airco 88300-52390 aaamc-26 rhd ec

7/30/2019 Airco 88300-52390 Aaamc-26 Rhd Ec

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- 0 -IN

STAL

LATIO

N

M

ANUA

L

AIR CONDITIONINGENGLISH

EUROPE

INSIDEENGINECOMPAR

TMENT


2/46

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.

INTRODUCTION

IMPORTANT NOTICE

DEFINITION OF TERMS

FOREWORDThis manual has been published to explain how to install the air conditioning for TOYOTA YARIS VERSO.When installing the air conditioning, installation should be performed as described in this manual.

[APPLICATION VEHICLE]

CAUTION

[DOCUMENT CODE AND DOCUMENT PART NUMBER]

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 arecertified 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 : Describes precautions that should be observed in order to prevent injury or death to the user

during installation.

CAUTION : 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.

NOTE : Provides additional information that facilitates installation work.

FRONT,REAR

LEFT,RIGHT

: Shows the direction when viewed from the drivers seat.

VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION

YARIS VERSO NLP20R 2001.9~ 1ND-TV 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.

MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER

GENERAL INFORMATION /AFTER INSTALLATION

AOAMC-01* 988963-475*

INSTALLATION MANUAL(INSIDE PASSENGER COMPARTMENT)

AAAMC-25* 988963-501*


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1. INSTRUCTION OF BRANCH CONNECTOR CONNECTION

AC1702

[1] Set the wire harness to which you are connecting on the

insulator assembly.

Put the press connection vehicle harness firmly into the

guide groove.

[2] Fold the connector about the A section.

The terminal is assembled on the insulator. In the unlikely event that it is out of place, since there is a press

fitting hole on the terminal, push the terminal in the direction of the arrow until it is completely press fit.

CONNECTING WIRE HARNESS

GUIDE

GROOVE

TERMINAL

INSULATOR ASSEMBLY A SECTION

CONNECTING WIRE

HARNESS

[3] Temporarily fasten. [4] Hold the temporarily fastened connector with the entire

tip surface of the pliers at the center of the connector

so that force is applied uniformly to A and B.

The temporary fastening lock is only on one side,

so fasten with the top and bottom of the permanent

fastening lock lined up.

When holding the connector with the pliers, check

the left and right lock click sound.

TEMPORARILY FASTENING

LOCK SECTION

PIVOT

PIVOT

B A

[1] Even if the A section is broken, this does not affect

performance, so use the connector as is.

[2] When removing the branch connector, with the

connector still press connected to the other

connecting wire harness, cut away the product

side wire harness leaving about 30 mm, and

insulate with vinyl tape or the like.

A SECTION

CONNECTING WIRE

HARNESS

PRODUCT SIDEWIRE HARNESS

INSULATE VINYL

TAPE OR THE LIKE.

BRANCH CONNECTOR

CAUTIONS FOR BRANCH CONNECTOR CONNECTIONS

PERMANENT

MUST NOT BE

DISCONNECTED.

CAUTION

OK

NG

Do not reuse a used branch connector.

CAUTION

CAUTION

CAUTION

CAUTION

FASTENING LOCK SECTIONS


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2. INSTALLATION INSIDEENGINE COMPARTMENT

CAUTION

1. Before starting installation, remove the negativecable 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.

CAUTION

Since this manual includes the installation methods

of main kit (standard kit) and the additional kit (a

vehicle without the vehicle harness for air

conditioning), part of the procedure will be different

according to availability of the additional kit.

A/C HARNESS No.1

A/C HARNESS No.2PLASTIC TIE

ALTERNATOR

PULLEY

(FOR 90A)

COVER

AC1894

ALTERNATOR

PULLEY

(FOR 70A)

CAUTION

First remove the negative terminal on the battery

and the vehicle harness connection before installing

the equipment.

VEHICLE HARNESS

BATTERY

Disconnect

the negative

cable first.

AC1895


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(1) REMOVAL OF PARTS

(a) Battery

(b) Battery tray

AC1732

BATTERY

TRAY

BATTERY

FRONT

(c) Air duct

AC1733

FRONT

AIR DUCT

AIR CLEANER BOX

(d) Vehicle harness

(e) Vehicle harness clip(f) Air cleaner box (upper side)

AC1734

FRONT

VEHICLE HARNESS

CLIP

LOOSEN

VEHICLE HARNESS

AIR CLEANER BOX

(UPPER SIDE)

(g) Filter

(h) Air cleaner box (lower side)

AC1735

FRONT

AIR CLEANER BOX (LOWER SIDE)

FILTER


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(i) Two vehicle harness clamps

(j) Vehicle bracket [A]

AC1736

FRONT

VEHICLE BRACKET [A]

FRONT

VEHICLE

BRACKET [A]

VEHICLE

HARNESS

CLAMPS

(k) Earth terminal

AC1737

FRONT

EARTH TERMINAL

(l) Front grille

AC1738

FRONT GRILLE

(m) Plates (LH,RH)

AC1739

PLATES (LH, RH)


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(n) Head lamp under cover (LH), bolt and clip (for

head lamp)

NOTE

Unlock the clip for the head lamp under cover at the

back of the head lamp.

RADIATOR UPPER BAFFLE

HEAD LAMP UNDER COVER (LH)

CLIP

AC1740

HEAD LAMP UNDER

COVER (LH) PUSH

(o) Disconnect the vehicle harness from the

connector of the horn.

AC1741

HORN

VEHICLE HARNESS (1-P)

(p) Hood lock

(q) Radiator upper baffle

HOOD LOCKAC1742

RADIATOR UPPER

BAFFLE


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(r) Lift up the head lamp (LH) when removing the

radiator upper baffle.HEAD LAMP(LH)

RADIATOR UPPER

BAFFLE

AC1743

FOR ADDITIONAL KIT ONLY [(s)~(t)]

(s) Front over fender (LH)

NOTE

Except for this clip, remove the other clips and

screws, slide the front over fender to the front of the

vehicle and remove.

AC1745

CLIPS

CLIPS

FRONT OVER FENDER (LH)

CLIP NOTE

(t) Front fender liner (LH)

NOTE

Take care not to remove the front fender liner (LH)

completely.

AC1746

FRONT FENDER

LINER (LH)

CLIPS

CLIPS

SCREWS

FRONT FENDER

LINER (LH)


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(u) Under cover

UNDER COVER

AC1744

(v) Three vehicle harness clamps

(w) Vehicle bracket [B]

AC1747VEHICLE BRACKET [B]

VEHICLE HARNESSCLAMPS

FRONT

(x) Vehicle harness clip

CAUTION

Needle-nose pliers must be used to remove the

vehicle harness clip.

VEHICLE HARNESS CLIP

AC1748

VIEWED FROM INSIDE

FRONT FENDER LINER (LH)



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(2) COMPRESSOR DRIVE BELT AND

COMPRESSOR-1

(a) Loosen the lock bolt of the alternator, then

loosen the adjusting bolt.

FRONT

ADJUSTING BOLT

ALTERNATOR

LOCK BOLTAC1749

ALTERNATOR

LOCK BOLT

ADJUSTINGBOLT

(b) Remove and discard the alternator belt.FRONT

ALTERNATOR BELT(DISCARD)

ALTERNATOR

AC1750

FOR ADDITIONAL KIT ONLY [(c)~(v)]

(c) Temporarily disconnect the vehicle connectorfrom the alternator.

(d) Temporarily remove the vehicle harness clip

from the bracket of the alternator.

(e) Temporarily remove the cap, then remove the

output terminal from the alternator.

FRONT

VEHICLE HARNESS

CLIP

VEHICLE CONNECTOR

ALTERNATOR

AC1751

CAP

OUTPUTTERMINAL

ALTERNATOR

(f) Temporarily remove the lock bolt and the

adjusting bolt from the alternator.FRONT

ADJUSTING BOLT

ALTERNATOR

LOCK BOLTAC1749

ALTERNATOR

LOCK BOLT

ADJUSTING

BOLT


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(g) Temporarily remove the vehicle harness clamp

from the adjusting bar.

(h) Temporarily remove the adjusting bar from the

oil pump.

(i) Temporarily remove the alternator from the

engine block.

AC1752

VEHICLE HARNESS CLAMP

ADJUSTING BAR

FRONT

ALTERNATOR

(j) Remove and discard the original alternator

pulley from the alternator.

NOTE

CAUTION

Procedure will be eased with using a impact

wrench.

Hold the original alternator pulley securely with a

hand as shown in left diagram when using the

impact wrench.

CAUTION

ORIGINAL ALTERNATORPULLEY (DISCARD)

SOCKET (22mm)

ALTERNATOR

CLOTH

IMPACT WRENCHAC1976

(k) Choose the alternator pulleys (included in kit)

according to the current value (90A or 70A)

written on the alternator label.

CAUTION

Identify the alternator pulley (included in kit)

according to collar size on the reverse side of the

pulley.

ALTERNATOR PULLEY

(FOR 70A, INCLUDED IN KIT)

ALTERNATOR PULLEY(FOR 90A, INCLUDED IN KIT)

COLLAR (SMALL)

AC1977

COLLAR (LARGE)

LABEL

ALTERNATOR

(l) Loosely assemble the alternator pulley (included

in kit) to the alternator.ALTERNATOR PULLEY

(HAND TIGHTEN,

INCLUDED IN KIT)

ALTERNATOR AC1978


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(m) Fix the SST by nipping with the vise as shown in

left figure.

CAUTION

Nip the SST with the vise securely to that the SST

won't be shaky.

VISE

SST

AC1979

(n) Set the SST to the alternator as shown in the left

figure.ALTERNATOR

SST

AC1980

(o) Fully tighten the alternator pulley.

CAUTION

Tightening Torque

110.5 Nm (1175 kgfcm, 85.0 lbfft)

1. Carrying out said procedure with 2 or 3 people

is necessary.

2. Hold the alternator with a hand securely as

shown in left figure, and carry out the procedure

with the 3 bosses of SST are set to the 3 holes

of the alternator pulley.

ALTERNATOR

PULLEY

SST

AC1981

ALTERNATOR


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(p) Install the cover to the alternator pulley.

ALTERNATOR

COVER

AC1982

(q) Temporarily tight the alternator to the engine

block with the lock bolt.FRONTALTERNATOR

LOCK BOLT

(HAND TIGHTEN)

AC1983

ALTERNATOR

LOCK BOLT

(r) Temporarily tight the adjusting bar to the oil

pump and the alternator with nut and adjustingbolt to carry out the adjusting bar positioning.

(s) Draw the alternator to the engine block side after

checking that the alternator rotates smoothly.

AC1984

VEHICLE HARNESS CLAMP

ADJUSTING BAR

FRONT

ALTERNATOR

ADJUSTING BOLT

(HAND TIGHTEN)

(t) Reinstall the output terminal and the cap to the

alternator.

(u) Reinstall the vehicle harness clip to the bracket

of the alternator.

(v) Reconnect the vehicle connector to the

alternator.

Tightening Torque

9.8 Nm (100 kgfcm, 7.2 lbfft)FRONT

VEHICLE HARNESSCLIP

VEHICLE CONNECTOR

ALTERNATOR

AC1985

CAP

OUTPUTTERMINAL

ALTERNATOR


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(3) COMPRESSOR DRIVE BELT AND

COMPRESSOR-2

(a) Install the compressor to the engine block using

four bolts.

CAUTION

Tightening Torque

24.5 Nm (250 kgfcm, 18.1 lbfft)

First, hand tighten the bolt No.4.

Tightening order; [1] [2] [3] [4]

AC1753

ENGINE BLOCK

COMPRESSOR

[1]

[3]

[4]

[2]

BOLT(M8 81)

EXCEPT FOR ADDITIONAL KIT [(b)~(c)]

(b) Pull the vehicle harness down.


TAPING (DISCARD)

AC1903

FRONT


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(c) Connect the vehicle harness to the Mg/C

connector.

Mg/C CONNECTOR (4-P)

FRONT


AC1904

(d) Install the compressor drive belt as shown in the

left figure.

(e) Rotate the water pump pulley a half-turn

clockwise to adjust the belt position.

COMPRESSOR

DRIVE BELT

COMPRESSOR

PULLEY

WATER PUMP PULLEY

(HALF-TURN CLOCKWISE)

CRANKSHAFT PULLEY

ALTERNATOR

PULLEY

AC1754

10kgf

(f) Adjust the belt tension, then tighten the adjusting

bolt.

CAUTION

Tightening Torque

18.5 Nm (189 kgfcm, 13.6 lbfft)

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 anypulleys 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.

Belt deflection at

98 N(10 kgf, 22

lbf) force

Belt tension using

the belt tension

gauge

New Belt 5-6 mm

(0.2-0.24 inch)

90-110 kgf

(198-242 lbf)Used Belt

(Re- adjustment)

7-8.5 mm

(0.28-0.33 inch)

40-60 kgf

(88-132 lbf)

FRONT

ADJUSTING BOLT

ALTERNATOR

AC1755

COMPRESSOR DRIVE BELT


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(g) Tighten the lock bolt.

CAUTION

Tighten the lock bolt with cohering the slide bush to

the engine block.

Tightening Torque

54 Nm (550 kgfcm, 39.6 lbfft)

FRONT

ALTERNATOR

LOCK BOLTALTERNATOR

LOCK BOLT

LOCK BOLT

SLIDE BUSH

ALTERNATOR

AC1756ENGINE BLOCK

(4) CONDENSER

(a) Install two rubber cushions to the condenserlower bracket.

(b) Install two bushings and two collars to the

condenser upper bracket.

AC1757

CONDENSER

RUBBER CUSHIONS

COLLARS

BUSHINGS

(c) Connect the liquid tube No.1 to the condenser

using a bolt.

Tightening Torque

5.4 Nm (55 kgfcm, 4.0 lbfft)

AC1758

CONDENSER

BOLT(M6 25, SILVER)

LIQUID TUBE No.1


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(d) Temporarily slide the radiator to the right side of

the vehicle.

(e) Insert a piece of cardboard along the front of the

radiator to avoid scratching the radiator fins.

(f) Insert the condenser in front of the radiator.

CAUTION

Make sure that the rubber cushion positively

inserted into the vehicle hole.

AC1759

CAUTION

CONDENSER

CARDBOARD

RADIATOR

(g) Fasten the liquid tube No.1 to the body using a

bolt.

CAUTION

The liquid tube No.1 must not interfere with the

vehicle body.

AC1760

LIQUID TUBE No.1

FRONTBOLT

(M6 14, BLACK)

(h) Reinstall the radiator to the original position.

AC1761

RADIATOR


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PIPING LAYOUT

AC1902

COMPRESSOR

SUCTION HOSE

CONDENSER

LIQUID TUBE No.2

COOLING UNIT

LIQUID TUBE No.1

DISCHARGE HOSE

DISCHARGE TUBE

(5) PIPING

(a) Connect the expansion valve to the cooling unitcase using two bolts.

Tightening Torque


AC1905

EXPANSION VALVE

FRONT

COOLING UNITBOLTS (M5 40)

(b) Fasten the plastic clamp to the frame.

PLASTIC CLAMP

FRONT

AC1906


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(c) Temporarily set the liquid tube No.2 as shown in

the left figure.

AC1907

LIQUID TUBE No.2

FRONT

(d) Insert the suction hose from upside.

AC1908

FRONT

SUCTION HOSE

(e) Route the suction hose while lifting up the

vehicle harness as shown in the left figure.

CAUTION

Avoid stretching the vehicle harness too hard.

AC1909

FRONT VEHICLE HARNESS

SUCTION HOSE

(f) Temporarily set the suction hose as shown in the

left figure.

AC1910

SUCTION HOSE

LIQUID TUBE No.2

FRONT


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(g) Connect the liquid tube No.2 to the expansion

valve.

AC1911

EXPANSION VALVE

FRONT

LIQUID TUBE No.2

(h) Route and connect the liquid tube No.2 to the

liquid tube No.1.

LIQUID TUBE No.1

LIQUID TUBE No.2

FRONT

AC1912

(i) Connect the suction hose to the expansion

valve.(j) Hand tighten a bolt of the expansion valve.

AC1913

SUCTION HOSE

FRONT

EXPANSION VALVE

LIQUID TUBE No.2

BOLT(M6 20, BLACK)

(k) Fasten the suction hose and the liquid tube No.2

to the plastic clamp.

SUCTION HOSE PLASTIC CLAMP

AC1914

LIQUID TUBE No.2


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(l) Connect the discharge tube to the condenser

using a bolt.

Tightening Torque


AC1915

FRONT

BOLT

(M6 25,SILVER)

DISCHARGE TUBE

CONDENSER

(m) Connect the discharge hose to the compressor

using a bolt.

Tightening Torque


COMPRESSOR

AC1916

DISCHARGEHOSE

FRONT

BOLT(M6 25,GOLD)

(n) Route the hood lock release wire as shown in

the left figure.

AC1917

HOOD LOCK RELEASE WIRE

FRONT

CONDENSER

(o) Reinstall the radiator upper baffle.

CAUTION

(p) Reinstall the hood lock.

Be careful not to pinch the hood lock release wire

when reinstallation the radiator upper baffle.

HOOD LOCKAC1742

RADIATOR UPPER

BAFFLE


22/46

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(q) Reconnect the vehicle harness to the connector

of the horn.

AC1919

HORN


(r) Install the condenser to the radiator upper baffle

using two bolts.BOLT (SILVER)(M8XR32)

AC1920

CONDENSER

(s) Connect the discharge hose to the discharge

tube using a nut.(t) Fasten the clamp of discharge hose to the

radiator upper baffle using a bolt.

Tightening Torque


AC1921

NUT(M6)

DISCHARGE TUBE

RADIATOR UPPERBAFFLE

DISCHARGE HOSE

BOLT

(M6 16 ) CLAMP OF

DISCHARGE HOSE

FRONT

(u) Connect the suction hose to the compressor

using a bolt.

Tightening Torque


COMPRESSOR

AC1922

SUCTIONHOSE

FRONT

BOLT(M6 25,GOLD)


23/46

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(v) Fully tighten the bolt.

Tightening Torque


AC1923

SUCTION HOSE

FRONT

EXPANSION VALVE

FULLY TIGHTEN

LIQUID TUBE No.2

(w) Fasten the suction hose to the frame using the

clamp and a bolt.

CLAMP

SUCTION

HOSE

SUCTION HOSE

CLAMP

AC1924

BOLT (M6X 16)

EXCEPT FOR ADDITIONAL KIT [(x)~(y)]

(x) Pull the vehicle harness down.(y) Connect the vehicle harness to the pressure

switch.

FRONT

VEHICLE HARHESS

(4-P)

PRESSURE SWITCH

AC1925

(6) RESISTOR

(a) Install the resistor to the body using two bolts.

BOLTS

(M6 14)RESISTOR

AC1926

HEAD LAMP (LH)


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EXCEPT FOR ADDITIONAL KIT [(b)~(c)]

(b) Pull the vehicle harness down.

(c) Connect the vehicle harness to the resistor.

AC1927

RESISTOR


(d) Head lamp under cover (LH), bolt and clip (for

head lamp)

AC1928

RADIATOR UPPER BAFFLE CLIPS

HEAD LAMP UNDER COVER (LH)

WIRING LAYOUT

AC1929

A/C HARNESS No.2

WIRING LAYOUT

TO RADIATOR FAN (2-P)

TO COMPRESSOR (4-P)

A/C HARNESS No.2

TO INSIDE ENGINE

COMPARTMENT

TO INSIDEPASSENGER

COMPARTMENT

RELAY BOX

TO PRESSURE SWITCH (4-P)

TO INSIDE FRONT FENDER

LINER (RH)

TO RESISTOR (2-P)

TO VEHICLE HARNESS

(2-P)


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(7) WIRING-1 (FOR ADDITIONAAL KIT ONLY)

(a) Temporarily remove the relay box from the body.

(b) Temporarily remove the relay box cover (upper

side) and the vehicle harness from the relay box.

AC1930

VEHICLE HARNESS

RELAY BOX

RELAY BOX COVER

(UPPER SIDE)

(c) Temporarily remove the relay box cover (lower

side) from the relay box.

CAUTION

Be careful not to break hooks of the relay box cover.

HOOKS

HOOKS

RELAY BOX COVER

(LOWER SIDE)AC1931

(d) Insert the A/C harness No.2 to inside front

fender liner (LH).

AC1932

FRONTA/C HARNESS No.2

[TO INSIDE FRONTFENDER LINER (LH)]

A/C HARNESS No.2

[TO RADIATOR FAN]

(e) Route the A/C harness No.2 above the vehicle

frame.INSIDE FRONT FENDER LINER (LH)

AC1933

TO INSIDE ENGINE

COMPARTMENT

A/C HARNESS No.2

VEHICLE FRAME


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(f) Remove and discard the vehicle grommet.

(g) Pass the A/C harness No.2 through the vehicle

hole and pull out it inside passenger

compartment.

NOTEFirst, route the A/C harness No.2 the inside

passenger compartment.

AC1934

A/C HARNESS No.2

TO INSIDE ENGINE

COMPARTMENT

VEHICLE GROMMET

(DISCARD)

TO INSIDE PASSENGER

COMPARTMENT

CAUTION

At this point, discontinue the engine compartment

and move to the work inside passenger

compartment.

(8) WIRING-2 (FOR ADDITIONAL KIT ONLY)

(a) Secure the A/C harness No.2 to the vehicleharness using three plastic ties.

CAUTION

Further work will be continued after the work inside

passenger compartment is completed.

AC1935

VEHICLE HARNESS

TO INSIDE PASSENGER

COMPARTMENT

PLASTIC TIES

A/C HARNESS No.2

TO INSIDE ENGINE

COMPARTMENT

(b) Disconnect the vehicle harness from the

connector of the radiator fan.

AC1936

FRONT

RADIATOR FAN

VEHICLE HARNESS

(2-P)


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(c) Connect the A/C harness No.2 to the vehicle

harness (disconnected the connector of the

radiator fan).

AC1937

FRONT

A/C HARNESS No.2 (2-P)VEHICLE HARNESS

(2-P, DISCONNECTED

THE CONNECTOR OF

THE RADIATOR FAN)

(d) Connect the A/C harness No.2 to the connector

of the radiator fan.

AC1938

FRONT

RADIATOR FAN

A/C HARNESS No.2

(2-P, GRAY)

(e) Connect the A/C harness No.2 to the pressure

switch.

PRESSURE SWITCH

A/C HARNESS No.2 (4-P)LIQUID TUBE No.1

AC1939

FRONT

(f) Connect the A/C harness No.2 to the resistor.

AC1940

RESISTOR

A/C HARNESS No.2

(2-P, BLACK)


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(g) Secure the A/C harness No.2 to the vehicle

harness using three plastic ties.

AC1941

A/C HARNESS No.2

PLASTIC TIES

PLASTIC TIE

FRONT

(9) WIRING-2 AND RELAY (FOR ADDITIONAL KIT

ONLY)

(a) Remove the fan relay No.1 (reuse) and the fan

relay No.2 (discard) from the relay box.

CAUTION

Depending on a vehicle model, fan relay No.2 might

not be installed.

FAN RELAY No.2

(DISCARD)

FAN RELAY No.1

(REUSE)

RELAY BOX

AC1942

(b) Push the terminal of the vehicle harness using

the precision (-) screwdriver when pulling out itfrom the relay box as shown in the left figure.

RELAY BOX

TERMINAL OF THE VEHICLE HARNESS

PRESION (-) SCREWDRIVER

AC1943

(c) Pull out the terminal of lead wire (white/blue) of

the vehicle harness from the relay box.

CAUTION

Do not mistake the lead wire colors.

AC1944

TERMINAL OF THE VEHICLE HARNESS

(WHITE/BLUE)

BOTTOM SIDE OF RELAY BOX


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(d) The left figure is the insulation processing

method of the lead wire after removing the

terminal of the vehicle harness from the relay

box.

CAUTIONBeware of the insulation processing method since

the method will differ according to number of the

lead wires caulked to the terminal of the vehicle

harness.

AC1945TERMINAL

VINYL

TAPE

LEAD WIRES

SINGLE LEAD WIRE ONLY TWIN LEAD WIRES ONLY

CAUTION

TERMINAL

VINYL

TAPE

LEAD WIRE

CUT OFF

(e) Insert the terminal of the A/C harness No.2 to

the relay box.

CAUTION

Check the wire colors before inserting the terminal

of the A/C harness No.2 to the relay box.

AC1946

YELLOW/RED


(f) Connect the A/C harness No.2 to the lead wire

(pink/blue) of the vehicle harness using thebranch connector.

CAUTION

NOTE

Do not mistake the lead wire color.

See the P.1 for the connection of the branch

connector.AC1947

BRANCH

CONNECTOR

BLACK/BLUE

LEAD WIRE

(PINK/BLUE)


VEHICLE HARNESS WITH THE TERMINAL IS

INSERTED IN THE RELAY BOX (BOTTOM

SIDE OF FAN RELAY No.2) ONLY [(g)~(h)]

(g) Pull out five terminals of the vehicle harness

from the relay box.

AC1948

FIVE TERMINALS OF THE VEHICLE HARNESS



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(h) The left figure is the insulation processing

method of the lead wire after removing the

terminal of the vehicle harness from the relay

box.

CAUTIONBeware of the insulation processing method since

the method will differ according to number of the

lead wires caulked to the terminal of the vehicle

harness.

AC1945TERMINAL

VINYL

TAPE

LEAD WIRES

SINGLE LEAD WIRE ONLY TWIN LEAD WIRES ONLY

CAUTION

TERMINAL

VINYL

TAPE

LEAD WIRE

CUT OFF

(i) Insert five terminals of the A/C harness No.2 to

the relay box.

CAUTION

Check the wire colors before inserting each terminal


AC1949

BLUE/WHITE

BLACK/BLUE

WHITE/BLACK

WHITE/BLUE

BLUE/YELLOW


(j) Insert four terminals of the A/C harness No.2 to

the relay box.

CAUTION

Check the wire colors before inserting each terminal


AC1950

BLACK/YELLOW

BLUE/BLACK

BLACK/WHITE

BLACK/RED


(k) Secure the A/C harness No.2 to the vehicle

harness using a plastic tie.

FRONT

AC1951

PLASTIC TIE

A/C HARNESS No.2

RELAY BOX


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(l) Reinstall the relay box cover (lower side) to the

relay box.

HOOKS

HOOKS

A/C HARNESS No.2RELAY BOX COVER

(LOWER SIDE)AC1952

(m) Reinstall the fan relay No.1 to the relay box.

(n) Install the fan relay No.2 (white, included in kit)

and Mg/C relay (white, included in kit) to the

relay box.

CAUTION

Be sure to install the relay box by supporting the

relay box by hand from the bottom side to prevent a

contact defect.

Mg/C RELAY

(WHITE, INCLUDED IN KIT)

FRONT

AC1953

FAN RELAY No.2


FAN RELAY No.1(REUSE)

(o) Reinstall the relay box to the body.

(p) Reinstall the relay box cover (upper side) andthe vehicle harness to the relay box.

AC1954

VEHICLE HARNESS

RELAY BOX

RELAY BOX COVER(UPPER SIDE)

(q) Secure the A/C harness No.2 to the vehicle

harness using two plastic ties.

AC1955

A/C HARNESS No.2

PLASTIC TIES

FRONT


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(r) Secure the A/C harness No.2 to the vehicle

harness using two plastic ties.

AC1956

FRONT

PLASTIC TIES

A/C HARNESS No.2

(s) Secure the A/C harness No.2 to the vehicle

harness using three plastic ties.

CAUTION

Care should be taken so that the plastic ties do not

interfere with the fuel system parts.

AC1957

PLASTIC TIES

A/C HARNESS No.2

FRONT

TO Mg/C CONNECTOR

(4-P)

(t) Secure the A/C harness No.2 to the vehicle

harness using a plastic tie.

AC1958

A/C HARNESS No.2

PLASTIC TIE

FRONT

(u) Connect the A/C harness No.2 to the Mg/C

connector.

FRONT

AC1959

Mg/C CONNECTOR (4-P)

A/C HARNESS No.2

(4-P)


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(10) RELAY (EXCEPT FOR ADDITIONAL KIT)

(a) Temporarily remove the relay box cover from the

ready box.

(b) Remove and discard the original fan relay No.2

from the relay box.

CAUTION

(c) Install the fan relay No.2 (white, included in kit

and Mg/C relay (white, included in kit) to the

relay box.

CAUTION

(d) Reinstall the relay box cover to the relay box.

Depending on a vehicle model, fan relay No.2 might

not be installed.

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

RELAY BOX

COVER

FRONT

FRONT

Mg/C RELAY

(WHITE, INCLUDED IN KIT) AC1960

FAN RELAY No.2


ORIGINAL FAN RELAY

No.2 (DISCARD)

(11) CAUTION PLATE

(a) Attach the caution plate to the radiator upperbaffle.

CAUTION

Stick on the caution plate after wiping off all dust

and oil from the radiator upper baffle.

RADIATOR UPPER BAFFLE

AC1961

CAUTION PLATE

(12) REINSTALLATION OF ORIGINAL PARTS

FOR ADDITIONAL KIT ONLY [(a)~(b)]

(a) Front fender liner (LH)

AC1962

CLIPS

CLIPS

SCREWS

FRONT FENDER

LINER (LH)


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(b) Front over fender (LH)

NOTE

Reinstall the front over fender to the original

position after installing this clip to the front over

fender.

AC1745

CLIPS

CLIPS

FRONT OVER FENDER (LH)

CLIP NOTE

(c) Under cover

UNDER COVER

AC1744

(d) Plates (LH,RH)

AC1739

PLATES (LH, RH)

(e) Front grille

AC1738

FRONT GRILLE


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(f) Vehicle harness clip


AC1964

(g) Vehicle bracket [B]

(h) Three vehicle harness clamps

Tightening Torque

19 Nm (194 kgfcm, 14 lbfft)

AC1965VEHICLE BRACKET [B]

VEHICLE HARNESSCLAMPS

FRONT

(i) Vehicle bracket [A]

(j) Tow vehicle harness clamps

Tightening Torque

19 Nm (194 kgfcm, 14 lbfft)

AC1966

FRONT

VEHICLE BRACKET [A]

FRONT

VEHICLE

BRACKET [A]

VEHICLE

HARNESS

CLAMPS

(k) Earth terminal

CAUTION

Tightening Torque


Catch the turning stopper to the vehicle hole surely.

AC1967

FRONT

CAUTION

EARTH TERMINAL


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(l) Air cleaner box (lower side)

(m) Filter

CAUTION

Handle the filter with care.In particular, the front/

back and top/bottom surfaces.

AC1968

FRONT

AIR CLEANER BOX (LOWER SIDE)

FILTER

FRONT

(n) Air cleaner box (upper side)

(o) Reconnect the vehicle harness to the air cleaner

box.

(p) Vehicle harness clip

AC1969

FRONT

VEHICLE HARNESS

CLIP

TIGHTEN

VEHICLE HARNESSAIR CLEANER BOX

(UPPER SIDE)

(q) Air duct

AC1733

FRONT

AIR DUCT

AIR CLEANER BOX

(r) Battery tray

(s) Battery

AC1732

BATTERY

TRAY

BATTERY

FRONT


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(t) Reinstall the battery terminals as shown in the

left figure.

AC1970FRONT

BATTERY TERMINAL (-)

BATTERY TERMINAL (+)

PARALLEL

BATTERY


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3. AFTER INSTALLATION

CAUTION

3-1.CHARGING REFRIGERANT (HFC-134a)

For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AF-TER INSTALLATION" (pages 12-15,21).

CAUTION

3-2.RE-ADJUSTMENT OF COMPRESSOR BELT

To correct belt deflection caused by initial elongation, the air conditioning must be operated for at least 5 minutes beforethe final adjustment of the belt.

CAUTION

3-3.ADJUSTMENT OF ENGINE IDLING SPEED

CAUTION

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*)

STANDARD AMOUNT OF REFRIGERANT 440 30 g (0.97 0.07 lbs)

Ensure to fill the refrigerant to the specified amount.

Belt deflection

[at 98N(10kgf, 22lbf)force]

Belt tension

[N (kgf)]

Vehicle equipped with 1ND-TV E/G 7 - 8.5 mm

(0.28 - 0.33 inch)

392 - 588 N

(40 - 60 kgf)

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.

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.)


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4. AMPLIFIER


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5. WIRING DIAGRAM

EXCEPT FOR ADDITONAL KIT

HEATER

MAIN RELAYBLOWER

MOTOR

BLOWER

RESISTERFAN RELAY No.1

12V

BLOWER

SWITCHA/C SW

A/C AMP

TAIL

TAIL

AC1972

IG SW


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246108-054

AC1973

RADIATOR

FAN MOTOR FAN RELAY No.2 RESISTOR

WATER TEMP.SWITCH

Mg/C RELAY

TRIPLE PRESSURE

SWITCH

COMPRESSOR

EFI ECU

EVA.

THERMISTOR


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FOR ADDITIONAL KIT

A/C AMP

A/C SWBLOWER

SWITCH

EARTH 1

TAIL

TAIL

12V

FUSE

IG SW

HEATER

MAIN RELAY

BLOWER

MOTOR

BLOWER

RESISTORFAN

RELAY No.1

AC1974


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246108-068

AC1975

TRIPLE PRESSURESWITCH

COMPRESSOR

Mg/C RELAY

WATER TEMP.

SWITCH

RESISTOR

FAN RELAY No.2RADIATOR

FAN MOTOR

EFI ECU

EVA.THERMISTOR


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DENSO CORPORATION

SERVICE DEPARTMENT

Kariya, Aichi, Japan

First lssue : SEPTEMBER 2001

Publication No. : AAAMC-26

Printed in Japan


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airco 88300-52390 aaamc-26 rhd ec

Documents