TOYOTA

AIR CONDITIONING
ENGLISH
EUROPE

INSIDE ENGINE COMPARTMENT

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 COROLLA VERSO. When installing the air conditioning, installation should be performed as described in this manual. [APPLICATION VEHICLE] VEHICLE NAME COROLLA VERSO MODEL CODE ZZE121R ZZE122R PRODUCTION PERIOD 2001.10~ ENGINE TYPE 3ZZ-FE 1ZZ-FE 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-28*

DOCUMENT PART NUMBER 988963-475* 988963-509*

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. 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
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

1ZZ-FE E/G MODEL ONLY ENGINE COVER

(1)

REMOVAL OF ORIGINAL PARTS
1ZZ-FE E/G MODEL ONLY [(a)] (a) Engine cover

AC4375

-100500089

(b) Battery & battery tray

BATTERY

FRONT

BATTERY TRAY

AC4368

AIR CLEANER BOX UPPER COVER VEHICLE HARNESS

(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.

AIR CLEANER HOSE

AC4369

VSV

(f)

Temporarily remove the VSV from the air cleaner box upper cover.

VSV HOOK AIR CLEANER BOX UPPER COVER

CAUTION
Do not disconnect the intake hoses from the VSV.

FRONT

AC4370

(g) Filter

FILTER

FRONT
AC4371

-200500089

VEHICLE HARNESS CLAMP

(h) Vehicle harness clamp

FRONT

AC4372

AIR CLEANER BOX LOWER COVER

(i)

Air cleaner box lower cover

FRONT AIR DUCT

AC4373

(j)

Air duct

FRONT
AC4374

(k) Plate (l) Front grille

FRONT GRILLE

PLATE
AC4376

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(m) Radiator upper supports (RH,LH)

RADIATOR UPPER SUPPORTS (RH,LH)

AC4377

(n) Front fender liner (LH)

CLIPS

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

FRONT FENDER LINER (LH) STEERING WHEEL

SCREWS

AC4378

(o) Fully turn the steering wheel counterclockwise, before removing the front fender liner (LH).

AC4379

VEHICLE WITH SURGE TANK ONLY

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

SCREW

FRONT BUMPER

AC4422

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VEHICLE WITH SURGE TANK ONLY

(q) Surge tank

SURGE TANK

AC4380

CLIPS

(r)

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) Pull the vehicle harness (2-P) down. (c) Route the vehicle harness (2-P) to the resistor.
FRONT TAPING

TO RESISTOR VEHICLE HARNESS (2-P)

AC4383

-500500089

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

RESISTOR

VEHICLE HARNESS (2-P)

AC4384

(3)
FRONT RADIATOR FAN MOTOR

VEHICLE HARNESS CLIP

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

VEHICLE HARNESS FAN SHROUD RADIATOR

AC4423

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

FRONT

LIQUID TUBE No.1

AC4385

(d) Route the liquid tube No.1 under the vehicle harness, when inserting the liquid tube No.1.
FRONT

VEHICLE HARNESS LIQUID TUBE No.1

AC4386

-600500089

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

LIQUID TUBE No.1

FRONT

AC4424

COLLARS

(4)

CONDENSER (a) Assemble two collars and two bushings to the condenser.

BUSHINGS

CONDENSER CONDENSER RADIATOR

AC4420

(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.

CORRUGATED BOARD

AC4387

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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
AC4388

BOLTS (M8

32,SILVER)

CONDENSER

(d) Install the condenser using two bolts.

AC4389

FRONT

RADIATOR FAN MOTOR

VEHICLE HARNESS CLIP

(e) Reinstall the vehicle harness clip to the fan shroud. (f) Reconnect the vehicle harness to the radiator fan motor.

VEHICLE HARNESS CLIP

VEHICLE HARNESS FAN SHROUD

AC4425

-800500089

(5)
NOTE ALTERNATOR BELT (DISCARD)

COMPRESSOR AND COMPRESSOR DRIVE BELT (a) 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 from the pulleys while pulling the box-end combination wrench to the front of the vehicle. (b) Remove and discard the alternator belt.
BOX-END COMBINATION WRENCH (19mm)

FRONT

FRONT
AC4390

-900500089

(c) Install the compressor to the engine block using three bolts. Tightening Torque 24.5 Nm (250 kgfcm, 18.1 lbfft)

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

[1]

[2]

BOLTS (M8 72)

[3] ENGINE BLOCK

COMPRESSOR
AC4392

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NOTE COMPRESSOR DRIVE BELT

(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.
FRONT

BOX-END COMBINATION WRENCH (19mm)

FRONT
AC4393

P/S PUMP PULLEY

ALTERNATOR PULLEY

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

WATER PUMP PULLEY TENSIONER PULLEY

CRANKSHAFT PULLEY

COMPRESSOR PULLEY

AC4391

(f)
VEHICLE HARNESS (4-P)

Pull the vehicle harness (4-P) down.

FRONT TAPING

AC4394

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Mg/C CONNECTOR VEHICLE HARNESS (4-P)

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

FRONT

COMPRESSOR

AC4395

PIPING LAYOUT
PLASTIC CLAMP No.3 TO PASSENGER COMPARTMENT BRACKET No.1

PLASTIC CLAMP No.2

SUCTION HOSE

LIQUID TUBE No.2 COMPRESSOR FRONT

BRACKET No.2

PLASTIC CLAMP No.1

LIQUID TUBE No.1 DISCHARGE HOSE CONDENSER

AC4396

(6)
PLASTIC CLAMP No.2

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

FRONT
AC4397

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LIQUID TUBE No.1

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

PLASTIC CLAMP No.1

BOLT(M6 CONDENSER

25)
AC4421

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

BRACKET No.1

BOLT(M6

12)

FRONT

AC4398

LIQUID TUBE No.2 PACKING LIQUID TUBE 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.

CROSS SECTION

PACKING PLASTIC CLAMP No.2 FRONT

AC4399

LIQUID TUBE No.2

(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).

BRACKET No.1

FRONT QUICK JOINT (SMALL)

AC4400

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(l)

Install the bracket No.2 to the body using a bolt.

CAUTION
BRACKET No.2

Catch the turning stopper to the vehicle hole surely.

CAUTION BOLT(M6 12) FRONT

AC4401

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

PLASTIC CLAMP No.3

FRONT

AC4402

SUCTION HOSE

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

FRONT

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 FRONT

AC4404

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PLASTIC CLAMP No.3

QUICK JOINT (BIG)

(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).

FRONT SUCTION HOSE

SUCTION HOSE
AC4405

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

FRONT

DISCHARGE HOSE

DISCHARGE HOSE

AC3585

(t)
CONDENSER

Connect the discharge hose to the condenser using a bolt.

Tightening Torque
BOLT (M6 25) DISCHARGE HOSE

5.4 Nm (55 kgfcm, 4.0 lbfft)

FRONT

AC4407

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COMPRESSOR

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

BOLT(M6

35)

DISCHARGE HOSE

FRONT

AC3584

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

VEHICLE HARNESS (4-P)

FRONT

TAPING

AC4409

VEHICLE HARNESS (4-P)

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

PRESSURE SWITCH
AC4410

(7)
RELAY BOX COVER

RELAYS (a) Temporarily remove the relay box cover.

FRONT
AC4411

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

Mg/C RELAY (4-P,BLACK)

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
AC4412

(c) Reinstall the relay box cover.

RELAY BOX COVER

FRONT
AC4413

(8)
ENGINE HOOD

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.

CAUTION PLATE
AC4414

(9)
CLIPS

REINSTALLATION OF ORIGINAL PARTS (a) Under cover (RH)

CLIPS UNDER COVER (RH) CLIP

SCREWS
AC4381

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VEHICLE WITH SURGE TANK ONLY

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

SURGE TANK

AC4380

VEHICLE WITH SURGE TANK ONLY

(c) Screw

SCREW

FRONT BUMPER

AC4422

(d) Front fender liner (LH)

CLIPS

FRONT FENDER LINER (LH)

SCREWS

AC4378

(e) Radiator upper supports (RH,LH)

RADIATOR UPPER SUPPORTS (RH,LH)

AC4377

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(f) Front grille (g) Plate

FRONT GRILLE

PLATE
AC4376

(h) Air duct

AIR DUCT

FRONT
AC4374

AIR CLEANER BOX LOWER COVER

(i)

Air cleaner box lower cover

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

CAUTION FRONT VEHICLE HARNESS CLAMP

AC4416

(j)

Vehicle harness clamp

FRONT

AC4417

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(k) Filter

FILTER

FRONT
AC4418

VSV

(l)

Reinstall the VSV to the air cleaner box upper cover.

VSV HOOK AIR CLEANER BOX UPPER COVER

FRONT

AC4419

AIR CLEANER BOX UPPER COVER VEHICLE HARNESS

(m) Air cleaner box upper cover (n) Reconnect the vehicle harness to the air cleaner box upper cover. (o) Reconnect the air cleaner hose to the air cleaner box upper cover.

AIR CLEANER HOSE

AC4369

(p) Battery & battery tray

BATTERY

FRONT

BATTERY TRAY

AC4368

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RIB

1ZZ-FE E/G MODEL ONLY ENGINE COVER

1ZZ-FE E/G MODEL ONLY [(q)] (q) Engine cover Tightening Torque 7.0 Nm (71 kgfcm, 5.1 lbfft)

AC4415

- 21 00500089

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: 988963-475*)

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

For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AFTER 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.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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3. AMPLIFIER

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4. WIRING DIAGRAM

IG RELAY

COMPRESSOR Mg/C RELAY

IG SW

12V

HEATER MAIN RELAY

BLOWER MOTOR

BLOWER RESISTOR

LH BLOWER RESISTOR

TO TAIL RELAY TO GND

RH

BLOWER SW
AC4498

A/C SW

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PRESSURE SW

EFI ECU

FAN RELAY No.1

RADIATOR FAN MOTOR

FAN RELAY No.2

RESISTOR

EVA.THERMISTOR A/C AMP

246108-711
AC4499

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- 26 00500089

- 27 00500089

- 28 00500089

DENSO CORPORATION SERVICE DEPARTMENT

Kariya, Aichi, Japan

Frist Issue :SEPTEMBER 2001 Publication No. : AAAMC-29

Printed in Japan

AAAMC-29 988963-5100