Airco inside engine comp.RHD aaamc29.pdf

7/27/2019 Airco inside engine comp.RHD aaamc29.pdf

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INSIDEEN

GINECOMPAR

TMENT

TOYOTA

ENGLISH

AIR CONDITIONING

EUROPE


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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 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 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

COROLLA VERSO ZZE121R 2001.10~ 3ZZ-FE RHD

ZZE122R 1ZZ-FE

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*


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1. INSTALLATION INSIDEPASSENGERCOMPARTMENT

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.

VEHICLE HARNESS

BATTERY

Disconnect

the negative

cable first.

AC1895

(1) REMOVAL OF ORIGINAL PARTS

1ZZ-FE E/G MODEL ONLY [(a)]

(a) Engine coverENGINE COVER

AC4375

1ZZ-FE E/G MODEL ONLY


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(b) Battery & battery tray

FRONT

AC4368

BATTERY

BATTERY TRAY

(c) Disconnect the vehicle harness from the air

cleaner box upper cover.

(d) Disconnect the air cleaner hose from the air

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

cover from the air cleaner lower cover.

AC4369

VEHICLE HARNESS

AIR CLEANER BOX UPPER COVER

AIR CLEANER HOSE

(f) Temporarily remove the VSV from the air

cleaner box upper cover.

CAUTION

Do not disconnect the intake hoses from the VSV.

VSV

FRONT

AIR CLEANER BOX

UPPER COVER

VSV

HOOK

AC4370

(g) Filter

FRONT

AC4371

FILTER


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(h) Vehicle harness clamp

FRONTAC4372

VEHICLE HARNESS CLAMP

(i) Air cleaner box lower cover

AC4373

AIR CLEANER BOX LOWER COVER

FRONT

(j) Air duct

FRONT

AC4374

AIR DUCT

(k) Plate

(l) Front grille

AC4376

PLATEFRONT GRILLE


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(m) Radiator upper supports (RH,LH)

AC4377

RADIATOR UPPER SUPPORTS (RH,LH)

(n) Front fender liner (LH)

NOTE

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

completely.

AC4378

FRONT FENDER

LINER (LH)

CLIPS

SCREWS

(o) Fully turn the steering wheel counterclockwise,

before removing the front fender liner (LH).

AC4379

STEERING WHEEL

VEHICLE WITH SURGE TANK ONLY [(p)~(q)]

(p) Screw

AC4422FRONT BUMPER

SCREW

VEHICLE WITH SURGE TANK ONLY


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(q) Surge tank

AC4380SURGE TANK


(r) Under cover (RH)

SCREWS

AC4381

UNDER COVER (RH)

CLIPS

CLIPS

CLIP

(2) RESISTOR

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

RESISTOR

BOLTS

(M6 16)

AC4382

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

(c) Route the vehicle harness (2-P) to the resistor.

FRONT

AC4383

VEHICLE HARNESS(2-P)

TAPING

TO RESISTOR


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(d) Connect the vehicle harness (2-P) to the

resistor.

RESISTOR

VEHICLE HARNESS

(2-P)

AC4384

(3) LIQUID TUBE

(a) Disconnect the vehicle harness from the radiator

fan motor.

(b) Temporarily remove the vehicle harness clipfrom the fan shroud.

FRONT

FAN SHROUD AC4423

RADIATOR FAN MOTOR

VEHICLE HARNESS

VEHICLE HARNESS CLIP


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

figure.

FRONT

LIQUID TUBE No.1

RADIATOR

AC4385

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

harness, when inserting the liquid tube No.1.

FRONT

AC4386

LIQUID TUBE No.1

VEHICLE HARNESS


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

figure.

LIQUID TUBE No.1

AC4424

FRONT

(4) CONDENSER

(a) Assemble two collars and two bushings to the

condenser.

AC4420CONDENSER

COLLARS

BUSHINGS

(b) Lean the radiator backward then insert the

condenser in front of radiator.

CAUTION

Insert a corrugated board and others before

inserting the condenser to prevent the radiator from

being damaged.

RADIATOR

CORRUGATED

BOARD AC4387

CONDENSER


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(c) Make sure that the bushings of condenser

positively inserted into the vehicle holes.

CONDENSER

CONDENSER

AC4388

VIEWED FROM THE BOTTOM SIDE OF VEHICLE

VIHICLE HOLE

VIHICLE HOLE

RUBBER CUSHION

RUBBER CUSHION

(d) Install the condenser using two bolts.CONDENSER

AC4389

BOLTS (M8 32,SILVER)

(e) Reinstall the vehicle harness clip to the fan

shroud.

(f) Reconnect the vehicle harness to the radiator

fan motor.

FRONT

FAN SHROUD AC4425

RADIATOR FAN MOTOR

VEHICLE HARNESS




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(5) COMPRESSOR AND COMPRESSOR DRIVE

BELT

(a) Use the following procedure to remove the

alternator belt.

NOTE

(b) Remove and discard the alternator belt.

Set the box-end combination wrench (19mm) as

shown in the left figure, and remove the alternator

belt from the pulleys while pulling the box-end

combination wrench to the front of the vehicle.

NOTE

FRONT

ALTERNATOR BELT

(DISCARD)

FRONT

AC4390

BOX-END COMBINATION

WRENCH (19mm)


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(c) Install the compressor to the engine block using

three bolts.

CAUTION

Tightening Torque

24.5 Nm (250 kgfcm, 18.1 lbfft)

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

COMPRESSOR

ENGINE BLOCK

AC4392

BOLTS(M8 72)

[3]

[1]

[2]


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(d) Use the following procedure to install the

compressor drive belt.

NOTE

Set the box-end combination wrench (19mm) as

shown in the left figure, and install the compressor

drive belt from the pulleys while pulling the box-end

combination wrench to the front of the vehicle.

NOTE

FRONT

COMPRESSOR DRIVE

BELT

FRONT

AC4393

BOX-END COMBINATION

WRENCH (19mm)

(e) Install the compressor drive belt to the pulleys as

shown in the left figure.

AC4391

TENSIONER

PULLEY

P/S PUMPPULLEY

ALTERNATOR

PULLEY

WATER PUMP

PULLEY

COMPRESSOR

PULLEYCRANKSHAFT PULLEY

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

TAPING

VEHICLE HARNESS (4-P)

FRONT

AC4394


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

connector.

FRONT

VEHICLE HARNESS

(4-P)

Mg/C CONNECTOR

AC4395COMPRESSOR

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

BRACKET No.2

BRACKET No.1

FRONT

TO PASSENGER COMPARTMENT

AC4396

(6) PIPING

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

FRONT

AC4397

PLASTIC CLAMP No.2


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(b) Assemble the plastic clamp No.1 to the

condenser.

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

using a bolt.

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

No.1.

Tightening Torque

5.4 Nm (55 kgfcm, 4.0 lbfft)

CONDENSER AC4421

LIQUID TUBE No.1

PLASTIC CLAMP No.1

BOLT(M6 25)

(e) Install the bracket No.1 to the body using a bolt.

FRONT

AC4398

BOLT(M6 12)

BRACKET No.1

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

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

No.2.

(h) Attach the packing around connecting portion of

the liquid tube No.1 and liquid tube No.2.

LIQUID TUBE No.2

AC4399PLASTIC CLAMP No.2FRONT

LIQUID TUBE No.1

PACKING

PACKING

CROSSSECTION

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

liquid & suction tube.

(j) Fasten the liquid tube No.2 to the bracket No.1.

(k) Fasten the liquid tube No.2 using a quick joint

(small).

QUICK JOINT (SMALL) AC4400

LIQUID TUBE No.2

BRACKET No.1

FRONT


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(l) Install the bracket No.2 to the body using a bolt.

CAUTION

Catch the turning stopper to the vehicle hole

surely.

BRACKET No.2

FRONT

AC4401

CAUTION

BOLT(M6 12)

(m) Install the plastic clamp No.3 to the body.

AC4402

PLASTIC CLAMP No.3

FRONT

(n) Connect the suction hose to the compressor

using a bolt.

Tightening Torque


FRONT

SUCTION HOSE

AC4403COMPRESSOR

BOLT(M6 35)

(o) Fasten the suction hose to the bracket No.2

using a nut.

AC4404

SUCTION HOSE

NUT (M6)

FRONT

BRACKET No.2


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(p) Connect the suction hose to the liquid and

suction tube.

(q) Fasten the suction hose to the plastic clamp

No.3.

(r) Fasten the suction hose using a quick joint (big).

QUICK JOINT (BIG)

AC4405

SUCTION HOSE

FRONT

SUCTION HOSE

PLASTIC CLAMP No.3

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

figure.

AC3585

FRONT

DISCHARGE HOSE

DISCHARGE HOSE

(t) Connect the discharge hose to the condenser

using a bolt.

Tightening Torque


AC4407

DISCHARGE HOSE

CONDENSER

FRONT

BOLT (M6 25)


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(u) Connect the discharge hose to the compressor

using a bolt.

Tightening Torque

9.8Nm (100 kgfcm, 7.2 lbfft)

FRONTDISCHARGE HOSE AC3584

COMPRESSOR

BOLT(M6 35)

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

FRONT

TAPING

AC4409


(w) Connect the vehicle harness (4-P) to the

pressure switch.

AC4410


PRESSURE SWITCH

(7) RELAYS

(a) Temporarily remove the relay box cover.

FRONT

RELAY BOX COVER

AC4411


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(b) Install the Mg/C relay into the relay box.

NOTE

Be sure to install the relay box by supporting the

relay box by hand from the bottom side to prevent

a contact defect.

FRONT

Mg/C RELAY (4-P,BLACK)

AC4412

(c) Reinstall the relay box cover.

FRONT

RELAY BOX COVER

AC4413

(8) CAUTION PLATE

(a) Attach the caution plate to the engine hood.

NOTE

Affix after completely wiping off dust and oil stains

from the engine hood.

AC4414

CAUTION PLATE

ENGINE HOOD

(9) REINSTALLATION OF ORIGINAL PARTS

(a) Under cover (RH)

SCREWS

AC4381

UNDER COVER (RH)

CLIPS

CLIPS

CLIP


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VEHICLE WITH SURGE TANK ONLY [(b)~(c)]

(b) Surge tank

AC4380SURGE TANK


(c) Screw

AC4422FRONT BUMPER

SCREW


(d) Front fender liner (LH)

AC4378

FRONT FENDER

LINER (LH)

CLIPS

SCREWS

(e) Radiator upper supports (RH,LH)

AC4377

RADIATOR UPPER SUPPORTS (RH,LH)


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(f) Front grille

(g) Plate

AC4376

PLATEFRONT GRILLE

(h) Air duct

FRONT

AC4374

AIR DUCT

(i) Air cleaner box lower cover

CAUTION

Make sure to be inserted the air duct into the air

cleaner box lower cover.

AC4416

AIR CLEANER BOX LOWER COVER

FRONT

CAUTION

(j) Vehicle harness clamp

FRONTAC4417

VEHICLE HARNESS CLAMP


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(k) Filter

FRONT

AC4418

FILTER

(l) Reinstall the VSV to the air cleaner box upper

cover.

VSV

FRONT

AIR CLEANER BOX

UPPER COVER

VSV

HOOK

AC4419

(m) Air cleaner box upper cover

(n) Reconnect the vehicle harness to the air cleanerbox upper cover.

(o) Reconnect the air cleaner hose to the air cleaner

box upper cover.

AC4369

VEHICLE HARNESS

AIR CLEANER BOX UPPER COVER

AIR CLEANER HOSE

(p) Battery & battery tray

FRONT

AC4368

BATTERY

BATTERY TRAY


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1ZZ-FE E/G MODEL ONLY [(q)]

(q) Engine cover

Tightening Torque


RIB

ENGINE COVER

AC4415

1ZZ-FE E/G MODEL ONLY


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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.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.

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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3. AMPLIFIER


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4. WIRING DIAGRAM

COMPRESSORMg/C

RELAY

IG

RELAY

IG SW

12V

HEATER

MAIN RELAY

BLOWER

MOTOR

BLOWER

RESISTOR

BLOWER

RESISTOR

LH

RH

BLOWER SW A/C SW

TO GND

TO TAIL RELAY

AC4498


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246108-711

EFI ECUPRESSURE SW

A/C AMP

EVA.THERMISTOR

RESISTOR

FAN RELAY No.2

RADIATOR

FAN MOTOR

FAN RELAY No.1

AC4499


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DENSO CORPORATION

SERVICE DEPARTMENT

Kariya, Aichi, Japan

Frist Issue :SEPTEMBER 2001

Publication No. : AAAMC-29

Printed in Japan


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Airco inside engine comp.RHD aaamc29.pdf

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