INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE
INTRODUCTION IMPORTANT NOTICE 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). DEFINITION OF TERMS NOTE WARNING,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 COROLLA VERSO. 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 COROLLA VERSO CDE120R 2001.10~ 1CD-FTV RHD 1. Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation. 2. Refer to the separate manual "INSTALLATION MANUAL (INSIDE PASSENGER COMPARTMENT)" for details on installation for the passenger compartment side. [DOCUMENT CODE AND DOCUMENT PART NUMBER] MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER GENERAL INFORMATION / AOAMC-01* 988963-475* AFTER INSTALLATION INSTALLATION MANUAL (INSIDE PASSENGER COMPARTMENT) AAAMC-28* 988963-509* 2001 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.
1. INSTALLATION INSIDE PASSENGER COMPARTMENT 1. Before starting installation, remove the negative cable from 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. VEHICLE HARNESS First remove the negative terminal on the battery and the vehicle harness connection before installing the equipment. Disconnect the negative cable first. BATTERY AC1895 ENGINE COVER (1) REMOVAL OF ORIGINAL PARTS (a) Engine cover AC4168-1 -
BATTERY (b) Battery and battery tray BATTERY TRAY AC4368 LOOSEN AIR CLEANER BOX UPPER COVER (c) (d) (e) Disconnect the vehicle harness from the air cleaner box upper cover. Temporarily remove the vehicle harness from the clamp of air cleaner box upper cover. Temporarily remove the air cleaner box upper cover from the air cleaner lower cover. VEHICLE HARNESS AIR CLEANER BOX LOWER COVER AC4169 (f) Filter FILTER AC4371 (g) Vehicle harness clamp VEHICLE HARNESS CLAMP AIR CLEANER BOX LOWER COVER AC3621-2 -
AIR CLEANER BOX LOWER COVER (h) Air cleaner box lower cover AC4373 AIR DUCT (i) Air duct AC4374 INSULATOR (j) Insulator AC4170 (k) Reservoir tank RESERVOIR TANK Do not splash cooling water. AC4171-3 -
CLOTH TAPE (l) Fasten the reservoir tank using the cloth tape as shown in the left figure. Ensure that the cloth tape is not put to the injection pipe when fixing the reservoir tank. RESERVOIR TANK AC4172 (m) Plate (n) Front grille GRILLE PLATE AC4376 (o) Radiator upper supports (RH, LH) RADIATOR UPPER SUPPORTS (RH,LH) AC4377 (p) Relay box No.1 RELAY BOX No.1 AC3626-4 -
VEHICLE HARNESS CLIP (q) (r) Temporarily disconnect the vehicle harness from the radiator fan motor. Temporarily remove the vehicle harness clip from the fan shroud. VEHICLE HARNESS AC3627 FAN SHROUD (s) Fan shroud AC3628 HEATER RELAY BOX (t) (u) (v) Temporarily remove the heater relay from the vehicle bracket. Temporarily remove the heater relay box. Temporarily remove the vehicle harness clamp from the vehicle bracket. VIEW:A VIEW:A HEATER RELAY VEHICLE BRACKET VEHICLE HARNESS CLAMP AC4173-5 -
LOOSEN (w) Shift the vehicle bracket as shown in the left figure. VEHICLE BRACKET HEATER RELAY BOX AC4174 (x) Put the heater relay box as shown in the left figure. AC4175 RADIATOR (2) LIQUID TUBE (a) Insert the liquid tube No.1 as shown in the left figure. LIQUID TUBE No.1 AC4385 (b) Route the liquid tube No.1 under the vehicle harness, when inserting the liquid tube No.1. VEHICLE HARNESS LIQUID TUBE No.1 AC4386-6 -
(c) Set the liquid tube No.1 as shown in the left figure. LIQUID TUBE No.1 AC4424 COLLARS (3) CONDENSER AND CONDENSER FAN (a) Assemble two collars and two bushings to the condenser. BUSHINGS CONDENSER AC4420 CONDENSER (b) Lean the radiator backward then insert the condenser in front of radiator. RADIATOR Insert a corrugated board and others before inserting the condenser to prevent the radiator from being damaged. CORRUGATED BOARD AC4387-7 -
VIEWED FROM THE BOTTOM SIDE OF VEHICLE (c) Make sure that the bushings of condenser positively inseter into the vehicle hole. VIHICLE HOLE RUBBER CUSHION CONDENSER VIHICLE HOLE CONDENSER RUBBER CUSHION AC4388 BOLTS (M8 32,SILVER) CONDENSER (d) Install the condeser using two bolts. AC4389-8 -
CONDENSER FAN MOTOR (e) Assemble the condenser fan motor to the fan shroud using three screws. CONDENSER FAN Tightening Torque 3.8 N m (39 kgf cm, 2.8 lbf ft) FAN SHROUD SCREWS (M5 11) NUT (M5) AC3633 The screws must be facing in the direction of installation. (f) Assemble the condenser fan to the condenser fan motor using a nut. Tightening Torque 6.2 N m (63 kgf cm, 4.5 lbf ft) CONDENSER FAN MOTOR CONNECTOR CLAMPS (g) (h) Fasten the condenser fan motor harness to four clamps of the fan shroud. Fasten the condenser fan motor connector to the holder. FAN SHROUD CONDENSER FAN MOTOR HARNESS AC3634-9 -
(4) COMPRESSOR AND COMPRESSOR DRIVE BELT (a) Loosen the lock nut and the adjusting bolt. (b) Remove and discard the P/S pump drive belt. P/S PUMP ADJUSTING BOLT P/S PUMP P/S PUMP DRIVE BELT (DISCARD) LOCK NUT AC4176-10 -
(c) Install the compressor bracket to the engine block using three bolts. Tightening Torque 31.4 N m (320 kgf cm, 23.1 lbf ft) Tightening order; [1]» [2]» [3]» [4] (d) Install the compressor to the compressor bracket using four bolts. Tightening Torque 24.5 N m (250 kgf cm, 18.1 lbf ft) Tightening order; [5]» [6]» [7]» [8] [2] BOLTS (M8 20) [1] COMPRESSOR ENGINE BLOCK [3] [4] [8] [5] COMPRESSOR BRACKET [6] BOLTS (M8 75) [7] AC4177-11 -
COMPRESSOR DRIVE BELT 10kgf P/S PUMP PULLEY (e) Install the compressor drive belt to the pulleys as shown in the left figure. IDLE PULLEY CLANKSHAFT PULLEY COMPRESSOR PULLEY AC4178 (f) Adjust the belt tension, then tighten the adjusting bolt. P/S PUMP ADJUSTING BOLT P/S PUMP 1. The threads on the compressor belt must fit into grooves on the pulley. 2. The belt tension must be measured between the specified pulleys. 3. The tension may be measured between any pulleys when using the DENSO belt tension gauge. 4. Adjust the belt to the center of the range. 5. Adjust the belt by tightening the adjusting bolt. COMPRESSOR DRIVE BELT Belt deflection at 98 N (10 kgf,22 lbf) force Belt tension using the belt tension gauge New Belt 10-12 mm (0.39-0.47 inch) 686-784 N (70-80 kgf, 154-176 lbf) AC4179 Used Belt (Readjustment) 14-17 mm (0.56-0.67 inch) 294-441 N (30-45 kgf, 66-99 lbf) P/S PUMP (g) Tighten the lock nut. Tightening Torque 38.2 N m (390 kgf cm, 28.2 lbf ft) LOCK NUT AC4180-12 -
(h) Pull the vehicle harness (4-P) down. COMPRESSOR TAPING (DISCARD) VEHICLE HARNESS (4-P) AC3650 Mg/C CONNECTOR (4-P) (i) Connect the vehicle harness (4-P) to the Mg/C connector. VEHICLE HARNESS (4-P) COMPRESSOR PIPING LAYOUT TO PASSENGER COMPARTMENT AC3651 BRACKET LIQUID TUBE No.2 SUCTION TUBE No.2 PLASTIC CLAMP No.2 PLASTIC CLAMP No.3 CONDENSER SUCTION HOSE PLASTIC CLAMP No.1 COMPRESSOR SUCTION TUBE No.1 DISCHARGE HOSE LIQUID TUBE No.1 AC3652-13 -
LIQUID TUBE No.1 PLASTIC CLAMP No.1 (5) PIPING (a) Assemble the plastic clamp No.1 to the condenser. (b) Connect the liquid tube No.1 to the condenser using a bolt. Tightening Torque 5.4 N m (55 kgf cm, 4.0 lbf ft) BOLT(M6 25) (c) Fasten the liquid tube No.1 to the plastic clamp No.1. CONDENSER AC4421 (d) Install the plastic clamp No.2 to the body. PLASTIC CLAMP No.2 AC4397 (e) Insert the liquid tube No.2 as shown in the left figure. LIQUID TUBE No.2 AC3653 SCTION TUBE No.2 (f) Insert the suction tube No.2 as shown in the left figure. AC3654-14 -
BOLT(M6 12) SUCTION TUBE No.2 BRACKET LIQUID TUBE No.2 SUCTION TUBE No.2 PIPING BLOCK (g) Install the bracket to the body using a bolt. Catch the turning stopper to the vehicle hole surely. BRACKET LIQUID TUBE No.2 AC3655 (h) (i) Connect the liquid tube No.2 and suction tube No.2 to the piping block. Fasten the liquid tube No.2 and suction tube No.2 to the bracket. SUCTION TUBE No.2 (j) (k) Install the plastic clamp No.3 to the frame. Fasten the suction tube No.2 to the plastic clamp No.3. PLASTIC CLAMP No.3 SUCTION TUBE No.2 PLASTIC CLAMP No.3 AC3656 LIQUID TUBE No.2 CROSS SECTION PACKING LIQUID TUBE No.1 (l) Connect the liquid tube No.2 to the liquid tube No.1. (m) Fasten the liquid tube No.1 to the plastic clamp No.2. (n) Attach the packing around connecting portion of the liquid tube No.1 and liquid tube No.2. PACKING PLASTIC CLAMP No.2 AC4399 COMPRESSOR SUCTION HOSE (o) Connect the suction hose to the compressor using a bolt. Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) BOLT (M6 35) AC3657-15 -
SUCTION TUBE No.2 BOLT (M6 12) (p) (q) (r) Connect the suction tube No.1 to the suction tube No.2. Connect the suction hose to the suction tube No.1. Fasten the bracket of suction tube No.1 to the side member using a bolt. SUCTION TUBE No.1 SUCTION HOSE Catch the turning stopper to the side member surely. AC3658 (s) Fasten the bracket of suction hose to the cross member using a nut. VIEWED FROM BOTTOM SIDE OF VEHICLE Catch the turning stopper to the cross member surely. BRACKET OF SUCTION HOSE NUT(M6) BRACKET OF SUCTION HOSE AC3659 (t) Insert the discharge hose as shown in the left figure. DISCHARGE HOSE DISCHARGE HOSE AC4406-16 -
CONDENSER (u) Connect the discharge hose to the condenser using a bolt. Tightening Torque BOLT (M6 25) 5.4 N m (55 kgf cm, 4.0 lbf ft) DISCHARGE HOSE AC4407 COMPRESSOR (v) Connect the discharge hose to the compressor using a bolt. Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) DISCHARGE HOSE BOLT (M6 35) AC4408 QUICK JOINTS(SMALL AND BIG) (w) Fasten the liquid tube No.2 and suction tube No.2 using two quick joints (small and big). LIQUID TUBE No.2 SUCTION TUBE No.2 AC3660 VEHICLE HARNESS (4-P) (x) Pull the vehicle harness (4-P) down. TAPING AC4409-17 -
VEHICLE HARNESS (4-P) (y) Connect the vehicle harness (4-P) to the pressure switch. PRESSURE SWITCH AC4410 FAN SHROUD (6) FAN SHROUD (a) Reinstall the fan shroud assy. AC3661 (b) Pull the vehicle harness (2-P) down. VEHICLE HARNESS (2-P) TAPING (DISCARD) VEHICLE HARNESS (2-P) AC3662 CONDENSER FAN MOTOR CONNECTOR (c) (d) (e) Reconnect the vehicle harness to the radiator fan motor. Reinstall the vehicle harness clip to the fan shroud. Connect the vehicle harness (2-P) to the condenser fan motor connector. VEHICLE HARNESS CLIP VEHICLE HARNESS AC3663-18 -
(f) Reinstall the reservoir tank to the fan shroud. RESERVOIR TANK AC4171 (g) Reinstall the relay box No.1 to the fan shroud. RELAY BOX No.1 AC3626 (7) RELAYS (a) Temporarily remove the relay box No.1 cover. RELAY BOX No.1 COVER FAN RELAY No.1 (5-P, BROWN) AC3665 FAN RELAY No.2 (4-P, WHITE, BIG) (b) Install the fan relay No.1 and No.2 into the relay box No.1. Be sure to install the relay box by supporting the relay box by hand from the bottom side to prevent a contact defect. RELAY BOX No.1 AC4185-19 -
(c) Reinstall the relay box No.1 cover. RELAY BOX No.1 COVER AC3667 RELAY BOX No.2 COVER (d) Temporarily remove the relay box No.2 cover. RELAY BOX No.2 AC5334 (e) Install the Mg/C relay into the relay box No.2. Mg/C RELAY (4-P, WHITE, SMALL) Be sure to install the relay box by supporting the relay box by hand from the bottom side to prevent a contact defect. AC4186 RELAY BOX No.2 COVER (f) Reinstall the relay box No.2 cover. AC5336-20 -
ENGINE HOOD (8) PLATE (a) Attach the caution plate to the engine hood. NOTE Affix after completely wiping off dust and oil stains from the engine hood. PLATE AC4414 TIGHTEN (9) REINSTALLATION OF ORIGINAL PARTS (a) Reinstall the vehicle bracket original position. VEHICLE BRACKET AC4181 HEATER RELAY BOX (b) (c) (d) Reinstall the vehicle harness clamp to the vehicle bracket. Reinstall the heater relay box. Reinstall the heater relay box to the vehicle bracket. VIEW:A VIEW:A HEATER RELAY VEHICLE BRACKET VEHICLE HARNESS CLAMP AC4182-21 -
(e) Radiator upper supports (RH,LH) RADIATOR UPPER SUPPORTS (RH,LH) AC4377 (f) (g) Front grille Plate GRILLE PLATE AC4376 INSULATOR (h) Insulator AC4183 AIR DUCT (i) Air duct AC4374-22 -
AIR CLEANER BOX LOWER COVER (j) Air cleaner box lower cover Make sure to be inserted the air duct into the air cleaner box lower cover. AC4416 (k) Vehicle harness clamp VEHICLE HARNESS CLAMP AIR CLEANER BOX LOWER COVER AC5341 (l) Filter FILTER AC4418 TIGHTEN AIR CLEANER BOX UPPER COVER (m) Reinstall the air cleaner box upper cover to the air cleaner box lower cover. (n) Reinstall the vehicle harness to the clamp of air cleaner box upper cover. (o) Reconnect the vehicle harness to the air cleaner box upper cover. VEHICLE HARNESS AIR CLEANER BOX LOWER COVER AC4184-23 -
BATTERY (p) Battery & battery tray BATTERY TRAY AC4368 ENGINE COVER (q) Engine cover AC4168-24 -
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2. AFTER INSTALLATION Refer to the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" for details on what to do after installation. (Document code: AOAMC-01*/Document part number: 988963-475*) 2-1.CHARGING REFRIGERANT (HFC-134a) For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AF- TER INSTALLATION: CHARGING REFRIGERANT (134a)". STANDARD AMOUNT OF REFRIGERANT 490 ± 30 g (1.08 ± 0.7 lbs) Ensure to fill the refrigerant to the specified amount. 2-2.RE-ADJUSTMENT OF COMPRESSOR BELT To correct belt deflection caused by initial elongation, the air conditioning must be operated for at least 5 minutes before the final adjustment of the belt. Vehicle equipped with 1CD-FTV E/G Belt deflection [at 98N(10kgf, 22lbf)force] 14-17 mm (0.56-0.67 inch) Belt tension [N (kgf, lbf)] 294-441 N (30-45 kgf, 66-99 lbf) 1. Excessive tension of belt may have an adverse effect on bearings, while excessive slackness can cause the belt to slip, make abnormal noise or shorten the belt life. 2. The belt deflection must be measured between the specified pulleys as indicated in this manual. 3. The belt tension must be measured between the specified pulleys as indicated in this manual. 4. The belt tension must be adjusted to the center of the specified belt tension range. 2-3.ADJUSTMENT OF ENGINE IDLING SPEED The engine revolution is controlled by a computer, therefore adjustment is not required. (when the air conditioning system is started, check whether idling revolution increases.) - 26 -
3. AMPLIFIER - 27 -
4. WIRING DIAGRAM VEHICLE WITH PTC HEATER IG RELAY Mg/C RELAY COMPRESSOR PRESSURE SW IG SW 12V HEATER MAIN RELAY BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND RH BLOWER SW A/C SW AC3934-28 -
PTC PTC RELAY 1 RELAY 2 EFI ECU PS HEATER CORE FAN RELAY No.1 CONDENSER FAN MOTOR RADIATOR FAN MOTOR FAN RELAY No.2 WATER TEMP.SW FAN RELAY No.3 A/C AMP EVA.THERMISTOR MAX HOT SW 246108-648 AC3935-29 -
VEHICLE WITH COMBUSTION HEATER IG RELAY Mg/C RELAY COMPRESSOR PRESSURE SW IG SW 12V HEATER MAIN RELAY BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND RH BLOWER SW A/C SW AC3936-30 -
EFI ECU POWER HEATER SW TO TAIL RELAY ALTER L TERMINAL COMBUSTION HEATER FUEL-PUMP FAN RELAY No.1 CONDENSER FAN MOTOR RADIATOR FAN MOTOR FAN RELAY No.2 WATER TEMP.SW FAN RELAY No.3 A/C AMP EVA.THERMISTOR 246108-648 AC3937-31 -
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DENSO CORPORATION SERVICE DEPARTMENT Kariya, Aichi, Japan Frist Issue :SEPTEMBER 2001 Publication No. : AAAMC-30 Printed in Japan
AAAMC-30 988963-5110