AIR CONDITIONING - Toyota-Tech.eu199E3A6B-B21B-401F-98E9-44E2D216FF9F... · (l) Fasten the reservoir tank using the cloth tape as shown in the left figure. CAUTION Ensure that the

INS

IDE

EN

GIN

E C

OM

PA

RT

ME

NT

TOYOTA

ENGLISH

AIR CONDITIONING

EUROPE

© 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.

INTRODUCTIONIMPORTANT NOTICE

DEFINITION OF TERMS

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

[APPLICATION VEHICLE]

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 are certified to handling refrigerant. 1. Take special care to ensure that clearance between air conditioning components and other components such as

brake parts, fuel system and electric wires as specified in this manual.2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct the

problem(s).3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without

prior notice. Refer to the latest installation manual and service information. Any changes affecting the above items will be given in the form of a “Installation instructions for air conditioning (Supplement)” (issued by DENSO) or a service bulletin (issued by the manufacturer).

WARNING : 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,REARLEFT,RIGHT

: Shows the direction when viewed from the driver’s seat.

VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION

COROLLA VERSO CDE120R 2001.10~ 1CD-FTV RHD

1. Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation.

2. Refer to the separate manual "INSTALLATION MANUAL (INSIDE PASSENGER COMPARTMENT)" for details on installation for the passenger compartment side.

MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER

GENERAL INFORMATION /AFTER INSTALLATION

AOAMC-01* 988963-475*

INSTALLATION MANUAL(INSIDE PASSENGER COMPARTMENT)

AAAMC-28* 988963-509*

- 1

005000

VEHICLE HARNESS

BATTERY

Disconnect the negative cable first.

AC1895

AC4168

ENGINE COVER

1. INSTALLATION INSIDE PASSENGER 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.

CAUTION

First remove the negative terminal on the battery and the vehicle harness connection before installing the equipment.

(1) REMOVAL OF ORIGINAL PARTS

-

90

- 2

005000

FRONT

AC4368

BATTERY

BATTERY TRAY

AIR CLEANER BOX LOWER COVER

AIR CLEANER BOX UPPER COVER

VEHICLE HARNESS

FRONT

LOOSEN

AC4169

FRONT

AC4371

FILTER

FRONT

VEHICLE HARNESS CLAMP

AIR CLEANER BOX LOWER COVER

AC3621

(b) Battery and battery tray

(c) Disconnect the vehicle harness from the air

(d) Temporarily remove the vehicle harness from the clamp of air cleaner box upper cover.

(e) Temporarily remove the air cleaner box upper cover from the air cleaner lower cover.

(f) Filter

(g) Vehicle harness clamp

-

90

- 3

005000

AC4373

AIR CLEANER BOX LOWER COVER

FRONT

FRONT

AC4374

AIR DUCT

AC4170

INSULATOR

FRONT

AC4171

RESERVOIR TANK

(h) Air cleaner box lower cover

(i) Air duct

(j) Insulator

(k) Reservoir tank

CAUTION

Do not splash cooling water.

-

90

- 4

005000

AC4172

RESERVOIR TANK

CLOTH TAPE

AC4376

PLATEFRONT GRILLE

AC4377

RADIATOR UPPER SUPPORTS (RH,LH)

AC3626

RELAY BOX No.1

FRONT

(l) Fasten the reservoir tank using the cloth tape as shown in the left figure.

CAUTION

Ensure that the cloth tape is not put to the injection pipe when fixing the reservoir tank.

(m) Plate

(o) Radiator upper supports (RH, LH)

(p) Relay box No.1

-

90

- 5

005000

AC3627

VEHICLE HARNESS

FRONT

VEHICLE HARNESSCLIP

AC3628

FRONT

FAN SHROUD

VIEW:AFRONT

AC4173

HEATER RELAY

VEHICLE BRACKET

VEHICLE HARNESS CLAMP

HEATER RELAY BOX

FRONT

VIEW:A

(q) Temporarily disconnect the vehicle harness from the radiator fan motor.

(r) Temporarily remove the vehicle harness clip from the fan shroud.

(s) Fan shroud

(t) Temporarily remove the heater relay from the

-

vehicle bracket.(u) Temporarily remove the heater relay box.(v) Temporarily remove the vehicle harness clamp

from the vehicle bracket.

90

- 6

005000

VEHICLE BRACKET

LOOSEN

FRONT

AC4174

FRONT

HEATER RELAY BOX

AC4175

FRONT

LIQUID TUBE No.1

RADIATOR

AC4385

FRONT

AC4386

LIQUID TUBE No.1

VEHICLE HARNESS

(w) Shift the vehicle bracket as shown in the left figure.

(x) Put the heater relay box as shown in the left

(2) LIQUID TUBE

figure.

(b) Route the liquid tube No.1 under the vehicle

-

90

- 7

005000

LIQUID TUBE No.1

AC4424

FRONT

AC4420CONDENSER

COLLARS

BUSHINGS

RADIATOR

CORRUGATED BOARD AC4387

CONDENSER

(c) Set the liquid tube No.1 as shown in the left figure.

(3) CONDENSER AND CONDENSER FAN

condenser.

(b) Lean the radiator backward then insert the

CAUTION

Insert a corrugated board and others beforeinserting the condenser to prevent the radiator frombeing damaged.

-

90

- 8

005000

CONDENSER

CONDENSER

AC4388

VIEWED FROM THE BOTTOM SIDE OF VEHICLE

VIHICLE HOLE

VIHICLE HOLE

RUBBER CUSHION

RUBBER CUSHION

CONDENSER

AC4389

BOLTS (M8 32,SILVER)

(c) Make sure that the bushings of condenser positively inseter into the vehicle hole.

(d) Install the condeser using two bolts.

-

90

- 9

005000

AC3633

CONDENSER FAN MOTOR

CONDENSER FAN

FAN SHROUD

SCREWS(M5 11)

NUT(M5)

AC3634

FAN SHROUD

CLAMPS

CONDENSERFAN MOTORCONNECTOR

CONDENSERFAN MOTORHARNESS

(e) Assemble the condenser fan motor to the fan shroud using three screws.

CAUTION

(f) Assemble the condenser fan to the condenser fan motor using a nut.

Tightening Torque

3.8 N•m (39 kgf•cm, 2.8 lbf•ft)

The screws must be facing in the direction of installation.

Tightening Torque

6.2 N•m (63 kgf•cm, 4.5 lbf•ft)

(g) Fasten the condenser fan motor harness to four

(h) Fasten the condenser fan motor connector to the holder.

-

90

- 10

005000

AC4176

P/S PUMP

LOCK NUT

FRONT

P/S PUMP DRIVE BELT(DISCARD)

ADJUSTING BOLT

P/S PUMP

FRONT

(4) COMPRESSOR AND COMPRESSOR DRIVE BELT

(a) Loosen the lock nut and the adjusting bolt.(b) Remove and discard the P/S pump drive belt.

-

90

- 11

005000

(c) Install the compressor bracket to the engine block using three bolts.

CAUTION

(d) Install the compressor to the compressor bracket using four bolts.

CAUTION

Tightening Torque

31.4 N•m (320 kgf•cm, 23.1 lbf•ft)

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

Tightening Torque

24.5 N•m (250 kgf•cm, 18.1 lbf•ft)

Tightening order; [5] » [6] » [7] » [8]

AC4177

BOLTS (M8 20)

BOLTS (M8 75)

COMPRESSOR

COMPRESSOR BRACKET

ENGINE BLOCK

[1]

[2]

[3]

[5]

[7]

[6]

[8][4]

-

90

- 12

005000

COMPRESSORDRIVE BELT

IDLE PULLEY

P/S PUMP PULLEY

AC4178CLANKSHAFT PULLEY

COMPRESSORPULLEY

10kgf

AC4179

P/S PUMP

FRONT

COMPRESSOR DRIVE BELT

ADJUSTING BOLT

P/S PUMP

FRONT

AC4180

P/S PUMP

LOCK NUT

FRONT

(e) Install the compressor drive belt to the pulleys as shown in the left figure.

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

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

Belt tension using the belt tension gauge

New Belt 10 - 12 mm(0.39 - 0.47 inch)

686 - 784 N(70 - 80 kgf, 154 - 176 lbf)

Used Belt (Re-adjustment)

14 - 17 mm(0.56 - 0.67 inch)

294 - 441 N(30 - 45 kgf, 66 - 99 lbf)

(g) Tighten the lock nut.

Tightening Torque

38.2 N•m (390 kgf•cm, 28.2 lbf•ft)

-

90

- 13

005000

AC3650FRONT

TAPING (DISCARD)

COMPRESSOR

VEHICLE HARNESS(4-P)

AC3651

FRONT

COMPRESSOR

Mg/C CONNECTOR (4-P)

VEHICLE HARNESS(4-P)

(h) Pull the vehicle harness (4-P) down.

(i) Connect the vehicle harness (4-P) to the Mg/C

� PIPING LAYOUT

COMPRESSOR

CONDENSER

LIQUID TUBE No.1

PLASTIC CLAMP No.1

LIQUID TUBE No.2

PLASTIC CLAMP No.2

PLASTIC CLAMP No.3

DISCHARGE HOSE

SUCTION HOSE

SUCTION TUBE No.2

SUCTION TUBE No.1

BRACKET

FRONT

TO PASSENGER COMPARTMENT

AC3652

-

90

- 14

005000

CONDENSER AC4421

LIQUID TUBE No.1

PLASTIC CLAMP No.1

BOLT(M6 25)

FRONT

AC4397

PLASTIC CLAMP No.2

LIQUID TUBE No.2

AC3653

FRONT

SCTION TUBE No.2

FRONT

AC3654

(5) PIPING(a) Assemble the plastic clamp No.1 to the

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

using a bolt.

(c) Fasten the liquid tube No.1 to the plastic clamp No.1.

Tightening Torque

5.4 N•m (55 kgf•cm, 4.0 lbf•ft)

(d) Install the plastic clamp No.2 to the body.

(e) Insert the liquid tube No.2 as shown in the left

(f) Insert the suction tube No.2 as shown in the left

-

90

- 15

005000

LIQUID TUBE No.2

PIPING BLOCK

BRACKET

SUCTION TUBE No.2

AC3655

FRONT

BOLT(M6 12)

BRACKET

LIQUID TUBENo.2

SUCTION TUBE No.2

SUCTION TUBENo.2

FRONT

PLASTICCLAMPNo.3

AC3656

PLASTIC CLAMPNo.3

SUCTION TUBENo.2

LIQUID TUBE No.2

AC4399PLASTIC CLAMP No.2 FRONT

LIQUID TUBE No.1

PACKING

PACKING

CROSSSECTION

COMPRESSOR SUCTION HOSE

AC3657FRONT

BOLT(M6 35)

(g) Install the bracket to the body using a bolt.

CAUTION

(h) Connect the liquid tube No.2 and suction tube No.2 to the piping block.

(i) Fasten the liquid tube No.2 and suction tube No.2 to the bracket.

Catch the turning stopper to the vehicle holesurely.

(j) Install the plastic clamp No.3 to the frame.

No.3.

(l) Connect the liquid tube No.2 to the liquid tube

(m) Fasten the liquid tube No.1 to the plastic clamp No.2.

(n) Attach the packing around connecting portion of the liquid tube No.1 and liquid tube No.2.

(o) Connect the suction hose to the compressor

Tightening Torque

9.8 N•m (100 kgf•cm, 7.2 lbf•ft)

-

90

- 16

005000

CAUTION

SUCTION TUBE No.1

SUCTION TUBE No.2

SUCTION HOSE

FRONT

BOLT(M6 12)

AC3658

AC3659

BRACKET OFSUCTION HOSE

CAUTION

VIEWED FROM BOTTOMSIDE OF VEHICLE

NUT(M6)

BRACKETOFSUCTIONHOSE

AC4406

DISCHARGE HOSE

FRONT

DISCHARGE HOSE

(p) Connect the suction tube No.1 to the suction tube No.2.

(q) Connect the suction hose to the suction tube No.1.

(r) Fasten the bracket of suction tube No.1 to the side member using a bolt.

CAUTION

Catch the turning stopper to the side membersurely.

(s) Fasten the bracket of suction hose to the cross

CAUTION

Catch the turning stopper to the cross membersurely.

(t) Insert the discharge hose as shown in the left

-

figure.

90

- 17

005000

AC4407

DISCHARGE HOSE

CONDENSER

FRONT

BOLT (M6 25)

AC4408

COMPRESSOR

FRONTBOLT (M6 35)

DISCHARGE HOSE

SUCTION TUBE No.2

LIQUID TUBE No.2

AC3660

FRONT

QUICK JOINTS(SMALL AND BIG)

FRONT

TAPING

AC4409

VEHICLE HARNESS (4-P)

(u) Connect the discharge hose to the condenser using a bolt.

Tightening Torque

5.4 N•m (55 kgf•cm, 4.0 lbf•ft)

(v) Connect the discharge hose to the compressor

Tightening Torque

9.8 N•m (100 kgf•cm, 7.2 lbf•ft)

(w) Fasten the liquid tube No.2 and suction tube

(x) Pull the vehicle harness (4-P) down.

-

90

- 18

005000

AC4410

VEHICLE HARNESS (4-P)

PRESSURE SWITCH

AC3661

FRONT

FAN SHROUD

AC3662

TAPING (DISCARD)

FRONT

VEHICLE HARNESS(2-P)

AC3663

VEHICLE HARNESS

FRONT

VEHICLE HARNESSCLIP

VEHICLE HARNESS(2-P)

CONDENSER FAN MOTORCONNECTOR

(y) Connect the vehicle harness (4-P) to the pressure switch.

(6) FAN SHROUD

(b) Pull the vehicle harness (2-P) down.

(c) Reconnect the vehicle harness to the radiator

(d) Reinstall the vehicle harness clip to the fan shroud.

(e) Connect the vehicle harness (2-P) to the condenser fan motor connector.

-

90

- 19

005000

AC4171

RESERVOIR TANK

AC3626

RELAY BOX No.1

FRONT

AC3665

RELAY BOX No.1 COVER

FRONT

AC4185

FRONT

FAN RELAY No.2(4-P, WHITE, BIG)

RELAY BOX No.1

FAN RELAY No.1(5-P, BROWN)

(f) Reinstall the reservoir tank to the fan shroud.

(g) Reinstall the relay box No.1 to the fan shroud.

(7) RELAYS

(b) Install the fan relay No.1 and No.2 into the relay

CAUTION

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

-

90

- 20

005000

AC3667

RELAY BOX No.1 COVER

FRONT

FRONT

RELAY BOX No.2 COVER

AC5334

AC4186

Mg/C RELAY(4-P, WHITE, SMALL)

FRONT

RELAY BOX No.2

FRONT

RELAY BOX No.2 COVER

AC5336

(c) Reinstall the relay box No.1 cover.

(d) Temporarily remove the relay box No.2 cover.

(e) Install the Mg/C relay into the relay box No.2.

CAUTION

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

(f) Reinstall the relay box No.2 cover.

-

90

- 21

005000

AC4414

CAUTION PLATE

ENGINE HOOD

VEHICLE BRACKET

TIGHTEN

FRONT

AC4181

VIEW:AFRONT

AC4182

HEATER RELAY

VEHICLE BRACKET

VEHICLE HARNESS CLAMP

HEATER RELAY BOX

FRONT

VIEW:A

(8) CAUTION PLATE(a) Attach the caution plate to the engine hood.

NOTEAffix after completely wiping off dust and oil stains from the engine hood.

(9) REINSTALLATION OF ORIGINAL PARTS

(b) Reinstall the vehicle harness clamp to the

-

vehicle bracket.(c) Reinstall the heater relay box.(d) Reinstall the heater relay box to the vehicle

bracket.

90

- 22

005000

AC4377

RADIATOR UPPER SUPPORTS (RH,LH)

AC4376

PLATEFRONT GRILLE

AC4183

INSULATOR

FRONT

FRONT

AC4374

AIR DUCT

(e) Radiator upper supports (RH,LH)

(f) Front grille

(h) Insulator

(i) Air duct

-

90

- 23

005000

AC4416

AIR CLEANER BOX LOWER COVER

FRONT

CAUTION

FRONT

VEHICLE HARNESS CLAMP

AIR CLEANER BOX LOWER COVER

AC5341

FRONT

AC4418

FILTER

AIR CLEANER BOX LOWER COVER

AIR CLEANER BOX UPPER COVER

VEHICLE HARNESS

FRONT

TIGHTEN

AC4184

(j) Air cleaner box lower cover

CAUTION

Make sure to be inserted the air duct into the aircleaner box lower cover.

(k) Vehicle harness clamp

(l) Filter

(m) Reinstall the air cleaner box upper cover to the

(n) Reinstall the vehicle harness to the clamp of air cleaner box upper cover.

(o) Reconnect the vehicle harness to the air cleaner box upper cover.

-

90

- 24

005000

FRONT

AC4368

BATTERY

BATTERY TRAY

AC4168

ENGINE COVER

(p) Battery & battery tray

(q) Engine cover

-

90

- 25

005000

-

90

- 26 -

00500090

2. AFTER INSTALLATION

CAUTION

2-1.CHARGING REFRIGERANT (HFC-134a)

For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AF-TER INSTALLATION: CHARGING REFRIGERANT (134a)".

CAUTION

2-2.RE-ADJUSTMENT OF COMPRESSOR BELT

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

CAUTION

2-3.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 490 ± 30 g (1.08 ± 0.7 lbs)

Ensure to fill the refrigerant to the specified amount.

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

Belt tension[N (kgf, lbf)]

Vehicle equipped with 1CD-FTV E/G 14 - 17 mm(0.56 - 0.67 inch)

294 - 441 N(30 - 45 kgf, 66 - 99 lbf)

1. Excessive tension of belt may have an adverse effect on bearings, while excessive slackness can cause the belt to slip, make abnormal noise or shorten the belt life.

2. The belt deflection must be measured between the specified pulleys as indicated in this manual.3. The belt tension must be measured between the specified pulleys as indicated in this manual.4. The belt tension must be adjusted to the center of the specified belt tension range.

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.)

- 27 -

00500090

3. AMPLIFIER

4. WIRING DIAGRAM� VEHICLE WITH PTC HEATER

PRESSURE SWCOMPRESSORMg/CRELAY

IGRELAY

12V

IG SW

HEATERMAIN RELAY

BLOWERMOTOR

BLOWERRESISTOR

BLOWERRESISTOR

BLOWER SW A/C SW

TO TAIL RELAY

TO GND

LH

RH

AC3934

- 28 -

00500090

EFI ECU

PTCRELAY 1

PTCRELAY 2

PS HEATER CORE

FAN RELAY No.1

FAN RELAY No.2

FAN RELAY No.3

WATER TEMP.SW

MAX HOT SW

EVA.THERMISTOR

A/C AMP

CONDENSER FAN MOTOR

RADIATOR FAN MOTOR

246108-648

AC3935

- 29 -

00500090

� VEHICLE WITH COMBUSTION HEATER

IGRELAY

HEATERMAIN RELAY

BLOWERMOTOR

BLOWERRESISTOR

BLOWERRESISTOR

BLOWER SW A/C SW

TO TAIL RELAY

TO GND

LH

RH

IG SW

12V

Mg/CRELAY

COMPRESSOR

PRESSURESW

AC3936

- 30 -

00500090

EFI ECU

TO TAILRELAY

POWERHEATER SW

ALTERL TERMINAL

COMBUSTIONHEATER

FUEL-PUMP

FAN RELAYNo.1

FAN RELAY No.2

WATER TEMP.SW

EVA.THERMISTOR

FAN RELAY No.3

246108-648

CONDENSER FAN MOTOR

RADIATOR FAN MOTOR

A/C AMP

AC3937

- 31 -

00500090

- 32 -

00500090

DENSO CORPORATION

SERVICE DEPARTMENT

Kariya, Aichi, Japan

Frist Issue :SEPTEMBER 2001

Publication No. : AAAMC-30

Printed in Japan

AAAMC-30988963-5110