EUROPE

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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 driver’s 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

-200500082

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 -300500082 .

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 -400500082 .

HORN VEHICLE HARNESS (1-P) AC1741 RADIATOR UPPER BAFFLE (p) Hood lock (q) Radiator upper baffle HOOD LOCK AC1742 -500500082 .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.

remove the other clips and screws. slide the front over fender to the front of the vehicle and remove. AC1743  CLIPS CLIPS CLIP NOTE FOR ADDITIONAL KIT ONLY [(s)~(t)] (s) Front over fender (LH) NOTE Except for this clip. 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.(r) RADIATOR UPPER BAFFLE HEAD LAMP(LH) Lift up the head lamp (LH) when removing the radiator upper baffle. SCREWS AC1746 FRONT FENDER LINER (LH) -600500082 .

VEHICLE HARNESS CLIP VIEWED FROM INSIDE FRONT FENDER LINER (LH) VEHICLE HARNESS CLIP AC1748 -700500082 .(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 CONNECTOR AC1751 ALTERNATOR FRONT ALTERNATOR ADJUSTING BOLT (f) Temporarily remove the lock bolt and the adjusting bolt from the alternator. (e) Temporarily remove the cap.(2) FRONT ALTERNATOR ADJUSTING BOLT COMPRESSOR DRIVE BELT AND COMPRESSOR-1 (a) Loosen the lock bolt of the alternator. then remove the output terminal from the alternator. 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. then loosen the adjusting bolt. ADJUSTING BOLT AC1749 LOCK BOLT ALTERNATOR LOCK BOLT -800500082 . ADJUSTING BOLT AC1749 LOCK BOLT ALTERNATOR LOCK BOLT (b) Remove and discard the alternator belt.

ALTERNATOR PULLEY (FOR 70A. ALTERNATOR CAUTION AC1976 IMPACT WRENCH Hold the original alternator pulley securely with a hand as shown in left diagram when using the impact wrench. (h) Temporarily remove the adjusting bar from the oil pump. ALTERNATOR AC1978 -900500082 .VEHICLE HARNESS CLAMP ADJUSTING BAR (g) Temporarily remove the vehicle harness clamp from the adjusting bar. (i) Temporarily remove the alternator from the engine block. INCLUDED IN KIT) COLLAR (LARGE) CAUTION Identify the alternator pulley (included in kit) according to collar size on the reverse side of the pulley. INCLUDED IN KIT) ALTERNATOR PULLEY (FOR 90A. INCLUDED IN KIT) (l) Loosely assemble the alternator pulley (included in kit) to the alternator. CLOTH ORIGINAL ALTERNATOR PULLEY (DISCARD) SOCKET (22mm) NOTE Procedure will be eased with using a impact wrench. (k) Choose the alternator pulleys (included in kit) according to the current value (90A or 70A) written on the alternator label. FRONT ALTERNATOR AC1752 (j) CAUTION Remove and discard the original alternator pulley from the alternator. LABEL COLLAR (SMALL) AC1977 ALTERNATOR ALTERNATOR PULLEY (HAND TIGHTEN.

Carrying out said procedure with 2 or 3 people is necessary. and carry out the procedure with the 3 bosses of SST are set to the 3 holes of the alternator pulley. 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. Hold the alternator with a hand securely as shown in left figure. Tightening Torque 110. 2.0 lbf•ft) CAUTION SST AC1981 1. CAUTION Nip the SST with the vise securely to that the SST won't be shaky.SST VISE (m) Fix the SST by nipping with the vise as shown in left figure.5 N•m (1175 kgf•cm. 85. .10 00500082 .

Tightening Torque CAP FRONT OUTPUT TERMINAL 9. ADJUSTING BOLT (HAND TIGHTEN) FRONT ALTERNATOR AC1984 (t) VEHICLE HARNESS CLIP ALTERNATOR Reinstall the output terminal and the cap to the alternator.(p) Install the cover to the alternator pulley.8 N•m (100 kgf•cm.2 lbf•ft) (u) Reinstall the vehicle harness clip to the bracket of the alternator. VEHICLE CONNECTOR AC1985 ALTERNATOR . 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. (v) Reconnect the vehicle connector to the alternator.11 00500082 . COVER ALTERNATOR AC1982 FRONT ALTERNATOR (q) Temporarily tight the alternator to the engine block with the lock bolt. 7.

hand tighten the bolt No. [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. 18.(3) COMPRESSOR DRIVE BELT AND COMPRESSOR-2 (a) Install the compressor to the engine block using four bolts. Tightening order. FRONT VEHICLE HARNESS (4-P) AC1903 .5 N•m (250 kgf•cm. Tightening Torque 24.12 00500082 .1 lbf•ft) CAUTION First.4.

28-0. Adjust the belt by tightening the adjusting bolt. Tightening Torque 18. Belt deflection at 98 N•(10 kgf.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) .33 inch) .24 inch) Used Belt 7-8. 13. The belt tension must be measured between the specified pulleys. 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.(c) Connect the vehicle harness to the Mg/C connector.5 mm (Re. 4. then tighten the adjusting bolt.2-0.6 lbf•ft) CAUTION 1. 5. The tension may be measured between any pulleys when using the DENSO belt tension gauge. 3.5 N•m (189 kgf•cm. 22 lbf) force New Belt 5-6 mm (0.adjustment) (0. 2. (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. Adjust the belt to the center of the range. The threads on the compressor belt must fit into grooves on the pulley.

4 N•m (55 kgf•cm.14 00500082 .1 BOLT(M6 25. 39. Tightening Torque 5. BUSHINGS RUBBER CUSHIONS AC1757 CONDENSER (c) Connect the liquid tube No. FRONT ALTERNATOR CAUTION Tighten the lock bolt with cohering the slide bush to the engine block. Tightening Torque 54 N•m (550 kgf•cm.0 lbf•ft) LIQUID TUBE No. 4.6 lbf•ft) 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.1 to the condenser using a bolt.(g) Tighten the lock bolt. (b) Install two bushings and two collars to the condenser upper bracket. SILVER) AC1758 .

1 must not interfere with the vehicle body. CAUTION AC1759 (g) Fasten the liquid tube No. (e) Insert a piece of cardboard along the front of the radiator to avoid scratching the radiator fins. AC1761 . CONDENSER CAUTION Make sure that the rubber cushion positively inserted into the vehicle hole.15 00500082 .RADIATOR CARDBOARD (d) Temporarily slide the radiator to the right side of the vehicle. LIQUID TUBE No. BLACK) AC1760 RADIATOR (h) Reinstall the radiator to the original position.1 to the body using a bolt. (f) Insert the condenser in front of the radiator. CAUTION The liquid tube No.1 FRONT (M6 BOLT 14.

5 lbf•ft) BOLTS (M5 40) COOLING UNIT FRONT AC1905 (b) Fasten the plastic clamp to the frame. PLASTIC CLAMP FRONT AC1906 . PIPING LAYOUT COOLING UNIT LIQUID TUBE No. Tightening Torque 3.1 COMPRESSOR CONDENSER DISCHARGE TUBE AC1902 (5) EXPANSION VALVE PIPING (a) Connect the expansion valve to the cooling unit case using two bolts.2 DISCHARGE HOSE SUCTION HOSE LIQUID TUBE No.4 N•m (35 kgf•cm. 2.16 00500082 .

LIQUID TUBE No. FRONT LIQUID TUBE No. CAUTION Avoid stretching the vehicle harness too hard. FRONT VEHICLE HARNESS AC1909 (f) Temporarily set the suction hose as shown in the left figure.(c) Temporarily set the 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.2 SUCTION HOSE FRONT AC1910 .17 00500082 .2 as shown in the left figure.

2 AC1913 LIQUID TUBE No.2 to the expansion valve. Hand tighten a bolt of the expansion valve. EXPANSION VALVE BOLT(M6 20.1 FRONT LIQUID TUBE No.2 (k) Fasten the suction hose and the liquid tube No.1. SUCTION HOSE PLASTIC CLAMP AC1914 . BLACK) FRONT LIQUID TUBE No.18 00500082 . EXPANSION VALVE LIQUID TUBE No.2 to the plastic clamp. LIQUID TUBE No.2 to the liquid tube No.(g) Connect the liquid tube No.2 FRONT AC1911 (h) Route and connect the liquid tube No.2 AC1912 (i) SUCTION HOSE (j) Connect the suction hose to the expansion valve.

Tightening Torque 5.8 N•m (100 kgf•cm.19 00500082 .2 lbf•ft) DISCHARGE HOSE FRONT BOLT(M6 25.(l) DISCHARGE TUBE CONDENSER Connect the discharge tube to the condenser using a bolt.4 N•m (55 kgf•cm. 4. Tightening Torque 9.GOLD) AC1916 (n) Route the hood lock release wire as shown in the left figure. 7.SILVER) AC1915 COMPRESSOR (m) Connect the discharge hose to the compressor using a bolt. HOOD LOCK RELEASE WIRE CONDENSER FRONT AC1917 (o) Reinstall the radiator upper baffle. HOOD LOCK AC1742 .0 lbf•ft) FRONT BOLT (M6 25. (p) Reinstall the hood lock. RADIATOR UPPER BAFFLE CAUTION Be careful not to pinch the hood lock release wire when reinstallation the radiator upper baffle.

Tightening Torque 9.GOLD) AC1922 . HORN VEHICLE HARNESS (1-P) AC1919 (r) BOLT (SILVER) (M8XR32) CONDENSER Install the condenser to the radiator upper baffle using two bolts.(q) Reconnect the vehicle harness to the connector of the horn.2 lbf•ft) SUCTION HOSE FRONT BOLT(M6 25. 7.0 lbf•ft) RADIATOR UPPER BAFFLE FRONT AC1921 COMPRESSOR (u) Connect the suction hose to the compressor using a bolt.20 00500082 . Tightening Torque 5. 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.8 N•m (100 kgf•cm. 4. (t) Fasten the clamp of discharge hose to the radiator upper baffle using a bolt.4 N•m (55 kgf•cm.

4 N•m (55 kgf•cm.21 00500082 .2 AC1923 (w) Fasten the suction hose to the frame using the clamp and a bolt. PRESSURE SWITCH VEHICLE HARHESS (4-P) AC1925 (6) RESISTOR (a) Install the resistor to the body using two bolts.(v) Fully tighten the bolt. SUCTION HOSE Tightening Torque FULLY TIGHTEN 5.0 lbf•ft) EXPANSION VALVE FRONT LIQUID TUBE No. (y) Connect the vehicle harness to the pressure switch. HEAD LAMP (LH) RESISTOR BOLTS (M6 14) AC1926 . CLAMP CLAMP SUCTION HOSE SUCTION HOSE AC1924 BOLT (M6X 16)  FRONT EXCEPT FOR ADDITIONAL KIT [(x)~(y)] (x) Pull the vehicle harness down. 4.

2 RELAY BOX A/C HARNESS No.22 00500082 . 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 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 . RESISTOR AC1927 RADIATOR UPPER BAFFLE CLIPS (d) Head lamp under cover (LH). (c) Connect the vehicle harness to the resistor. VEHICLE HARNESS (2-P) EXCEPT FOR ADDITIONAL KIT [(b)~(c)] (b) Pull the vehicle harness down.

2 [TO RADIATOR FAN] AC1932 INSIDE FRONT FENDER LINER (LH) TO INSIDE ENGINE COMPARTMENT VEHICLE FRAME (e) Route the A/C harness No.2 AC1933 . A/C HARNESS No. (b) Temporarily remove the relay box cover (upper side) and the vehicle harness from the relay box.(7) VEHICLE HARNESS RELAY BOX COVER (UPPER SIDE) WIRING-1 (FOR ADDITIONAAL KIT ONLY) (a) Temporarily remove the relay box from the body. HOOKS RELAY BOX COVER (LOWER SIDE) A/C HARNESS No.2 to inside front fender liner (LH). CAUTION Be careful not to break hooks of the relay box cover.23 00500082 . RELAY BOX AC1930 HOOKS (c) Temporarily remove the relay box cover (lower side) from the relay box.2 above the vehicle frame.2 [TO INSIDE FRONT FENDER LINER (LH)] AC1931 FRONT (d) Insert the A/C harness No. A/C HARNESS No.

TO INSIDE ENGINE COMPARTMENT TO INSIDE PASSENGER COMPARTMENT (f) Remove and discard the vehicle grommet.2 to the vehicle harness using three plastic ties. discontinue the engine compartment and move to the work inside passenger compartment. route the A/C harness No.24 00500082 .2 VEHICLE HARNESS Further work will be continued after the work inside passenger compartment is completed.2 the inside passenger compartment. CAUTION PLASTIC TIES A/C HARNESS No.2 through the vehicle hole and pull out it 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. AC1935 (b) Disconnect the vehicle harness from the connector of the radiator fan.2 First. VEHICLE GROMMET (DISCARD) NOTE A/C HARNESS No. FRONT VEHICLE HARNESS (2-P) RADIATOR FAN AC1936 . AC1934 CAUTION At this point. (g) Pass the A/C harness No.

LIQUID TUBE No. BLACK) Connect the A/C harness No. A/C HARNESS No.2 to the connector of the radiator fan. FRONT A/C HARNESS No.25 00500082 . RESISTOR AC1940 . GRAY) RADIATOR FAN AC1938 (e) Connect the A/C harness No.2 (4-P) FRONT PRESSURE SWITCH AC1939 (f) A/C HARNESS No.2 to the vehicle harness (disconnected the connector of the radiator fan).2 (2-P. DISCONNECTED THE CONNECTOR OF THE RADIATOR FAN) AC1937 (d) Connect the A/C harness No.1 A/C HARNESS No.2 (2-P) VEHICLE HARNESS (2-P.2 (2-P.2 to the pressure switch.2 to the resistor.FRONT (c) Connect the A/C harness No.

fan relay No.1 (REUSE) RELAY BOX AC1942 Depending on a vehicle model. FRONT PLASTIC TIES A/C HARNESS No.2 PLASTIC TIE FAN RELAY No.2 might not be installed.26 00500082 .(g) Secure the A/C harness No.2 (discard) from the relay box. 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.2 to the vehicle harness using three plastic ties. CAUTION Do not mistake the lead wire colors.1 (reuse) and the fan relay No. CAUTION FAN RELAY No. 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.2 (DISCARD) AC1941 (9) WIRING-2 AND RELAY (FOR ADDITIONAL KIT ONLY) (a) Remove the fan relay No. AC1944 .

2 to the lead wire (pink/blue) of the vehicle harness using the branch connector. YELLOW/RED CAUTION Check the wire colors before inserting the terminal of the A/C harness No.2) ONLY [(g)~(h)] (g) Pull out five terminals of the vehicle harness from the relay box. BRANCH CONNECTOR CAUTION Do not mistake the lead wire color. TERMINAL BOTTOM SIDE OF RELAY BOX (e) Insert the terminal of the A/C harness No. AC1946 BOTTOM SIDE OF RELAY BOX LEAD WIRE (PINK/BLUE) (f) Connect the A/C harness No. AC1947  VEHICLE HARNESS WITH THE TERMINAL IS INSERTED IN THE RELAY BOX (BOTTOM SIDE OF FAN RELAY No.1 for the connection of the branch connector. AC1948 .27 00500082 . 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.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. NOTE BLACK/BLUE BOTTOM SIDE OF RELAY BOX FIVE TERMINALS OF THE VEHICLE HARNESS See the P.2 to the relay box.2 to the relay box.

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. 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.2 (k) Secure the A/C harness No. AC1950 A/C HARNESS No.2 to the vehicle harness using a plastic tie.28 00500082 . 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.2 to the relay box.2 to the relay box. BLUE/BLACK CAUTION Check the wire colors before inserting each terminal of the A/C harness No.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. CAUTION Check the wire colors before inserting each terminal of the A/C harness No. PLASTIC TIE RELAY BOX FRONT AC1951 .

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. HOOKS RELAY BOX COVER (LOWER SIDE) A/C HARNESS No. RELAY BOX AC1954 (q) Secure the A/C harness No.1 (REUSE) (m) Reinstall the fan relay No.2 to the vehicle harness using two plastic ties.1 to the relay box. (n) Install the fan relay No. included in kit) to the relay box.2 AC1955 .2 (white.HOOKS (l) Reinstall the relay box cover (lower side) to the relay box.2 AC1952 FAN RELAY No.2 (WHITE. (p) Reinstall the relay box cover (upper side) and the vehicle harness to the relay box. INCLUDED IN KIT) FAN RELAY No. included in kit) and Mg/C relay (white. AC1953 VEHICLE HARNESS RELAY BOX COVER (UPPER SIDE) (o) Reinstall the relay box to the body. PLASTIC TIES FRONT A/C HARNESS No.29 00500082 . CAUTION FRONT Mg/C RELAY (WHITE.

PLASTIC TIE FRONT AC1958 A/C HARNESS No.2 to the vehicle harness using three plastic ties.(r) PLASTIC TIES Secure the A/C harness No. A/C HARNESS No. CAUTION Care should be taken so that the plastic ties do not interfere with the fuel system parts.2 FRONT AC1956 PLASTIC TIES (s) Secure the A/C harness No.2 to the Mg/C connector. FRONT AC1959 .2 to the vehicle harness using a plastic tie. 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 (4-P) Mg/C CONNECTOR (4-P) (u) Connect the A/C harness No.30 00500082 .2 to the vehicle harness using two plastic ties.

AC1960 RADIATOR UPPER BAFFLE (11) CAUTION PLATE (a) Attach the caution plate to the radiator upper baffle. (d) Reinstall the relay box cover to the relay box.2 (WHITE. FAN RELAY No.2 from the relay box. CAUTION FRONT RELAY BOX Depending on a vehicle model. CAUTION Stick on the caution plate after wiping off all dust and oil from the radiator upper baffle.RELAY BOX COVER (10) RELAY (EXCEPT FOR ADDITIONAL KIT) (a) Temporarily remove the relay box cover from the ready box. fan relay No.2 might not be installed. (b) Remove and discard the original fan relay No. 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.31 00500082 . included in kit and Mg/C relay (white. INCLUDED IN KIT) CAUTION ORIGINAL FAN RELAY No.2 (white. included in kit) to the relay box. (c) Install the fan relay No. 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 .2 (DISCARD) FRONT Mg/C RELAY (WHITE.

FRONT OVER FENDER (LH) AC1745 (c) Under cover UNDER COVER AC1744 (d) Plates (LH.(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.32 00500082 .RH) PLATES (LH. RH) AC1739 (e) Front grille FRONT GRILLE AC1738 .

14 lbf•ft) (j) Tow vehicle harness clamps FRONT VEHICLE BRACKET [A] AC1966 (k) Earth terminal CAUTION Tightening Torque 7.33 00500082 . 5.8 N•m (80 kgf•cm. 14 lbf•ft) (h) Three vehicle harness clamps VEHICLE BRACKET [B] FRONT AC1965 (i) FRONT VEHICLE HARNESS CLAMPS VEHICLE BRACKET [A] Vehicle bracket [A] Tightening Torque 19 N•m (194 kgf•cm.8 lbf•ft) CAUTION EARTH TERMINAL Catch the turning stopper to the vehicle hole surely. FRONT AC1967 .(f) Vehicle harness clip VEHICLE HARNESS CLIP AC1964 (g) Vehicle bracket [B] Tightening Torque VEHICLE HARNESS CLAMPS 19 N•m (194 kgf•cm.

34 00500082 .FRONT FILTER (l) Air cleaner box (lower side) (m) Filter CAUTION FRONT Handle the filter with care. the front/ back and top/bottom surfaces.In particular. 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 .

35 00500082 . PARALLEL BATTERY TERMINAL (-) FRONT AC1970 .BATTERY TERMINAL (+) BATTERY (t) Reinstall the battery terminals as shown in the left figure.

3.97 ± 0. Belt deflection [at 98N(10kgf. 3-3. (when the air conditioning system is started.RE-ADJUSTMENT OF COMPRESSOR BELT To correct belt deflection caused by initial elongation. The belt tension must be adjusted to the center of the specified belt tension range. while excessive slackness can cause the belt to slip. therefore adjustment is not required. Excessive tension of belt may have an adverse effect on bearings. refer to "GENERAL INFORMATION/AFTER INSTALLATION" (pages 12-15.60 kgf) CAUTION 1. the air conditioning must be operated for at least 5 minutes before the final adjustment of the belt.ADJUSTMENT OF ENGINE IDLING SPEED CAUTION The engine revolution is controlled by a computer.8. 2. The belt deflection must be measured between the specified pulleys as indicated in this manual. AFTER INSTALLATION CAUTION Refer to the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" for details on what to do after installation.33 inch) Belt tension [N (kgf)] 392 .3.) .21).28 .588 N (40 .0. 3-2.5 mm (0. 22lbf)force] Vehicle equipped with 1ND-TV E/G 7 . STANDARD AMOUNT OF REFRIGERANT 440 ± 30 g (0. The belt tension must be measured between the specified pulleys as indicated in this manual. make abnormal noise or shorten the belt life. (Document code: AOAMC-01*/Document part number: 988963-475*) 3-1. 4.CHARGING REFRIGERANT (HFC-134a) For additional information on charging refrigerant using the charging cylinder.36 00500082 . check whether idling revolution increases.07 lbs) CAUTION Ensure to fill the refrigerant to the specified amount.

37 00500082 . AMPLIFIER .4.

38 00500082 .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 .

2 RESISTOR WATER TEMP.39 00500082 . THERMISTOR EFI ECU 246108-054 AC1973 .SWITCH Mg/C RELAY TRIPLE PRESSURE SWITCH COMPRESSOR EVA.RADIATOR FAN MOTOR FAN RELAY No.

40 00500082 .1 IG SW FUSE 12V TAIL TAIL EARTH 1 A/C AMP BLOWER SWITCH A/C SW AC1974 . FOR ADDITIONAL KIT HEATER MAIN RELAY BLOWER MOTOR BLOWER RESISTOR FAN RELAY No.

2 RESISTOR WATER TEMP.RADIATOR FAN MOTOR FAN RELAY No.THERMISTOR EFI ECU 246108-068 AC1975 .41 00500082 . SWITCH Mg/C RELAY TRIPLE PRESSURE SWITCH COMPRESSOR EVA.

.42 00500082 .

Japan First lssue : SEPTEMBER 2001 Publication No. : AAAMC-26 Printed in Japan -0- .DENSO CORPORATION SERVICE DEPARTMENT Kariya. Aichi.

AAAMC-26 988963-5020 -1- .