INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA

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1 INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA

2 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 NOTE WARNING CAUTION,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 COROLLA. When installing the air conditioning, installation should be performed as described in this manual. [APPLICATION VEHICLE] VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION COROLLA NZE12#R ~ 1NZ/2NZ-FE RHD ZZE12#R 1ZZ/3ZZ/4ZZ-FE,2ZZ-GE 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 DOCUMENT CODE DOCUMENT PART NUMBER GENERAL INFORMATION / AOAMC-01* * AFTER INSTALLATION INSTALLATION MANUAL (INSIDE PASSENGER COMPARTMENT) AAAMB-24* * 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.

3 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. VEHICLE HARNESS CAUTION First remove the negative terminal on the battery and the vehicle harness connection before installing the equipment. Disconnect the negative cable first. BATTERY AC1895 1ZZ-FE E/G MODEL ONLY ENGINE COVER (1) REMOVAL OF ORIGINAL PARTS 1ZZ-FE E/G MODEL ONLY [(a)] (a) Engine cover AC

4 BATTERY (b) Battery and battery tray BATTERY TRAY AC4368 VEHICLE HARNESS AIR CLEANER BOX UPPER COVER (c) (d) (e) Disconnect the vehicle harness from the air cleaner box upper cover. Disconnect the air cleaner hose from the air cleaner box upper cover. Temporarily remove the air cleaner box upper cover from the air cleaner lower cover. AIR CLEANER HOSE VSV AC4369 (f) Temporarily remove the VSV from the air cleaner box upper cover. AIR CLEANER BOX UPPER COVER VSV HOOK CAUTION Do not disconnect the intake hoses from the VSV. AC4370 (g) Filter FILTER AC

5 VEHICLE HARNESS CLAMP (h) Vehicle harness clamp AC4372 AIR CLEANER BOX LOWER COVER (i) Air cleaner box lower cover AC4373 AIR DUCT (j) Air duct AC4374 RADIATOR UPPER SUPPORTS (RH,LH) (k) (l) Radiator upper supports. (RH,LH) Front grille GRILLE AC

6 (m) Front fender liner (LH) CLIPS NOTE Take care not to remove the front fender liner (LH) completely. FENDER LINER (LH) SCREWS AC3570 STEERING WHEEL (n) Fully turn the steering wheel counterclockwise, before removing the front fender liner (LH). VEHICLE WITH SURGE TANK ONLY AC4379 (o) VEHICLE WITH SURGE TANK ONLY [o)~(p)] Screw SCREW BUMPER VEHICLE WITH SURGE TANK ONLY AC3571 (p) Surge tank SURGE TANK AC

7 CLIPS (q) Under cover (RH) CLIPS UNDER COVER (RH) CLIP SCREWS AC4381 (2) RESISTOR (a) Install the resistor to the body using two bolts. RESISTOR BOLTS (M6 16) AC4382 (b) (c) Pull the vehicle harness (2-P) down. Route the vehicle harness (2-P) to the resistor. TAPING TO RESISTOR VEHICLE HARNESS (2-P) AC4383 (d) Connect the vehicle harness (2-P) to the resistor. RESISTOR VEHICLE HARNESS (2-P) AC

8 VEHICLE HARNESS CLIP RADIATOR FAN MOTOR (3) LIQUID TUBE (a) Disconnect the vehicle harness from the radiator fan motor. (b) Temporarily remove the vehicle harness clip from the fan shroud. VEHICLE HARNESS CLIP FAN SHROUD VEHICLE HARNESS AC4423 RADIATOR (c) Insert the liquid tube No.1 as shown in the left figure. LIQUID TUBE No.1 AC4385 (d) Route the liquid tube No.1 under the vehicle harness, when inserting the liquid tube No.1. VEHICLE HARNESS LIQUID TUBE No.1 AC4386 (e) Set the liquid tube No.1 as shown in the left figure. LIQUID TUBE No.1 AC

9 COLLARS (4) CONDENSER (a) Assemble two collars and two bushings to the condenser. BUSHINGS CONDENSER AC4420 CONDENSER (b) Lean the radiator backward then insert the condenser in front of radiator. RADIATOR CAUTION Insert a corrugated board and others before inserting the condenser to prevent the radiator from being damaged. CORRUGATED BOARD AC4387 VIEWED FROM THE BOTTOM SIDE OF VEHICLE (c) Make sure that the bushings of condenser positively inserted into the vehicle holes. VIHICLE HOLE RUBBER CUSHION CONDENSER VIHICLE HOLE CONDENSER RUBBER CUSHION AC

10 BOLTS (M8 32,SILVER) CONDENSER (d) Install the condenser using two bolts. AC4389 VEHICLE HARNESS CLIP RADIATOR FAN MOTOR (e) (f) Reinstall the vehicle harness clip to the fan shroud. Reconnect the vehicle harness to the radiator fan motor. VEHICLE HARNESS CLIP FAN SHROUD VEHICLE HARNESS AC4425 1NZ/2NZ-FE E/G MODEL ONLY ALTERNATOR BELT (DISCARD) ADJUSTING BOLT (5) COMPRESSOR AND COMPRESSOR DRIVE BELT 1NZ/2NZ-FE E/G MODEL ONLY [(a)~(g)] (a) Loosen the lock bolt and the adjusting bolt. (b) Remove and discard the alternator belt. LOCK BOLT AC

11 (c) Install the compressor to the engine block using four bolts. Tightening Torque 24.5 N m (250 kgf cm, 18.1 lbf ft) CAUTION Tightening order; [1]» [2]» [3]» [4] 1NZ/2NZ-FE E/G MODEL ONLY [3] [1] BOLTS (M8 72) [2] ENGINE BLOCK [4] COMPRESSOR AC

12 1NZ/2NZ-FE E/G MODEL ONLY COMPRESSOR DRIVE BELT 10kgf CRANKSHAFT PULLEY ROD ALTERNATOR ADJUSTING BAR OCV ALTERNATOR PULLEY WATER PUMP PULLEY COMPRESSOR PULLEY ALTERNATOR AC3575 (d) (e) Install the compressor drive belt to the pulleys as shown in the left figure. 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. New Belt Adjust the belt tension as shown in the left figure. Belt deflection at 98 N (10 kgf,22 lbf) force mm ( inch) Used Belt mm (Re-adjustment) ( inch) Belt tension using the belt tension gauge N (55-65 kgf, lbf) N (25-40 kgf, lbf) CAUTION Insert the rod between the alternator adjusting bar and the engine mount bracket, and adjust the belt tension. Do not insert the rod between the alternator adjusting bar and OCV since the OCV might get damaged. 1NZ/2NZ-FE E/G MODEL ONLY COMPRESSOR DRIVE BELT ADJUSTING BOLT (f) Tighten the adjusting bolt. Tightening Torque 18.5 N m (189 kgf cm, 13.6 lbf ft) (g) Tighten the lock bolt. Tightening Torque 54 N m (550 kgf cm, 40 lbf ft) LOCK BOLT AC

13 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY NOTE ALTERNATOR BELT (DISCARD) (h) 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY [(h)~(l)] Use the following procedure to remove the alternator belt. NOTE Set the box-end combination wrench (19mm) as shown in the left figure, and remove the alternator belt to the pulleys while pulling the box-end combination wrench to the front of the vehicle. (i) Remove and discard the alternator belt. BOX-END COMBINATION WRENCH (19mm) AC

14 (j) Install the compressor to engine block using three bolts. Tightening Torque 24.5 N m (250 kgf cm, 18.1 lbf ft) CAUTION Tightening order; [1]» [2]» [3] 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY [1] [2] BOLTS (M8 72) ENGINE BLOCK [3] COMPRESSOR AC

15 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY NOTE COMPRESSOR DRIVE BELT (k) NOTE Use the following procedure to install the compressor drive belt. Set the box-end combination wrench (19mm) as shown in the left figure, and install the compressor drive belt to the pulleys while pulling the box-end combination wrench to the front of the vehicle. BOX-END COMBINATION WRENCH (19mm) AC3580 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY P/S PUMP PULLEY OR IDLE PULLEY ALTERNATOR PULLEY (l) Install the compressor drive belt to the pulleys as shown in the left figure. TENSIONER PULLEY WATER PUMP PULLEY CRANKSHAFT PULLEY COMPRESSOR PULLEY AC3578 VEHICLE HARNESS (4-P) (m) Pull the vehicle harness (4-P) down. TAPING AC

16 Mg/C CONNECTOR VEHICLE HARNESS (4-P) (n) Connect the vehicle harness (4-P) to the Mg/C connector. COMPRESSOR PIPING LAYOUT PLASTIC CLAMP No.3 AC4395 TO PASSENGER COMPARTMENT BRACKET No.1 PLASTIC CLAMP No.2 SUCTION HOSE LIQUID TUBE No.2 COMPRESSOR BRACKET No.2 PLASTIC CLAMP No.1 DISCHARGE HOSE CONDENSER LIQUID TUBE No.1 AC4396 PLASTIC CLAMP No.2 (6) PIPING (a) Install the plastic clamp No.2 to the body. AC

17 LIQUID TUBE No.1 (b) (c) Assemble the plastic clamp No.1 to the condenser. Connect the liquid tube No.1 to the condenser using a bolt. PLASTIC CLAMP No.1 Tightening Torque 5.4 N m (55 kgf cm, 4.0 lbf ft) BOLT(M6 25) (d) Fasten the liquid tube No.1 to the plastic clamp No.1. CONDENSER AC4421 (e) Install the bracket No.1 to the body using a bolt. BRACKET No.1 BOLT(M6 12) AC4398 LIQUID TUBE No.2 CROSS SECTION PACKING LIQUID TUBE No.1 (f) (g) (h) Connect the liquid tube No.2 to the liquid tube No.1. Fasten the liquid tube No.1 to the plastic clamp No.2. Attach the packing around connecting portion of the liquid tube No.1 and liquid tube No.2. PACKING PLASTIC CLAMP No.2 AC4399 LIQUID TUBE No.2 (i) (j) (k) Route and connect the liquid tube No.2 to the liquid and suction tube. Fasten the liquid tube No.2 to the bracket No.1. Fasten the liquid tube No.2 using a quick joint (small). BRACKET No.1 QUICK JOINT (SMALL) AC

18 (l) Install the bracket No.2 to the body using a bolt. BRACKET No.2 CAUTION Catch the turning stopper to the vehicle hole surely. CAUTION BOLT(M6 12) AC4401 (m) Install the plastic clamp No.3 to the body. PLASTIC CLAMP No.3 AC4402 SUCTION HOSE (n) Connect the suction hose to the compressor using a bolt. Tightening Torque 9.8 N m (100 kgf cm, 7.2 lbf ft) COMPRESSOR BOLT(M6 35) AC4403 (o) Fasten the suction hose to the bracket No.2 using a nut. NUT (M6) BRACKET No.2 SUCTION HOSE AC

19 PLASTIC CLAMP No.3 QUICK JOINT (BIG) (p) (q) (r) Connect the suction hose to the liquid and suction tube. Fasten the suction hose to the plastic clamp No.3. Fasten the suction hose using a quick joint (big). SUCTION HOSE SUCTION HOSE AC4405 (s) Insert the discharge hose as shown in the left figure. DISCHARGE HOSE DISCHARGE HOSE AC3585 CONDENSER (t) Connect the discharge hose to the condenser using a bolt. BOLT (M6 25) Tightening Torque 5.4 N m (55 kgf cm, 4.0 lbf ft) DISCHARGE HOSE AC

20 COMPRESSOR (u) Connect the discharge hose to the compressor using a bolt. Tightening Torque 9.8N m (100 kgf cm, 7.2 lbf ft) BOLT(M6 35) DISCHARGE HOSE AC3584 VEHICLE HARNESS (4-P) (v) Pull the vehicle harness (4-P) down. TAPING AC4409 VEHICLE HARNESS (4-P) (w) Connect the vehicle harness (4-P) to the pressure switch. PRESSURE SWITCH AC4410 RELAY BOX COVER (7) RELAYS (a) Temporarily remove the relay box cover. AC

21 Mg/C RELAY (4-P,BLACK) (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. RELAY BOX COVER AC4412 (c) Reinstall the relay box cover. AC4413 CAUTION PLATE (8) CAUTION PLATE (a) Attach the caution plate to the frame. NOTE Affix after completely wiping off dust and oil stains from the frame. CLIPS AC3581 (9) REINSTALLATION OF ORIGINAL PARTS (a) Under cover (RH) CLIPS UNDER COVER (RH) CLIP SCREWS AC

22 VEHICLE WITH SURGE TANK ONLY (b) VEHICLE WITH SURGE TANK ONLY [(b)~(c)] Surge tank SURGE TANK AC3572 VEHICLE WITH SURGE TANK ONLY (c) Screw SCREW BUMPER AC3571 (d) Front fender liner (LH) CLIPS FENDER LINER (LH) SCREWS AC3570 RADIATOR UPPER SUPPORTS (RH,LH) (e) (f) Radiator upper supports (RH,LH) Front grille GRILLE AC

23 AIR DUCT (g) Air duct AC4374 AIR CLEANER BOX LOWER COVER (h) Air cleaner box lower cover CAUTION Make sure to be inserted the air duct into the air cleaner box lower cover. CAUTION AC4416 VEHICLE HARNESS CLAMP (i) Vehicle harness clamp AC4417 (j) Filter FILTER AC

24 VSV (k) Reinstall the VSV to the air cleaner box upper cover. VSV HOOK AIR CLEANER BOX UPPER COVER AC4419 AIR CLEANER BOX UPPER COVER VEHICLE HARNESS (l) Air cleaner box upper cover (m) Reconnect the vehicle harness to the air cleaner box upper cover. (n) Reconnect the air cleaner hose to the air cleaner box upper cover. AIR CLEANER HOSE AC4369 BATTERY (o) Battery and battery tray BATTERY TRAY RIB AC4368 1ZZ-FE E/G MODEL ONLY ENGINE COVER (p) 1ZZ-FE E/G MODEL ONLY [(p)] Engine cover Tightening Torque 7.0 N m (71 kgf cm, 5.1 lbf ft) AC

25 2. 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: *) 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)". STANDARD AMOUNT OF REFRIGERANT 490 ± 30 g (1.08 ± 0.7 lbs) CAUTION Ensure to fill the refrigerant to the specified amount. 2-2.RE-ADJUSTMENT OF COMPRESSOR BELT (1NZ/2NZ E/G MODEL ONLY) 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. Vehicle equipped with 1NZ/2NZ E/G Belt deflection [at 98N(10kgf, 22lbf)force] mm ( inch) Belt tension [N (kgf, lbf)] N (25-40 kgf, lbf) 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. 2-3.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.)

26 3. AMPLIFIER ALL EUROPEAN SPEC. AND 1NZ/2NZ-FE E/G MODEL (VEHICLE WITH HEATER)

27 1NZ/2NZ-FE E/G MODEL (VEHICLE WITHOUT HEATER)

28 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL (VEHICLE WITH HEATER AND GENERALLY SPEC.)

29 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL (VEHICLE WITHOUT HEATER AND GENERALLY SPEC.)

30 4. WIRING DIAGRAM 1NZ/2NZ-FE E/G MODEL (VEHICLE WITH HEATER) IG RELAY Mg/C RELAY MIDDLE EAST EXCEPT COMPRESSOR IG SW 12V HEATER MAIN RELAY BLOWER MOTOR RH LH BLOWER RESISTOR TO TAIL RELAY TO RHEOSTAT BLOWER RESISTOR BLOWER SW RH A/C SW AC

31 PRESSURE SW EFI ECU ONLY MIDDLE EAST COMPRESSOR FAN RELAY No.1 RADIATOR FAN MOTOR FAN RELAY No.2 RESISTOR LH A/C SW EVA.THERMISTOR A/C AMP AC

32 1NZ/2NZ-FE E/G MODEL (VEHICLE WITHOUT HEATER) IG RELAY Mg/C RELAY MIDOLE EAST EXCEPT COMPRESSOR IG SW 12V HEATER MAIN RELAY RH BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND BLOWER SW VOLUME SW AC

33 PRESSURE SW EFI ECU ONLY MIDDLE EAST COMPRESSOR FAN RELAY No.1 RADIATOR FAN MOTOR FAN RELAY No.2 RESISTOR A/C AMP EVA.THERMISTOR AC

34 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL (VEHICLE WITH HEATER) IG RELAY Mg/C RELAY COMPRESSOR IG SW 12V HEATER MAIN RELAY BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND RH BLOWER SW A/C SW AC

35 PRESSURE SW EFI ECU FAN RELAY No.1 RADIATOR FAN MOTOR FAN RELAY No.2 RESISTOR EVA.THERMISTOR A/C AMP AC

36 1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL (VEHICLE WITHOUT HEATER) IG RELAY Mg/C RELAY MIDDLE EAST EXCEPT COMPRESSOR IG SW 12V HEATER MAIN RELAY RH BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND AC3790 BLOWER SW VOLUME SW

37 PRESSURE SW EFI ECU ONLY MIDDLE EAST COMPRESSOR FAN RELAY No.1 RADIATOR FAN MOTOR FAN RELAY No.2 RESISTOR A/C AMP EVA.THERMISTOR AC

38 ALL EUROPEAN SPEC. IG RELAY Mg/C RELAY COMPRESSOR IG SW 12V HEATER MAIN RELAY BLOWER MOTOR BLOWER RESISTOR LH BLOWER RESISTOR TO TAIL RELAY TO GND RH AC4498 BLOWER SW A/C SW

39 PRESSURE SW EFI ECU FAN RELAY No.1 RADIATOR FAN MOTOR FAN RELAY No.2 RESISTOR A/C AMP EVA.THERMISTOR AC

40 - 38 -

41 DENSO CORPORATION SERVICE DEPARTMENT Kariya, Aichi, Japan Frist Issue : AUGUST 2000 Second Issue : SEPTEMBER 2001 Publication No. : AAAMB-25A Printed in Japan

42 AAAMB-25A

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