EUROPE

ENGLISH

INSTALLATION

AIR CONDITIONING
INSIDE ENGINE COMPARTMENT

-0-

MANUAL

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
WARNING CAUTION NOTE FRONT,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 drivers seat.

FOREWORD
This 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] VEHICLE NAME YARIS VERSO MODEL CODE NLP20R PRODUCTION PERIOD 2001.9~ ENGINE TYPE 1ND-TV STEERING POSITION RHD

CAUTION
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 GENERAL INFORMATION / AFTER INSTALLATION INSTALLATION MANUAL
(INSIDE PASSENGER COMPARTMENT)

DOCUMENT CODE AOAMC-01* AAAMC-25*

DOCUMENT PART NUMBER 988963-475* 988963-501*

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. INSTRUCTION OF BRANCH CONNECTOR CONNECTION

[1] Set the wire harness to which you are connecting on the insulator assembly. [2] Fold the connector about the A section.

CAUTION
Put the press connection vehicle harness firmly into the guide groove. CONNECTING WIRE HARNESS GUIDE GROOVE TERMINAL CONNECTING WIRE HARNESS

INSULATOR ASSEMBLY

A SECTION

CAUTION
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. [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. PIVOT

OK
B TEMPORARILY FASTENING LOCK SECTION A PIVOT

NG
CAUTION
When holding the connector with the pliers, check the left and right lock click sound.

PERMANENT

FASTENING LOCK SECTIONS

CAUTION
The temporary fastening lock is only on one side, so fasten with the top and bottom of the permanent fastening lock lined up. CAUTIONS FOR BRANCH CONNECTOR CONNECTIONS [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

MUST NOT BE DISCONNECTED.

CAUTION
Do not reuse a used branch connector. INSULATE VINYL TAPE OR THE LIKE. BRANCH CONNECTOR PRODUCT SIDE WIRE HARNESS
AC1702

-100500082

2.

INSTALLATION INSIDE ENGINE COMPARTMENT

CAUTION

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.

A/C HARNESS No.1

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.2

ALTERNATOR PULLEY PLASTIC TIE (FOR 90A)

COVER ALTERNATOR PULLEY (FOR 70A)

AC1894

CAUTION
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

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BATTERY

(1)

REMOVAL OF PARTS (a) Battery (b) Battery tray

BATTERY TRAY

FRONT

AC1732

(c) Air duct

AIR CLEANER BOX

AIR DUCT FRONT

AC1733

FRONT

AIR CLEANER BOX (UPPER SIDE)

VEHICLE HARNESS

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

LOOSEN

VEHICLE HARNESS CLIP

AC1734

FRONT FILTER

(g) Filter (h) Air cleaner box (lower side)

AIR CLEANER BOX (LOWER SIDE)

AC1735

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FRONT VEHICLE HARNESS CLAMPS VEHICLE BRACKET [A]

(i) (j)

Two vehicle harness clamps Vehicle bracket [A]

FRONT VEHICLE BRACKET [A]

AC1736

(k) Earth terminal

EARTH TERMINAL

FRONT
AC1737

(l)

Front grille

FRONT GRILLE
AC1738

(m) Plates (LH,RH)

PLATES (LH, RH)

AC1739

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RADIATOR UPPER BAFFLE

(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.

HEAD LAMP UNDER COVER (LH)

CLIP

HEAD LAMP UNDER COVER (LH)

AC1740

PUSH

(o) Disconnect the vehicle harness from the connector of the horn.

HORN

VEHICLE HARNESS (1-P)

AC1741

RADIATOR UPPER BAFFLE

(p) Hood lock (q) Radiator upper baffle

HOOD LOCK
AC1742

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(r)
RADIATOR UPPER BAFFLE HEAD LAMP(LH)

Lift up the head lamp (LH) when removing the radiator upper baffle.

AC1743

CLIPS CLIPS CLIP NOTE

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.

FRONT OVER FENDER (LH)

AC1745

CLIPS CLIPS FRONT FENDER LINER (LH)

(t)

Front fender liner (LH)

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

SCREWS

AC1746

FRONT FENDER LINER (LH)

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(u) Under cover

UNDER COVER

AC1744

(v) Three vehicle harness clamps (w) Vehicle bracket [B]

VEHICLE HARNESS CLAMPS

VEHICLE BRACKET [B]

FRONT
AC1747

(x) Vehicle harness clip

CAUTION
Needle-nose pliers must be used to remove the vehicle harness clip.

VEHICLE HARNESS CLIP

VIEWED FROM INSIDE FRONT FENDER LINER (LH) VEHICLE HARNESS CLIP

AC1748

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(2)
FRONT ALTERNATOR ADJUSTING BOLT

COMPRESSOR DRIVE BELT AND COMPRESSOR-1 (a) Loosen the lock bolt of the alternator, then loosen the adjusting bolt.

ADJUSTING BOLT

AC1749

LOCK BOLT

ALTERNATOR LOCK BOLT

(b) Remove and discard the alternator belt.

FRONT ALTERNATOR ALTERNATOR BELT (DISCARD)

AC1750

VEHICLE HARNESS CLIP ALTERNATOR

CAP FRONT OUTPUT TERMINAL

FOR ADDITIONAL KIT ONLY [(c)~(v)] (c) Temporarily disconnect the vehicle connector from 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.

VEHICLE CONNECTOR
AC1751

ALTERNATOR

FRONT ALTERNATOR ADJUSTING BOLT

(f)

Temporarily remove the lock bolt and the adjusting bolt from the alternator.

ADJUSTING BOLT

AC1749

LOCK BOLT

ALTERNATOR LOCK BOLT

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VEHICLE HARNESS CLAMP

ADJUSTING BAR

(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.

FRONT ALTERNATOR
AC1752

(j)
CAUTION

Remove and discard the original alternator pulley from the alternator.

CLOTH

ORIGINAL ALTERNATOR PULLEY (DISCARD) SOCKET (22mm)

NOTE
Procedure will be eased with using a impact wrench.

ALTERNATOR

CAUTION
AC1976

IMPACT WRENCH

Hold the original alternator pulley securely with a hand as shown in left diagram when using the impact wrench. (k) Choose the alternator pulleys (included in kit) according to the current value (90A or 70A) written on the alternator label.

ALTERNATOR PULLEY (FOR 70A, INCLUDED IN KIT)

ALTERNATOR PULLEY (FOR 90A, INCLUDED IN KIT) COLLAR (LARGE)

CAUTION
Identify the alternator pulley (included in kit) according to collar size on the reverse side of the pulley.

LABEL COLLAR (SMALL)

AC1977

ALTERNATOR ALTERNATOR PULLEY (HAND TIGHTEN, INCLUDED IN KIT)

(l)

Loosely assemble the alternator pulley (included in kit) to the alternator.

ALTERNATOR

AC1978

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SST VISE

(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.

AC1979

ALTERNATOR

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

SST
AC1980

ALTERNATOR PULLEY ALTERNATOR

(o) Fully tighten the alternator pulley. Tightening Torque 110.5 Nm (1175 kgfcm, 85.0 lbfft)

CAUTION
SST

AC1981

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.

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(p) Install the cover to the alternator pulley.

COVER

ALTERNATOR

AC1982

FRONT ALTERNATOR

(q) Temporarily tight the alternator to the engine block with the lock bolt.

ALTERNATOR

LOCK BOLT (HAND TIGHTEN)

AC1983

LOCK BOLT

(r)
VEHICLE HARNESS CLAMP

ADJUSTING BAR

Temporarily tight the adjusting bar to the oil pump and the alternator with nut and adjusting bolt to carry out the adjusting bar positioning. (s) Draw the alternator to the engine block side after checking that the alternator rotates smoothly.

ADJUSTING BOLT (HAND TIGHTEN)

FRONT ALTERNATOR
AC1984

(t)
VEHICLE HARNESS CLIP ALTERNATOR

Reinstall the output terminal and the cap to the alternator.

Tightening Torque
CAP FRONT OUTPUT TERMINAL

9.8 Nm (100 kgfcm, 7.2 lbfft) (u) Reinstall the vehicle harness clip to the bracket of the alternator. (v) Reconnect the vehicle connector to the alternator.

VEHICLE CONNECTOR
AC1985

ALTERNATOR

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(3)

COMPRESSOR DRIVE BELT AND COMPRESSOR-2 (a) Install the compressor to the engine block using four bolts. Tightening Torque 24.5 Nm (250 kgfcm, 18.1 lbfft)

CAUTION
First, hand tighten the bolt No.4. Tightening order; [1] [2] [3] [4]

COMPRESSOR

[4]

[2]

ENGINE BLOCK [3] [1]

BOLT(M8

81)
AC1753

TAPING (DISCARD)

EXCEPT FOR ADDITIONAL KIT [(b)~(c)] (b) Pull the vehicle harness down.

FRONT

VEHICLE HARNESS (4-P)

AC1903

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

Mg/C CONNECTOR (4-P) VEHICLE HARNESS (4-P)

FRONT

AC1904

COMPRESSOR DRIVE BELT 10kgf

ALTERNATOR PULLEY

(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.

WATER PUMP PULLEY (HALF-TURN CLOCKWISE)

CRANKSHAFT PULLEY

COMPRESSOR PULLEY

AC1754

(f)
FRONT ALTERNATOR ADJUSTING BOLT

Adjust the belt tension, then tighten the adjusting bolt.

Tightening Torque 18.5 Nm (189 kgfcm, 13.6 lbfft)

CAUTION
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. Belt deflection at 98 N(10 kgf, 22 lbf) force New Belt 5-6 mm (0.2-0.24 inch) Used Belt 7-8.5 mm (Re- adjustment) (0.28-0.33 inch) - 13 00500082

COMPRESSOR DRIVE BELT

AC1755

Belt tension using the belt tension gauge 90-110 kgf (198-242 lbf) 40-60 kgf (88-132 lbf)

(g) Tighten the lock bolt.

FRONT ALTERNATOR

CAUTION
Tighten the lock bolt with cohering the slide bush to the engine block.

Tightening Torque 54 Nm (550 kgfcm, 39.6 lbfft)

ALTERNATOR LOCK BOLT ALTERNATOR

LOCK BOLT

LOCK BOLT SLIDE BUSH ENGINE BLOCK

COLLARS CONDENSER
AC1756

(4)

CONDENSER (a) Install two rubber cushions to the condenser lower bracket. (b) Install two bushings and two collars to the condenser upper bracket.

BUSHINGS

RUBBER CUSHIONS

AC1757

CONDENSER

(c) Connect the liquid tube No.1 to the condenser using a bolt. Tightening Torque 5.4 Nm (55 kgfcm, 4.0 lbfft)

LIQUID TUBE No.1

BOLT(M6

25, SILVER)

AC1758

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RADIATOR

CARDBOARD

(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.

CONDENSER

CAUTION
Make sure that the rubber cushion positively inserted into the vehicle hole.

CAUTION
AC1759

(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.
LIQUID TUBE No.1 FRONT (M6 BOLT 14, BLACK)
AC1760

RADIATOR

(h) Reinstall the radiator to the original position.

AC1761

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PIPING LAYOUT

COOLING UNIT

LIQUID TUBE No.2

DISCHARGE HOSE SUCTION HOSE LIQUID TUBE No.1 COMPRESSOR

CONDENSER DISCHARGE TUBE

AC1902

(5)
EXPANSION VALVE

PIPING (a) Connect the expansion valve to the cooling unit case using two bolts. Tightening Torque 3.4 Nm (35 kgfcm, 2.5 lbfft)

BOLTS (M5

40)

COOLING UNIT

FRONT

AC1905

(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.
FRONT

LIQUID TUBE No.2

AC1907

(d) Insert the suction hose from upside.

FRONT

SUCTION HOSE

AC1908

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.

FRONT

VEHICLE HARNESS

AC1909

(f)

Temporarily set the suction hose as shown in the left figure.

LIQUID TUBE No.2

SUCTION HOSE FRONT

AC1910

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

EXPANSION VALVE LIQUID TUBE No.2

FRONT

AC1911

(h) Route and connect the liquid tube No.2 to the liquid tube No.1.
LIQUID TUBE No.1
FRONT

LIQUID TUBE No.2

AC1912

(i)
SUCTION HOSE

(j)

Connect the suction hose to the expansion valve. Hand tighten a bolt of the expansion valve.

EXPANSION VALVE BOLT(M6 20, BLACK)

FRONT

LIQUID TUBE No.2

AC1913

LIQUID TUBE No.2

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

SUCTION HOSE

PLASTIC CLAMP

AC1914

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(l)
DISCHARGE TUBE CONDENSER

Connect the discharge tube to the condenser using a bolt.

Tightening Torque 5.4 Nm (55 kgfcm, 4.0 lbfft)

FRONT BOLT (M6 25,SILVER)

AC1915

COMPRESSOR

(m) Connect the discharge hose to the compressor using a bolt. Tightening Torque 9.8 Nm (100 kgfcm, 7.2 lbfft)

DISCHARGE HOSE

FRONT BOLT(M6 25,GOLD)

AC1916

(n) Route the hood lock release wire as shown in the left figure.
HOOD LOCK RELEASE WIRE

CONDENSER

FRONT
AC1917

(o) Reinstall the radiator upper baffle.

RADIATOR UPPER BAFFLE

CAUTION
Be careful not to pinch the hood lock release wire when reinstallation the radiator upper baffle. (p) Reinstall the hood lock.

HOOD LOCK
AC1742

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(q) Reconnect the vehicle harness to the connector of the horn.

HORN

VEHICLE HARNESS (1-P)

AC1919

(r)
BOLT (SILVER) (M8XR32) CONDENSER

Install the condenser to the radiator upper baffle using two bolts.

AC1920

NUT(M6) BOLT (M6 16 ) DISCHARGE TUBE

CLAMP OF DISCHARGE HOSE DISCHARGE HOSE

(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)

RADIATOR UPPER BAFFLE

FRONT

AC1921

COMPRESSOR

(u) Connect the suction hose to the compressor using a bolt. Tightening Torque 9.8 Nm (100 kgfcm, 7.2 lbfft)

SUCTION HOSE FRONT BOLT(M6 25,GOLD)

AC1922

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(v) Fully tighten the bolt.

SUCTION HOSE

Tightening Torque
FULLY TIGHTEN

5.4 Nm (55 kgfcm, 4.0 lbfft)

EXPANSION VALVE

FRONT

LIQUID TUBE No.2

AC1923

(w) Fasten the suction hose to the frame using the clamp and a bolt.
CLAMP

CLAMP

SUCTION HOSE SUCTION HOSE

AC1924

BOLT (M6X 16)

FRONT

EXCEPT FOR ADDITIONAL KIT [(x)~(y)] (x) Pull the vehicle harness down. (y) Connect the vehicle harness to the pressure switch.

PRESSURE SWITCH VEHICLE HARHESS (4-P)

AC1925

(6)

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

HEAD LAMP (LH)

RESISTOR

BOLTS (M6 14)

AC1926

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VEHICLE HARNESS (2-P)

EXCEPT FOR ADDITIONAL KIT [(b)~(c)] (b) Pull the vehicle harness down. (c) Connect the vehicle harness to the resistor.

RESISTOR

AC1927

RADIATOR UPPER BAFFLE

CLIPS

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

HEAD LAMP UNDER COVER (LH)

AC1928

WIRING LAYOUT
TO INSIDE PASSENGER COMPARTMENT TO INSIDE ENGINE COMPARTMENT WIRING LAYOUT

A/C HARNESS No.2 RELAY BOX

A/C HARNESS No.2

TO VEHICLE HARNESS (2-P) TO INSIDE FRONT FENDER LINER (RH) TO RESISTOR (2-P)

TO RADIATOR FAN (2-P)

TO PRESSURE SWITCH (4-P)

TO COMPRESSOR (4-P)

AC1929

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(7)
VEHICLE HARNESS RELAY BOX COVER (UPPER SIDE)

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.

RELAY BOX
AC1930

HOOKS

(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

RELAY BOX COVER (LOWER SIDE) A/C HARNESS No.2 [TO INSIDE FRONT FENDER LINER (LH)]

AC1931

FRONT

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

A/C HARNESS No.2 [TO RADIATOR FAN]

AC1932

INSIDE FRONT FENDER LINER (LH) TO INSIDE ENGINE COMPARTMENT VEHICLE FRAME

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

A/C HARNESS No.2

AC1933

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TO INSIDE ENGINE COMPARTMENT

TO INSIDE PASSENGER COMPARTMENT

(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.

VEHICLE GROMMET (DISCARD)

NOTE
A/C HARNESS No.2

First, route the A/C harness No.2 the inside passenger compartment.

AC1934

CAUTION
At this point, discontinue the engine compartment and move to the work inside passenger compartment.

TO INSIDE ENGINE COMPARTMENT

TO INSIDE PASSENGER COMPARTMENT

(8)

WIRING-2 (FOR ADDITIONAL KIT ONLY) (a) Secure the A/C harness No.2 to the vehicle harness using three plastic ties.

CAUTION
PLASTIC TIES A/C HARNESS No.2 VEHICLE HARNESS

Further work will be continued after the work inside passenger compartment is completed.

AC1935

(b) Disconnect the vehicle harness from the connector of the radiator fan.
FRONT VEHICLE HARNESS (2-P)

RADIATOR FAN

AC1936

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FRONT

(c) Connect the A/C harness No.2 to the vehicle harness (disconnected the connector of the radiator fan).

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

VEHICLE HARNESS (2-P, DISCONNECTED THE CONNECTOR OF THE RADIATOR FAN)

AC1937

(d) Connect the A/C harness No.2 to the connector of the radiator fan.
FRONT A/C HARNESS No.2 (2-P, GRAY)

RADIATOR FAN

AC1938

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

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

FRONT

PRESSURE SWITCH

AC1939

(f)
A/C HARNESS No.2 (2-P, BLACK)

Connect the A/C harness No.2 to the resistor.

RESISTOR

AC1940

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

FRONT

PLASTIC TIES

A/C HARNESS No.2

PLASTIC TIE FAN RELAY No.2 (DISCARD)

AC1941

(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
FAN RELAY No.1 (REUSE) RELAY BOX
AC1942

Depending on a vehicle model, fan relay No.2 might not be installed.

TERMINAL OF THE VEHICLE HARNESS PRESION (-) SCREWDRIVER

(b) Push the terminal of the vehicle harness using the precision (-) screwdriver when pulling out it from the relay box as shown in the left figure.

RELAY BOX
AC1943

BOTTOM SIDE OF RELAY BOX TERMINAL OF THE VEHICLE HARNESS (WHITE/BLUE)

(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

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SINGLE LEAD WIRE ONLY

TWIN LEAD WIRES ONLY

(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.

LEAD WIRE

LEAD WIRES

VINYL TAPE

CAUTION
CAUTION VINYL TAPE TERMINAL
AC1945

CUT OFF

Beware 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.

TERMINAL
BOTTOM SIDE OF RELAY BOX

(e) Insert the terminal of the A/C harness No.2 to the relay box.
YELLOW/RED

CAUTION
Check the wire colors before inserting the terminal of the A/C harness No.2 to the relay box.

AC1946

BOTTOM SIDE OF RELAY BOX LEAD WIRE (PINK/BLUE)

(f)

Connect the A/C harness No.2 to the lead wire (pink/blue) of the vehicle harness using the branch connector.

BRANCH CONNECTOR

CAUTION
Do not mistake the lead wire color.

NOTE
BLACK/BLUE BOTTOM SIDE OF RELAY BOX FIVE TERMINALS OF THE VEHICLE HARNESS

See the P.1 for the connection of the branch connector.

AC1947

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

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SINGLE LEAD WIRE ONLY

TWIN LEAD WIRES ONLY

(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.

LEAD WIRE

LEAD WIRES

VINYL TAPE

CAUTION
CAUTION VINYL TAPE TERMINAL
AC1945

CUT OFF

Beware 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.

TERMINAL BOTTOM SIDE OF RELAY BOX

(i)

WHITE/BLACK BLACK/BLUE BLUE/YELLOW BLUE/WHITE WHITE/BLUE

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

BOTTOM SIDE OF RELAY BOX BLACK/RED BLACK/WHITE

(j)
BLACK/YELLOW

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

BLUE/BLACK

CAUTION
Check the wire colors before inserting each terminal of the A/C harness No.2 to the relay box.

AC1950

A/C HARNESS No.2

(k) Secure the A/C harness No.2 to the vehicle harness using a plastic tie.

PLASTIC TIE RELAY BOX FRONT

AC1951

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HOOKS

(l)

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

HOOKS

RELAY BOX COVER (LOWER SIDE)

A/C HARNESS No.2

AC1952

FAN RELAY No.2 (WHITE, INCLUDED IN KIT)

FAN RELAY No.1 (REUSE)

(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
FRONT Mg/C RELAY (WHITE, INCLUDED IN KIT)

Be sure to install the relay box by supporting the relay box by hand from the bottom side to prevent a contact defect.

AC1953

VEHICLE HARNESS

RELAY BOX COVER (UPPER SIDE)

(o) Reinstall the relay box to the body. (p) Reinstall the relay box cover (upper side) and the vehicle harness to the relay box.

RELAY BOX
AC1954

(q) Secure the A/C harness No.2 to the vehicle harness using two plastic ties.
PLASTIC TIES

FRONT

A/C HARNESS No.2

AC1955

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(r)
PLASTIC TIES

Secure the A/C harness No.2 to the vehicle harness using two plastic ties.

A/C HARNESS No.2 FRONT

AC1956

PLASTIC TIES

(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.
TO Mg/C CONNECTOR (4-P) FRONT A/C HARNESS No.2

AC1957

(t)
A/C HARNESS No.2

Secure the A/C harness No.2 to the vehicle harness using a plastic tie.

PLASTIC TIE FRONT

AC1958

A/C HARNESS No.2 (4-P) Mg/C CONNECTOR (4-P)

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

FRONT

AC1959

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RELAY BOX COVER

(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
FRONT RELAY BOX

Depending on a vehicle model, fan relay No.2 might not be installed. (c) Install the fan relay No.2 (white, included in kit and Mg/C relay (white, included in kit) to the relay box.

FAN RELAY No.2 (WHITE, INCLUDED IN KIT)

CAUTION
ORIGINAL FAN RELAY No.2 (DISCARD) FRONT Mg/C RELAY (WHITE, INCLUDED IN KIT)

Be sure to install the relay box by supporting the relay box by hand from the bottom side to prevent a contact defect. (d) Reinstall the relay box cover to the relay box.

AC1960

RADIATOR UPPER BAFFLE

(11) CAUTION PLATE (a) Attach the caution plate to the radiator upper baffle.

CAUTION
Stick on the caution plate after wiping off all dust and oil from the radiator upper baffle.
CAUTION PLATE

AC1961

CLIPS CLIPS FRONT FENDER LINER (LH)

(12) REINSTALLATION OF ORIGINAL PARTS
FOR ADDITIONAL KIT ONLY [(a)~(b)] (a) Front fender liner (LH)

SCREWS

AC1962

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(b) Front over fender (LH)

CLIPS CLIPS CLIP NOTE

NOTE
Reinstall the front over fender to the original position after installing this clip to the front over fender.

FRONT OVER FENDER (LH)

AC1745

(c) Under cover

UNDER COVER

AC1744

(d) Plates (LH,RH)

PLATES (LH, RH)

AC1739

(e) Front grille

FRONT GRILLE
AC1738

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(f)

Vehicle harness clip

VEHICLE HARNESS CLIP

AC1964

(g) Vehicle bracket [B] Tightening Torque

VEHICLE HARNESS CLAMPS

19 Nm (194 kgfcm, 14 lbfft) (h) Three vehicle harness clamps

VEHICLE BRACKET [B]

FRONT
AC1965

(i)
FRONT VEHICLE HARNESS CLAMPS VEHICLE BRACKET [A]

Vehicle bracket [A]

Tightening Torque 19 Nm (194 kgfcm, 14 lbfft) (j) Tow vehicle harness clamps

FRONT VEHICLE BRACKET [A]

AC1966

(k) Earth terminal

CAUTION

Tightening Torque 7.8 Nm (80 kgfcm, 5.8 lbfft)

CAUTION
EARTH TERMINAL

Catch the turning stopper to the vehicle hole surely.

FRONT
AC1967

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FRONT FILTER

(l) Air cleaner box (lower side) (m) Filter

CAUTION
FRONT

Handle the filter with care.In particular, the front/ back and top/bottom surfaces.

AIR CLEANER BOX (LOWER SIDE)

AC1968

FRONT

AIR CLEANER BOX (UPPER SIDE)

VEHICLE HARNESS

(n) Air cleaner box (upper side) (o) Reconnect the vehicle harness to the air cleaner box. (p) Vehicle harness clip

TIGHTEN

VEHICLE HARNESS CLIP

AC1969

(q) Air duct

AIR CLEANER BOX

AIR DUCT FRONT

AC1733

BATTERY

(r) Battery tray (s) Battery

BATTERY TRAY

FRONT

AC1732

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BATTERY TERMINAL (+)

BATTERY

(t)

Reinstall the battery terminals as shown in the left figure.

PARALLEL

BATTERY TERMINAL (-) FRONT

AC1970

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3. AFTER INSTALLATION
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*)

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

For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AFTER INSTALLATION" (pages 12-15,21). STANDARD AMOUNT OF REFRIGERANT 440 30 g (0.97 0.07 lbs)

CAUTION
Ensure to fill the refrigerant to the specified amount.

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 before the final adjustment of the belt. Belt deflection [at 98N(10kgf, 22lbf)force] Vehicle equipped with 1ND-TV E/G 7 - 8.5 mm (0.28 - 0.33 inch) Belt tension [N (kgf)] 392 - 588 N (40 - 60 kgf)

CAUTION
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.

3-3.ADJUSTMENT OF ENGINE IDLING SPEED

CAUTION
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 RELAY

BLOWER MOTOR

BLOWER RESISTER

FAN RELAY No.1

IG SW

12V

TAIL TAIL

A/C AMP BLOWER SWITCH

AC1972

A/C SW

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RADIATOR FAN MOTOR

FAN RELAY No.2

RESISTOR

WATER TEMP.SWITCH

Mg/C RELAY

TRIPLE PRESSURE SWITCH

COMPRESSOR

EVA. THERMISTOR EFI ECU

246108-054
AC1973

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FOR ADDITIONAL KIT

HEATER MAIN RELAY

BLOWER MOTOR

BLOWER RESISTOR

FAN RELAY No.1

IG SW

FUSE 12V

TAIL TAIL

EARTH 1

A/C AMP BLOWER SWITCH A/C SW

AC1974

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RADIATOR FAN MOTOR

FAN RELAY No.2

RESISTOR

WATER TEMP. SWITCH

Mg/C RELAY

TRIPLE PRESSURE SWITCH

COMPRESSOR

EVA.THERMISTOR EFI ECU

246108-068
AC1975

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- 42 00500082

DENSO CORPORATION SERVICE DEPARTMENT

Kariya, Aichi, Japan

First lssue : SEPTEMBER 2001 Publication No. : AAAMC-26

Printed in Japan

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AAAMC-26 988963-5020

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