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STAL
LATIO
N
M
ANUA
L
AIR CONDITIONINGENGLISH
EUROPE
INSIDEENGINECOMPAR
TMENT
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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)
VEHICLE HARNESS CLIP
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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.
VEHICLE HARNESS (4-P)
TAPING (DISCARD)
AC1903
FRONT
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(c) Connect the vehicle harness to the Mg/C
connector.
Mg/C CONNECTOR (4-P)
FRONT
VEHICLE HARNESS (4-P)
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
3.4 Nm (35 kgfcm, 2.5 lbfft)
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
5.4 Nm (55 kgfcm, 4.0 lbfft)
AC1915
FRONT
BOLT
(M6 25,SILVER)
DISCHARGE TUBE
CONDENSER
(m) Connect the discharge hose to the compressor
using a bolt.
Tightening Torque
9.8 Nm (100 kgfcm, 7.2 lbfft)
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
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(q) Reconnect the vehicle harness to the connector
of the horn.
AC1919
HORN
VEHICLE HARNESS (1-P)
(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
5.4 Nm (55 kgfcm, 4.0 lbfft)
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
9.8 Nm (100 kgfcm, 7.2 lbfft)
COMPRESSOR
AC1922
SUCTIONHOSE
FRONT
BOLT(M6 25,GOLD)
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(v) Fully tighten the bolt.
Tightening Torque
5.4 Nm (55 kgfcm, 4.0 lbfft)
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
VEHICLE HARNESS (2-P)
(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
BOTTOM SIDE OF RELAY BOX
(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)
BOTTOM SIDE OF RELAY BOX
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
BOTTOM SIDE OF RELAY BOX
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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
of the A/C harness No.2 to the relay box.
AC1949
BLUE/WHITE
BLACK/BLUE
WHITE/BLACK
WHITE/BLUE
BLUE/YELLOW
BOTTOM SIDE OF RELAY BOX
(j) Insert four terminals of the A/C harness No.2 to
the relay box.
CAUTION
Check the wire colors before inserting each terminal
of the A/C harness No.2 to the relay box.
AC1950
BLACK/YELLOW
BLUE/BLACK
BLACK/WHITE
BLACK/RED
BOTTOM SIDE OF RELAY BOX
(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
(WHITE, INCLUDED IN KIT)
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
(WHITE, INCLUDED IN KIT)
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
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
7.8 Nm (80 kgfcm, 5.8 lbfft)
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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