamps VEHICLE CLAMPS A

57 (e) Three vehicle clamps VEHICLE CLAMPS A (f) Radiator reserve tank CAUTION 1. Take care not to damage the hose. 2. Make sure that the hose is not disconnected. RADIATOR RESERVE TANK HOSE CAUTION A RADIATOR UPPER SUPPORT (g) Radiator upper support Tightening Torque 5.5 N m (56 kgf cm, 4.1 lbf ft) (h) Pressure sensor harness clamp PRESSURE SENSOR HARNESS CLAMP RADIATOR UPPER SUPPORT A

58 (i) Bolt BOLT A (j) Center brace CENTER BRACE A HOOD LOCK (k) Hood lock Tightening Torque 7.5 N m (76 kgf cm, 5.5 lbf ft) A VEHICLE CLAMP (l) Hood lock release wire HOOD LOCK HOOD LOCK RELEASE WIRE A

59 VEHICLE CLAMP VEHICLE WITH VEHICLE HARNESS ONLY [(m) ~ (n)] (m) Vehicle connector (n) Vehicle clamp VEHICLE CONNECTOR A HORN (o) Reconnect the vehicle harness to the horn. VEHICLE HARNESS A HEATER INSULATOR (p) Heater insulator Tightening Torque 7.0 N m (71 kgf cm, 5.2 lbf ft) A VEHICLE CONNECTOR (q) Vehicle bracket No.3 Tightening Torque 8.0 N m (82 kgf cm, 5.9 lbf ft) A VEHICLE BRACKET No

60 VEHICLE BRACKET No.2 (r) Vehicle bracket No.2 VEHICLE CONNECTOR A VEHICLE CLAMPS (s) Vehicle bracket No.1 Tightening Torque 11.0 N m (112 kgf cm, 8.1 lbf ft) VEHICLE BRACKET No.1 A (t) Bolt CAUTION HOSE BOLT CAUTION Make sure that the hose is not disconnected. A

61 (u) Cowl top panel Tightening Torque 6.5 N m (66 kgf cm, 4.8 lbf ft) COWL TOP PANEL COWL TOP PANEL A VEHICLE CONNECTOR (v) Wiper motor and link Tightening Torque 5.5 N m (56 kgf cm, 4.1 lbf ft) VEHICLE CLAMPS WIPER MOTOR AND LINK A

62 COVER (w) Cover A : HOOK COWL TOP VENTILATOR LOUVER (LH) (x) Cowl top ventilator louver (LH) A : HOOK COWL TOP VENTILATOR LOUVER (RH) (y) Cowl top ventilator louver (RH) HOOD COWL TOP SEAL HOOD COWL TOP SEAL CLIPS A WIPER ARM SERRATION (z) Clean the wiper arm serration and wiper pivot serration with a wire brush. WIRE BRUSH WIPER PIVOT SERRATION A

63 WIPER ARM (LH) (11) REINSTALLATION OF ORIGINAL PARTS - 2 (a) Attach the wiper arm (LH) with a locknut as shown in the illustration on the left. Tightening Torque 26.0 N m (265 kgf cm, 19.2 lbf ft) CAUTION Holding the arm hinge down with your hand, tighten the locknut. COVER ARM HINGE A (b) Attach the wiper arm (RH) with a locknut as shown in the illustration on the left. WIPER ARM (RH) Tightening Torque 26.0 N m (265 kgf cm, 19.2 lbf ft) CAUTION Holding the arm hinge down with your hand, tighten the locknut. COVER ARM HINGE A

64 (c) Engine cover ENGINE COVER CLIPS A (d) Under cover A UNDER COVER (e) Absorber ABSORBER A

65 (f) Front bumper BUMPER A BATTERY NEGATIVE TERMINAL (g) Reinstall the negative terminal to the battery as shown in the left figure. A

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67 3. AFTER INSTALLATION CAUTION Refer to the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" for details on what to do after installation. CHARGING REFRIGERANT (HFC-134a) For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AF- TER INSTALLATION: CHARGING REFRIGERANT (HFC-134a)". STANDARD AMOUNT OF REFRIGERANT 360 ± 30 g (0.79 ± 0.07 lbs) CAUTION Ensure to fill the refrigerant to the specified amount

68 4. WIRING DIAGRAM IG1 RELAY HEATER MAIN RELAY M4 MB *SMART PUSH: IG ECU HTR MAIN ALTER 12V 40A AM1 *IG SW AM1 AM2 ACC IG1 ST1 IG2 ST2 A/C, GAUGE 7.5A 25 NC IG SW-3 SW-5 27 OUT-7 28 MANUAL A/C ECU CANH CANL 8 9 AD NC SG-1 TE SG-2 PRE S5-2 SOL+ 13 GND GND Vout Vc FIN THERMISTOR PRESSURE SENSOR A

69 A OUTLET TEMPERATURE SENSOR ONLY ECO-RUN CAR ECO-RUN ECU VARIABLE COMPRESSOR METER CANH CANH CANL CANL TX1- SBL TFAL E2 TX1+ EFI ECU CANH CANL HEATER CONTROL OFF OFF A/C Lo M1 M2 Hi BLOWER SW A/C SW ILL M 2 BLOWER MOTOR AMBIENT SENSOR ONLY ECO-RUN CAR RESISTOR

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71 Published : March 2009 Edited and published by: DENSO CORPORATION Service Department 1-1 Showa-cho, Kariya, Aichi Prefecture, Japan Printed in Japan - 0 -

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