Airco Passenger Kit RHD Aaamc94

ENGLISH

AIR CONDITIONING

INS

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EUROPE,GENERAL,AUSTRALIA

© 2002 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.

IMPORTANT NOTICE

INTRODUCTION

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 manufactuer).

DEFINITION OF TERMS

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

LEFT, RIGHT

!

!

FOREWORDThis manual has been published to explain how to install the air conditioning for TOYOTA YARIS/ECHO.

When installing the air conditioning, installation should be performed as described in this manual.

[APPLICATION VEHICLE]

STEERING POSITION

RHD

VEHICLE NAME

YARIS/ECHO

PRODUCTION PERIOD

1999.8~

AAAMC-94

CAUTION!

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

2. Refer to the separate manual "INSTALLATION MANUAL (INSIDE ENGINE COMPARTMENT)" for details oninstallation for the engine compartment side.

AAAMC-94– 1 –

AU1130

q Set the wire harness to which you are connecting on the insulator assembly.

Put the press connection vehicle harness firmly into the guidegroove.

w Fold the connector about the A section.

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.

CONNECTING WIRE HARNESSGUIDEGROOVE

TERMINAL

INSULATOR ASSEMBLY A SECTION

CONNECTING WIREHARNESS

e Temporarily fasten. r 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.

The temporary fastening lock is only on one side,

so fasten with the top and bottom of the permanent

fastening lock lined up.

When holding the connector with the pliers, check

the left and right lock click sound.

TEMPORARILY FASTENINGLOCK SECTION

PIVOT

PIVOT

B A

q Even if the A section is broken, this does not affect

performance, so use the connector as is.

w 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 WIREHARNESS

PRODUCT SIDEWIRE HARNESS

INSULATE VINYLTAPE OR THE LIKE.

BRANCH CONNECTOR

CAUTIONS FOR BRANCH CONNECTOR CONNECTIONS

Do not reuse a used branch connector.

Instruction of branch connector connection

PERMANENT FASTENING LOCK SECTIONS

MUST NOT BEDISCONNECTED.

CAUTION

CAUTION

CAUTIONCAUTION

CAUTION

AAAMC-94– 2 –

According to the vehicle production period, theECU vehicle connector shape differs as in the leftdrawing.The following procedure is divided into the“TYPE [A] VEHICLE” and “TYPE B VEHICLE”.

NOTE

CAUTION!

In case of “TYPE [A] VEHICLE”, refer to “1.INSTALLATION INSIDE PASSENGERCOMPARTMENT (1)” and perform the operation.In case of “TYPE [B] VEHICLE”, refer to “2.INSTALLATION INSIDE PASSENGERCOMPARTMENT (2)” and perform the operation.

Concerning ECU confirmation, confirm after (1)REMOVAL OF PARTS (a) to (p) has beenperformed.

NOTE

ECU

AC9257

VEHICLE CONNECTORVEHICLE CONNECTOR

2 ROW 4 ROW

TYPE [A] VEHICLE TYPE [B] VEHICLE

INSIDE PASSENGER COMPARTMENT

AAAMC-94– 3 –

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(RH)

COWL SIDEPANEL

CAUTION

COWL SIDE PANEL (RH)

AU0647

GLOVE BOX

BOSSBOSS

PUSH

PUSH

PULL UP

q

ew

OU0026

(1) REMOVAL OF PARTS

(a) Scuff plate (RH)(b) Cowl side panel (RH)

(c) Scuff plate (LH)(d) Cowl side panel (LH)

CAUTION!

A hook is interconnected to the cowl side panel,therefore, be careful when removing to preventdamage.

CAUTION!


(e) Glove box

Remove the glove compartment in the followingorder.q Press in the sides of the glove compartment.w Bypass the bosses.e Lift.

NOTE

1. Be sure to use the correct oil, refrigerant and charging/recovery equipment.2. Before starting installation, read all “PRECAUTIONS FOR SAFETY INSTALLATION” thoroughly and follow the

instructions described in it.3. Before starting installation, remove the (–) terminal of the battery and ensure seat/floor covers are in position.4. Take care not to scratch any parts of the vehicle.5. Sort removed bolts and tapping screws into groups so that they can be reassembled correctly.

CAUTION!

1. INSTALLATION INSIDE PASSENGER COMPARTMENT (1)

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(LH)

COWL SIDEPANEL AU0646

CAUTION

COWL SIDE PANEL (LH)

AAAMC-94– 4 –

CENTER CLUSTERPANEL

AU0679

ORIGINALCOVER(DISCARD)

CONTROLKNOB(REUSE)

CENTER CLUSTERPANEL

AU0650

CONTROLKNOBS(REUSE)

METER PANEL

HOOKS

HOOKS

AU0648

CLOTH TAPE

METER

AU0649

(f) Meter panel

(g) Meter

Disconnect the connector of the meter from thevehicle harness.

NOTE

CAUTIONAttach the cloth tape as shown, before removingthe meter panel.

!

VEHICLE WITHOUT HEATER MODEL ONLY [(i)](i) Control knob (reuse) and original cover

(discard)

VEHICLE WITH HEATER MODEL ONLY [(h)](h) Control knobs (reuse)

Disconnect the connector of the meter panel fromthe vehicle harness.

NOTE

AAAMC-94– 5 –

HOOKS

HOOKS

CENTER CLUSTERPANEL

CENTER CLUSTERLOWER PANEL

OU0038

CLOTHTAPE CAUTION

Attach the cloth tape as shown, before removingthe center cluster panel.

!

Disconnect the connector of the center clusterpanel from the vehicle harness.

NOTE

(j) Center cluster panel(k) Center cluster lower panel

CENTER CLUSTER PANELAU0651

VEHICLE HARNESS(3-P)

A vehicle harness from the A/C switch is connectedto the center cluster panel.Be sure to remove this harness before proceedingwith the work.

NOTE

VIEW : A

VIEW : A

HOOKS

HOOKS

ASHTRAY OR COINHOLDER

AU1529

BOX OR AUDIO(l) Ashtray or coin holder(m) Box or audio

Disconnect the connector of the audio from thevehicle harness.

NOTE


NOTE

CAUTION!

Connect the vehicle harness (3-P) to the originallocation in recovery.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(CAUTION)]

VEHICLE WITH HEATER MODEL ONLY

VEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY

AC9921

x VEHICLE HARNESS (3-P)

z CENTER CLUSTER PANEL

CAUTIONc

AAAMC-94– 6 –

ECUOU0015

OU0007

ECU HARNESS COVER

(p) ECU

(o) ECU harness cover

BOLTS(FOR INSTRUMENT PANEL)

AU0652

(n) Three bolts (for instrument panel)

NOTE

Disconnect the vehicle harness from ECU.

HEATER CONTROL ASSY

VEHICLE HARNESS(3-P) OU0030


Pull the vehicle harness for the A/C switch to thefront.

NOTE


AAAMC-94– 7 –

OU0040

VEHICLE HARNESS

COOLING UNIT CASE

VEHICLE HARNESS CLAMP

(r) Vehicle harness clamp

CAUTION!

Vehicle harness clamp must be removed withneedle-nose pliers to prevent breakage of theclamp.

Rotate the clamp counter-clockwise once andremove the vehicle harness clamp.

NOTE

VEHICLE HARNESS

ECU

AU0654

CAUTION!

Be careful when removing ECU to prevent damage.

VEHICLE HARNESS

AC9070

COOLING UNIT CASE

VEICLE HARNESS CLAMPS

FRONT

COOLING UNIT CASE


VEHICLE BRACKET

VIEW:A

VIEW:A

(r) Vehicle bracket(s) Two vehicle harness clamps

AAAMC-94– 8 –

BOX

VEHICLE HARNESSCLAMPS

VEHICLEHARNESS

AU1404

BOX

w

q

VEHICLE HARNESS q

FRONT

FRONT

FRONT

BOX

BOX

VEHICLE HARNESS w

VEHICLE HARNESS e

OU0046

(s) Box(t) Vehicle harness clamps

CAUTION!

1. The clamps for the vehicle harness must beremoved with needle-nose pliers to preventbreakage of the clamps.

2. Moving the storage tray simplifies removal ofthe vehicle harness clamps. (Refer to thefollowing illustrations)

3. Be careful when moving the small parts box toprevent damage to other vehicle parts.

Press-in the box one time to the vehicle front innumerical order, insert the needle-nose pliers fromthe bottom, and remove the vehicle harness q bytilting.

NOTE 1

Disconnect the connection of the vehicle harness,then temporarily remove the vehicle harness fromthe box.

NOTE

Remove vehicle harness w in the same position as NOTE 1 .

NOTE 2

Tilt the box to the front, insert the needle-nosepliers from the side, and remove the vehicleharness e.

NOTE 3

AAAMC-94– 9 –

AU1406

DRAIN HOSE

FLOOR CARPET

COOLING UNIT CASE

SILENCER MAT

OU0048

COOLING UNIT CASE

PULL

FILTER CASEKONB

KONB

COOLING UNIT CASE

VEHICLE HARNESS (6-P)(FOR BLOWER RESISTOR)

OU0029

COOLING UNIT CASE

FRS/REC CONTROL BOX

LOCK CLAMP(DISCARD)

OU0028

(x) Vehicle harness for blower resistor connection(Remove the connection for the cooling unitcase.)

(y) Filter case

Hold the left and right knobs at both ends of thefilter case at the same time, and pull out the knobto the front.

NOTE

Push upward with a (-) screwdriver to remove thelock clamp.

NOTE

(w) Remove and discard the lock clamp fromconnection part of the cooling unit case andFRS/REC control box.

(u) Temporarily pull the floor carpet down, thentemporarily remove the silencer mat.

(v) Drain hose (pull up the vehicle hole.)

The floor carpet and silencer mat must be removedas far as necessary. (To simplify removal of thecooling unit case)

NOTE

AAAMC-94– 10 –

CLOTH TAPE

HOOK

HOOK

AU2837

TAPPING SCREW(REUSE)

TAPPINGSCREW(REUSE)

CAUTION 2

CAUTION 1

NUT(DISCARD)

NUT(REUSE)

FILTER CASEFITTING PLACE

COOLING UNIT CASE

FROM BOX OPENING AREA

COOLING UNIT CASE

TAPPING SCREW (REUSE)

NUT(DISCARD)

COOLINGUNIT CASE

FROM METER OPENING AREA

CAUTION 2

(z) Cooling unit case

CAUTION!

1. Attach the cloth tape as shown, beforeremoving the cooling unit case.

2. Follow the instructions specified inbecause the pawl of cooling unit case and thefilter case installation portion are easily damaged.

NOTE

AAAMC-94– 11 –

AU2929COOLING UNITCASE

CAUTION 1

CAUTION 2

CAUTION 1

COOLING UNIT CASE

HOOK

w

w

w

e

FILTER CASEINSTALLATION SECTION

COOLING UNIT CASE

r

rAU2702

AU2364COOLING UNIT CASE

HOOKHOOK

CAUTION

q q

1. Move both the filter case installation sectionand cooling unit case slowly so that stress isnot applied only to the pawl.

2. Never hold the middle part of filter caseinstallation section with hands because it iseasily damaged.

CAUTION!

Remove the cooling unit case in the followingprocedures.q Remove the catch of pawl.

NOTE

CAUTION!

Unhook the catch of pawl and keep as it is.(Do not pull the pawl forcibly because it is easilydamaged.)

w Lift the filter case installation section upward sothat the pawls do not interfere with the caseand place the cooling unit case downward.

e Pull the whole cooling unit case toward youthrough the pawls.

NOTE

r Pull out the cooling unit from the stud bolts.

NOTE

AAAMC-94– 12 –

wCOOLING UNITCASE

t

PULL

COOLING UNIT CASE

PULL

INSTRUMENTPANEL

y

u

AU2838

COOLING UNIT CASE

INSTRUMENTPANEL

A/C AMPLIFIER

FRONT

AU0686

TAPPING SCREWS( 4 10, SILVER)

VIEWED FROM METER OPENING AREA

FRS/RECCONTROLBOX

y Take out the right side of the cooling unit casewhile pulling the instrument panel towards you.

NOTE

u Then, pull out the left side of the cooling unitcase while pulling the instrument panel towardsyou, and remove the unit.

NOTE

(2) AMPLIFIER

(a) Install the A/C amplifier to the FRS/REC controlbox using a tapping screw.

t Lower the cooling unit case midway and hold it.(Do not lower all the way to the bottom.)

NOTE

AAAMC-94– 13 –

AU2072

COOLING UNIT LOWER CASE

PLATE (DISCARD)

TAPPING SCREW (DISCARD)

AU1542


COOLING UNIT UPPER CASE

(b) Temporarily remove the cooling unit upper casefrom the cooling unit lower case.

(c) Remove and discard the plate from the coolingunit lower case.

AU0658

COOLING UNIT CASE ORIGINAL PACKING

(DISCARD)

(3) COOLING UNIT

(a) Remove and discard the original packing fromthe cooling unit case.

AAAMC-94– 14 –

THERMISTOR HARNESS

THERMISTOR HOLDER

THERMISTOR HOLDER

TUBEAU0681 PULL UP

OU0010

COOLING UNIT LOWER CASE INSULATOR

(f) Install the insulator to the cooling unit lowercase.

(e) Assemble the thermistor harness to thethermistor holder.

After the above is assembled, pull the tubing on thethermistor harness up to the thermistor holder.

NOTE


CUT OUT

CUT OUT


OU0031

(d) Cut the shaded portion shown in the illustrationfor the cooling unit upper case and cooling unitlower case.

AAAMC-94– 15 –

THERMISTORASSYCOOLING UNIT

CASE AU1533

VIEW : A

AU1542



CLAMP CLAMP

THERMISTORHARNESS

AU1534

COOLING UNITCASE

VIEW : A (j) Secure the thermistor harness to the coolingunit case.

(i) Install the thermistor assy to the cooling unitcase.

OU0011


EVAPORATOR

(h) Reinstall the cooling unit upper case to thecooling unit lower case.

(g) Install the evaporator to the cooling unit lowercase.

AAAMC-94– 16 –

AU0659

PACKING(INCLUDED IN KIT)

COOLING UNIT CASE

(k) Attach the packing on the cooling unit case.

CAUTION!

At this point, discontinue the work inside passenger compartment and move to the engine compartment.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]

AAAMC-94– 17 –

COOLING UNIT CASE

REINFORCEMENT

COOLING UNIT CASE

OU0017

e

q

w

Use the following procedure to install the coolingunit case.q Insert the left side of the cooling unit case in the

instrument panel.

NOTE

w Slide the cooling unit case edge towards thereinforcement while pulling the instrument paneltowards you.

e Insert the right side of the cooling unit case inthe instrument panel.

NOTE

(4) REINSTALLATION OF THE COOLING UNIT

A/C HARNESS 2

FRONTAU0687

A/C HARNESS 2

FROM INSIDE ENGINECOMPARTMENT

Make sure the A/C harness w is pulled out fromthe engine compartment.

NOTE

Pull out the A/C harness w toward you.

NOTE

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(NOTE)]


AAAMC-94– 18 –

BOSS

INSERT

COOLING UNIT CASE

COOLING UNIT CASE

FRS/REC CONTROL BOX

HEATER UNIT

AU0670

t

r

r With the cooling unit case pulled out to thefront, lift upwards. (Lift so that the head portionof the cooling unit case is higher than the gapfor the FRS/REC control box and heater unit.)

t Push in towards the vehicle front, then the bossfor the cooling unit case must be inside the holefor the FRS/REC control box.Align the hole in the cooling unit case with thestud bolt and insert.

NOTE

AAAMC-94– 19 –


CAUTION 1

CAUTION 2

CAUTION 1

COOLING UNIT CASE

HOOK

u

u

u


i


HOOKHOOK

CAUTION

o o

COOLING UNIT CASE

y

yAU2839



CAUTION!

o Engage the pawl catch and fix it.

NOTE

CAUTION!

Engage the pawl catch only. (Do not pull the pawlforcibly because it is easily damaged.)

u Lift the filter case installation section upward sothat the pawls do not interfere with the caseand place the cooling unit case downward.

i Push the whole cooling unit case behindthrough the pawls.

NOTE

y Put on the cooling unit case so that the studbolts are inserted.

NOTE

AAAMC-94– 20 –

CLOTH TAPEAU2842


TAPPINGSCREW(REUSE)

NUT(INCLUDED IN KIT)

NUT(REUSE)

COOLING UNIT CASE


COOLING UNIT CASE



COOLINGUNIT CASE


(a) Reinstall the cooling unit case using three nutsand three tapping screws.

CAUTION!

Be careful not to pinch the vehicle harness whenreinstalling the cooling unit case.

AAAMC-94– 21 –

AU1535

COOLING UNIT CASE

FILTER CASE

(b) Vehicle harness clamp

(6) REINSTALLATION OF ORIGINAL PARTS qqqqq

(a) Filter case

OU0041

VEHICLE HARNESS

COOLINGUNIT CASE


DRAIN HOSE

GROMMET

BULKHEAD

AU0661

CAUTION!

Do not bend the drain hose.Make sure the prepared grommet is installedcorrectly.

FRONTAU0660

VEHICLE GROMMET

DRAIN HOSE

VIEWED FROM ENGINE COMPARTMENT

CAUTION!

Take care not to bend the drain hose and makesure that the drain hose comes out from thebulkhead.

(5) DRAIN HOSE

(a) Pass the drain hose through the vehiclegrommet.

AAAMC-94– 22 –

BOX

AU1408

BOX

BOX

INSTRUMENT PANEL

LIFT UP

BOX

BOX INSTALLATIONPORTION

w

e

r

OU0033

e Rotate so that the box is facing the front innumerical order.

r pull towards the box installation portion.

NOTE

Install the box in the following order.q Face the vehicle harness installation portion for

the box towards the front, and set as shown inthe figure on the left.

NOTE

w Lift upwards while pulling the box to the front.

NOTE

(c) Box

AAAMC-94– 23 –

BOXVEHICLE HARNESS

OU0021

t

t Reinstall the vehicle harness to the box andreconnect the connection of the vehicleharness.

NOTE


AU0652

(f) Three bolts (for instrument panel)

(d) Reinstall the vehicle bracket to the cooling unitcase.

(e) Reinstall two vehicle harness clamps to thecooling unit case.

VEHICLE HARNESS

AC9071

COOLING UNIT CASE


FRONT

COOLING UNIT CASE


VEHICLE BRACKET

VIEW:A

VIEW:A

AAAMC-94– 24 –

ECUOU0015

(i) ECU

CAUTION!

Must be inserted in the ECU hole for the coolingunit case.

VIEW : A

VIEW : A

HOOKS

HOOKS


AU1529

BOX OR AUDIO(g) Box or audio

(h) Ashtray or coin holder

Reconnect the connector of the audio to thevehicle harness.

NOTE

AAAMC-94– 25 –

AC9279

TYPE [A] ECU

BLACK

BLACK

A/C HARNESS (INSIDE PASSENGER COMPARTMENT)

TYPE [B] ECU

BLUE

BLUE


PART NUMBER

PART NUMBER

(7) WIRING qqqqq

According to the vehicle production period, the ECUvehicle connector shape differs as in the leftdrawing.

NOTE

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(7)]


NOTE

TYPE [A] ECU

Part number

TYPE [B] ECU

88605-52130 (246460-7590)

88605-52220 (246470-1330)

DENSO part number inside ( ).

ECU

AC9257


2 ROW 4 ROW



AAAMC-94– 26 –

PLASTICTIES

TO A/C SWITCH AU1151

THERMISTORCONNECTOR (2-P)

A/C HARNESS q

A/C AMPLIFIER (14-P)


A/C HARNESS q (3-P)

FRONT

AU1152

HEATERCONTROLASSY

(e) Pass the A/C harness q through the hole of theheater control assy.

(b) Connect the A/C harness q to the thermistorconnector.

(c) Connect the A/C harness q to the A/C amplifier.(d) Secure the A/C harness q to the vehicle

harness using two plastic ties.

INSTRUMENT PANELA/C HARNESS q

TO A/C AMPLIFIER

AU2908

TO A/C HARNESS(INSIDE ENGINE COMPARTMENT)

(a) Insert the A/C harness q to inside of theinstrument panel as shown in the left figure.

TO VEHICLEEARTH TERMINAL


TO A/CSWITCH

TO A/C AMPLIFIER

TO THERMISTORCONNECTOR


FUSE

TO VEHICLE CONNECTOR (22-P)(TO EFI ECU CONNECTOR)

TO VEHICLECONNECTOR(26-P)

TO VEHICLECONNECTOR (6-P)

TO VEHICLE CONNECTOR (6-P)(FOR BLOWER RESISTOR AND BLOWER MOTOR)

AU2905

The figure shows the connections of A/C harnessconnector and terminal in the compartment.

NOTE

AAAMC-94– 27 –

CONNECTOR(26-P)

AU1156

A/C HARNESS 1

LEAD WIRE OF THEVEHICLE HARNESS(WHITE/BLUE)

30mm

BRANCH CONNECTOR

BRANCH CONNECTOR

PLASTIC TIES

COOLING UNIT CASE

AU1155

A/C HARNESS q

(h) Secure the A/C harness q to the cooling unitcase using two plastic ties.

(i) Connect the A/C harness q to the lead wire(white/blue) of the vehicle harness using thebranch connector.

See the P.1 for the connection of the branchconnector.

NOTE

CAUTION!

Do not mistake the lead wire color.

AU1154

1A/C HARNESS(6-P)

VEHICLE CONNECTOR

VEHICLE HARNESS

PLASTIC TIE

PLASTIC TIES

AU1153

A/C HARNESS q

PLASTIC TIECOOLINGUNIT CASE

(f) Secure the A/C harness q to the vehicleharness using three plastic ties.

(g) Connect the A/C harness q to the vehicleharness and vehicle connector, then secure thevehicle harness using a plastic tie.

AAAMC-94– 28 –

VIEW:A TERMINALSTOPPER

VEHICLE CONNECTOR(22-P)

PUSH

AU1159

PUSH

VIEW:A

PRECISION (-) SCREWDRIVER

(o) Restore the terminal stopper of the connector(22-P).

Check to see that the terminal is locked.

NOTE

VEHICLECONNECTOR (22-P)

1-P TERMINAL OFTHE A/C HARNESS 1(BLACK/WHITE)

1-P TERMINAL OFTHE A/C HARNESS 1(BLACK)

AU1158BLACK

BLACK/WHITE

(n) Insert the terminal of the A/C harness q to thevehicle connector (22-P).

CAUTION!

Check the wire colors before inserting the terminalof the A/C harness q to the vehicle connector.

BLACK/WHITE

WHITE/RED AU2366

1-P TERMINAL OFTHE VEHICLE HARNESS(BLACK/WHITE)

1-P TERMINAL OFTHE VEHICLEHARNESS(WHITE/RED)

TERMINAL

VINYL TAPE

LEAD WIRE

CUT OFF

VEHICLE CONNECTOR (22-P)(TO EFI ECU CONNECTOR)

(k) Pull out the terminal of two lead wires(black/white and white/red) of the vehicle harnessfrom the vehicle connector (22-P).

(l) Cut off the terminal from two lead wires of thevehicle harness.

(m) Attach the vinyl tape around two lead wires of thevehicle harness.

CAUTION!

Do not mistake the lead wire colors.

VEHICLE WITH THE TERMINAL IS INSERTED INTHE VEHICLE CONNECTOR (22-P) ONLY[(k)~(m)]

VIEW:A TERMINALSTOPPER

GAP

VEHICLE CONNECTOR(22-P)

PRECISION(-) SCREWDRIVER

VIEW:A

AU1157

(j) Lift the terminal stopper of the connector (22-P)with the precision (-) screwdriver.

Insert the precision (-) screwdriver to the gap forthe terminal stopper, and lift the terminal stopper.

NOTE

AAAMC-94– 29 –

A/C HARNESS q

AU1160

VEHICLE EARTH TERMINAL

PLASTIC TIE

COOLING UNIT CASE

AU1161

A/C HARNESS q

ECU VEHICLE HARNESS

AU0667

(q) Install the A/C harness q together with vehicleearth terminal.

(p) Reconnect the vehicle harness to ECU.

(r) Secure the excess A/C harness q to the vehicleharness, using a plastic tie.

A/C HARNESS q

PLASTIC TIE

A/C HARNESS q

A/C HARNESS w

AU1162


(s) Connect the A/C harness q to the A/C harnessw.

Perform this work after laying out A/C harness w.

NOTE

(t) Secure the A/C harness q to the vehicleharness using a plastic tie.

CAUTION!

Make sure that the A/C harness w pull out fromthe engine compartment.

AAAMC-94– 30 –

SWITCH MODULE

CENTER CLUSTER PANEL AU0663

HOOKS

CENTER CLUSTERPANEL

AU0662

CONTROL KNOB(REUSE)

(b) Temporarily remove the switch module from thecenter cluster panel.

CAUTION!

Do not damage the hooks when removing theswitch module.

(9) A/C SWITCH

VEHICLE WITH HEATER MODEL ONLY[(a)~(h)]

(a) Temporarily remove the control knob from thecenter cluster panel.

A/C AMPLIFIER

SHORT CIRCUIT CONNECTOR

VEHICLE HARNESS

VEHICLE HARNESS(TO A/C AMPLIFIER)

AU2079

AU1539




VEHICLE HARNESS

(b) Connect the vehicle harness to the thermistorconnector.

(c) Connect the vehicle harness to the A/Camplifier.

CAUTION!

Connect when laying out the A/C harness w forvehicles made for Europe.

VEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(8)]

(8) WIRING wwwww

(a) Remove and discard the short circuit connectorfrom the vehicle harness.

AAAMC-94– 31 –

CENTER CLUSTERPANEL

AU0662

CONTROL KNOB(REUSE)

SWITCH MODULE

CENTER CLUSTER PANEL AU0663

HOOKS

(e) Reinstall the switch module to the center clusterpanel.

CAUTION!

The hooks must be inserted when installing theswitch module.

(f) Reinstall the control knob (reuse) to the centercluster panel.

A/C SWITCHSWITCH MODULE

AU0664

A/C

ORIGINALCOVER (DISCARD)

(c) Remove and discard the original cover from theswitch module.

(d) Assemble the A/C switch to the switch module.

CAUTION!

Do not connect the vehicle harness (3-P) to theA/C switch.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(g)]

(g) Connect the A/C harness q to the A/C switch.

A/C HARNESS 1 (3-P)

AD1171

A/C SWITCH

CENTER CLUSTER PANEL

VEHICLE HARNESS (3-P)

AAAMC-94– 32 –

FRONT

HEATER CONTROL ASSY

CONTROL DIAL ASSY

NOTE

AU0675

VIEW : A

q

HEATERCONTROL ASSY

CAUTION

VIEW : A

BALL

CONTROL DIALASSY

w

180°

(k) Insert the control dial assy to the heater controlassy.

Assemble the control dial assy by inserting the ballinto the heater control assy from directly above.

NOTE

CAUTION!

Do not drop the ball.

(l) Rotate the control dial assy until the ball isdirectly underneath.

BALL

CONTROL DIAL

AU0674

SPRING

CONTROL DIAL

AU0673

(j) Install the ball to the control dial.

CAUTION!


VEHICLE WITHOUT HEATER MODEL ONLY[(i)~(p)]

(i) Install the spring to the control dial.



AU1522

A/C SWITCHVEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(h)]

(h) Connect the vehicle harness to the A/C switch.

AAAMC-94– 33 –


AU2083

HEATER CONTROL ASSY


AU2073

HEATER CONTROL ASSY

VIEWED FROM BACK SIDEOF HEATER CONTROL ASSY

HEATER CONTROL ASSY

TEMPERATURECONTROLRESISTOR HARNESS

VIEW : B

CAUTION

AU0677

TAPPINGSCREW( 3 8)

VIEW : B

(p) Connect the vehicle harness to the connector ofthe temperature control resistor.

(n) Route the temperature control resistor harnessas shown in the left figure.

CAUTION!

The pawl for the temperature control resistorharness must be installed on the heater controlassy.

(o) Pull out the vehicle harness which is affixed withtape through the opening.

HEATER CONTROL ASSY

CONTROL DIAL ASSY

w

q

AU0676

BALL

LOCK

CONTROL DIAL ASSY

FACE SIDE (m) Push in the control dial assy once.The operator will watch the pushed-in status,and rotate clockwise until the lock is engaged.

AAAMC-94– 34 –

VEHICLE WITHOUT HEATER MODEL ONLY [(t)](t) Reinstall the control knob (reuse), then install

the control knob (included in kit).

When installing the control knob (included in kit),set it to "MAX COOL".

NOTE

CENTER CLUSTERPANEL

AU0650

CONTROLKNOBS(REUSE)

VEHICLE WITH HEATER MODEL ONLY [(s)](s) Reinstall two control knobs to the center cluster

panel.

HOOKSCENTER CLUSTERPANEL


OU0039

HOOKS


REINFORCEMENT

(q) Reinstall the center cluster panel.(r) Reinstall the center cluster lower panel.

Insert the center cluster lower panel onto thereinforcement.

NOTE

CENTER CLUSTERPANEL

AD1172

CONTROLKNOBS(REUSE)

CONTROL KNOB(INCLUDED IN KIT)

CAUTION!

Note that assording to the vehicle type, the usecontrol knob differs.

AAAMC-94– 35 –

METER PANEL

HOOKS

HOOKS

AU0668

(d) Meter panel

Reconnect the connector of the meter panel to thevehicle harness.

NOTE

ECU VEHICLE HARNESS

AU0667

OU0007

ECU HARNESS COVER

(b) ECU harness cover

(10) REINSTALLATION OF ORIGINAL PARTS wwwww

VEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(a)]

(a) Reconnect the vehicle harness to ECU.

METER

AU0649

(c) Meter

Reconnect the connector of the meter to thevehicle harness.

NOTE

AAAMC-94– 36 –

GLOVE BOX

AU0669

(e) Glove box

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(LH)


CAUTION


(h) Cowl side panel (RH)(i) Scuff plate (RH)

CAUTION!

Make sure the clips are engaged with the cowl sidepanel and scuff plate.

(f) Cowl side panel (LH)(g) Scuff plate (LH)

CAUTION!


HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(RH)

COWL SIDEPANEL

CAUTION


AU0647

AAAMC-94– 37 –

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(RH)

COWL SIDEPANEL

CAUTION


AU0647

GLOVE BOX

BOSSBOSS

PUSH

PUSH

PULL UP

q

ew

OU0026

(1) REMOVAL OF PARTS

(a) Scuff plate (RH)(b) Cowl side panel (RH)

(c) Scuff plate (LH)(d) Cowl side panel (LH)

CAUTION!


CAUTION!


(e) Glove box

Remove the glove compartment in the followingorder.q Press in the sides of the glove compartment.w Bypass the bosses.e Lift.

NOTE

1. Be sure to use the correct oil, refrigerant and charging/recovery equipment.2. Before starting installation, read all “PRECAUTIONS FOR SAFETY INSTALLATION” thoroughly and follow the

instructions described in it.3. Before starting installation, remove the (–) terminal of the battery and ensure seat/floor covers are in position.4. Take care not to scratch any parts of the vehicle.5. Sort removed bolts and tapping screws into groups so that they can be reassembled correctly.

CAUTION!

2. INSTALLATION INSIDE PASSENGER COMPARTMENT (2)

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(LH)


CAUTION


AAAMC-94– 38 –

METER PANEL

HOOKS

HOOKS

AU0648

CLOTH TAPE

METER

AU0649

(f) Meter panel

(g) Meter

Disconnect the connector of the meter from thevehicle harness.

NOTE

CAUTIONAttach the cloth tape as shown, before removingthe meter panel.

!

VEHICLE WITHOUT HEATER MODEL ONLY [(i)](i) Control knob (reuse) and original cover

(discard)

VEHICLE WITH HEATER MODEL ONLY [(h)](h) Control knobs (reuse)

Disconnect the connector of the meter panel fromthe vehicle harness.

NOTE

AD1173

CENTER CLUSTERPANEL

CONTROLKNOBS(REUSE)

AD1180

CENTER CLUSTERPANEL

CONTROLKNOB (REUSE)

ORIGINAL COVER (DISCARD)

AAAMC-94– 39 –

CAUTIONAttach the cloth tape as shown, before removingthe center cluster panel.

!


NOTE

(j) Center cluster panel(k) Center cluster lower panel

CENTER CLUSTER PANELAU0651


A vehicle harness from the A/C switch is connectedto the center cluster panel.Be sure to remove this harness before proceedingwith the work.

NOTE

VIEW : A

VIEW : A

HOOKS

HOOKS


AU1529

BOX OR AUDIO(l) Ashtray or coin holder(m) Box or audio

Disconnect the connector of the audio from thevehicle harness.

NOTE


NOTE

CAUTION!

Connect the vehicle harness (3-P) to the originallocation in recovery.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(CAUTION)]



AC9921

x VEHICLE HARNESS (3-P)

z CENTER CLUSTER PANEL

CAUTIONc

AD1174

CENTER CLUSTERPANEL

CLOTHTAPE


HOOKS

HOOKS

AAAMC-94– 40 –

OU0007

ECU HARNESS COVER

(p) ECU

(o) ECU harness cover


AU0652

(n) Three bolts (for instrument panel)

NOTE

Disconnect the vehicle harness from ECU.

HEATER CONTROL ASSY

VEHICLE HARNESS(3-P) OU0030


Pull the vehicle harness for the A/C switch to thefront.

NOTE


ECU

AC9267

AAAMC-94– 41 –

OU0040

VEHICLE HARNESS

COOLING UNIT CASE


(r) Vehicle harness clamp

CAUTION!

Vehicle harness clamp must be removed withneedle-nose pliers to prevent breakage of theclamp.

Rotate the clamp counter-clockwise once andremove the vehicle harness clamp.

NOTE

VEHICLE HARNESS

ECU

AU0654

CAUTION!

Be careful when removing ECU to prevent damage.

VEHICLE HARNESS

AC9070

COOLING UNIT CASE


FRONT

COOLING UNIT CASE


VEHICLE BRACKET

VIEW:A

VIEW:A

(r) Vehicle bracket(s) Two vehicle harness clamps

AAAMC-94– 42 –

BOX

VEHICLE HARNESSCLAMPS

VEHICLEHARNESS

AU1404

BOX

w

q

VEHICLE HARNESS q

FRONT

FRONT

FRONT

BOX

BOX

VEHICLE HARNESS w

VEHICLE HARNESS e

OU0046

(s) Box(t) Vehicle harness clamps

CAUTION!

1. The clamps for the vehicle harness must beremoved with needle-nose pliers to preventbreakage of the clamps.

2. Moving the storage tray simplifies removal ofthe vehicle harness clamps. (Refer to thefollowing illustrations)

3. Be careful when moving the small parts box toprevent damage to other vehicle parts.

Press-in the box one time to the vehicle front innumerical order, insert the needle-nose pliers fromthe bottom, and remove the vehicle harness q bytilting.

NOTE 1

Disconnect the connection of the vehicle harness,then temporarily remove the vehicle harness fromthe box.

NOTE

Remove vehicle harness w in the same position as NOTE 1 .

NOTE 2

Tilt the box to the front, insert the needle-nosepliers from the side, and remove the vehicleharness e.

NOTE 3

AAAMC-94– 43 –

AU1406

DRAIN HOSE

FLOOR CARPET

COOLING UNIT CASE

SILENCER MAT

OU0048

COOLING UNIT CASE

PULL

FILTER CASEKONB

KONB

COOLING UNIT CASE

VEHICLE HARNESS (6-P)(FOR BLOWER RESISTOR)

OU0029

COOLING UNIT CASE

FRS/REC CONTROL BOX

LOCK CLAMP(DISCARD)

OU0028

(x) Vehicle harness for blower resistor connection(Remove the connection for the cooling unitcase.)

(y) Filter case

Hold the left and right knobs at both ends of thefilter case at the same time, and pull out the knobto the front.

NOTE

Push upward with a (-) screwdriver to remove thelock clamp.

NOTE

(w) Remove and discard the lock clamp fromconnection part of the cooling unit case andFRS/REC control box.

(u) Temporarily pull the floor carpet down, thentemporarily remove the silencer mat.

(v) Drain hose (pull up the vehicle hole.)

The floor carpet and silencer mat must be removedas far as necessary. (To simplify removal of thecooling unit case)

NOTE

AAAMC-94– 44 –

CLOTH TAPE

HOOK

HOOK

AU2837


TAPPINGSCREW(REUSE)

CAUTION 2

CAUTION 1

NUT(DISCARD)

NUT(REUSE)

FILTER CASEFITTING PLACE

COOLING UNIT CASE


COOLING UNIT CASE


NUT(DISCARD)

COOLINGUNIT CASE


CAUTION 2

(z) Cooling unit case

CAUTION!

1. Attach the cloth tape as shown, beforeremoving the cooling unit case.

2. Follow the instructions specified inbecause the pawl of cooling unit case and thefilter case installation portion are easily damaged.

NOTE

AAAMC-94– 45 –


CAUTION 1

CAUTION 2

CAUTION 1

COOLING UNIT CASE

HOOK

w

w

w

e


COOLING UNIT CASE

r

rAU2702


HOOKHOOK

CAUTION

q q



CAUTION!

Remove the cooling unit case in the followingprocedures.q Remove the catch of pawl.

NOTE

CAUTION!

Unhook the catch of pawl and keep as it is.(Do not pull the pawl forcibly because it is easilydamaged.)

w Lift the filter case installation section upward sothat the pawls do not interfere with the caseand place the cooling unit case downward.

e Pull the whole cooling unit case toward youthrough the pawls.

NOTE

r Pull out the cooling unit from the stud bolts.

NOTE

AAAMC-94– 46 –

wCOOLING UNITCASE

t

PULL

COOLING UNIT CASE

PULL

INSTRUMENTPANEL

y

u

AU2838

COOLING UNIT CASE

INSTRUMENTPANEL

A/C AMPLIFIER

FRONT

AU0686

TAPPING SCREWS( 4 10, SILVER)


FRS/RECCONTROLBOX

y Take out the right side of the cooling unit casewhile pulling the instrument panel towards you.

NOTE

u Then, pull out the left side of the cooling unitcase while pulling the instrument panel towardsyou, and remove the unit.

NOTE

(2) AMPLIFIER

(a) Install the A/C amplifier to the FRS/REC controlbox using a tapping screw.

t Lower the cooling unit case midway and hold it.(Do not lower all the way to the bottom.)

NOTE

AAAMC-94– 47 –

AU2072


PLATE (DISCARD)

TAPPING SCREW (DISCARD)

(b) Temporarily remove the cooling unit upper casefrom the cooling unit lower case.

(c) Remove and discard the plate from the coolingunit lower case.

AU0658

COOLING UNIT CASE ORIGINAL PACKING

(DISCARD)

(3) COOLING UNIT

(a) Remove and discard the original packing fromthe cooling unit case.



AD1181

AAAMC-94– 48 –

THERMISTOR HARNESS

THERMISTOR HOLDER

THERMISTOR HOLDER

TUBEAU0681 PULL UP

OU0010

COOLING UNIT LOWER CASE INSULATOR

(f) Install the insulator to the cooling unit lowercase.

(e) Assemble the thermistor harness to thethermistor holder.

After the above is assembled, pull the tubing on thethermistor harness up to the thermistor holder.

NOTE


CUT OUT

CUT OUT


OU0031

(d) Cut the shaded portion shown in the illustrationfor the cooling unit upper case and cooling unitlower case.

AAAMC-94– 49 –

THERMISTORASSYCOOLING UNIT

CASE AU1533

VIEW : A

CLAMP CLAMP

THERMISTORHARNESS

AU1534

COOLING UNITCASE

VIEW : A (j) Secure the thermistor harness to the coolingunit case.

(i) Install the thermistor assy to the cooling unitcase.

OU0011


EVAPORATOR

(h) Reinstall the cooling unit upper case to thecooling unit lower case.

(g) Install the evaporator to the cooling unit lowercase.



AD1181

AAAMC-94– 50 –

AU0659

PACKING(INCLUDED IN KIT)

COOLING UNIT CASE

(k) Attach the packing on the cooling unit case.

CAUTION!

At this point, discontinue the work inside passenger compartment and move to the engine compartment.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]

AAAMC-94– 51 –

COOLING UNIT CASE

REINFORCEMENT

COOLING UNIT CASE

OU0017

e

q

w

Use the following procedure to install the coolingunit case.q Insert the left side of the cooling unit case in the

instrument panel.

NOTE

w Slide the cooling unit case edge towards thereinforcement while pulling the instrument paneltowards you.

e Insert the right side of the cooling unit case inthe instrument panel.

NOTE

(4) REINSTALLATION OF THE COOLING UNIT

A/C HARNESS 2

FRONTAU0687

A/C HARNESS 2


Make sure the A/C harness w is pulled out fromthe engine compartment.

NOTE

Pull out the A/C harness w toward you.

NOTE



AAAMC-94– 52 –

BOSS

INSERT

COOLING UNIT CASE

COOLING UNIT CASE

FRS/REC CONTROL BOX

HEATER UNIT

AU0670

t

r

r With the cooling unit case pulled out to thefront, lift upwards. (Lift so that the head portionof the cooling unit case is higher than the gapfor the FRS/REC control box and heater unit.)

t Push in towards the vehicle front, then the bossfor the cooling unit case must be inside the holefor the FRS/REC control box.Align the hole in the cooling unit case with thestud bolt and insert.

NOTE

AAAMC-94– 53 –


CAUTION 1

CAUTION 2

CAUTION 1

COOLING UNIT CASE

HOOK

u

u

u


i


HOOKHOOK

CAUTION

o o

COOLING UNIT CASE

y

yAU2839



CAUTION!

o Engage the pawl catch and fix it.

NOTE

CAUTION!

Engage the pawl catch only. (Do not pull the pawlforcibly because it is easily damaged.)

u Lift the filter case installation section upward sothat the pawls do not interfere with the caseand place the cooling unit case downward.

i Push the whole cooling unit case behindthrough the pawls.

NOTE

y Put on the cooling unit case so that the studbolts are inserted.

NOTE

AAAMC-94– 54 –

CLOTH TAPEAU2842


TAPPINGSCREW(REUSE)


NUT(REUSE)

COOLING UNIT CASE


COOLING UNIT CASE



COOLINGUNIT CASE


(a) Reinstall the cooling unit case using three nutsand three tapping screws.

CAUTION!

Be careful not to pinch the vehicle harness whenreinstalling the cooling unit case.

AAAMC-94– 55 –

AU1535

COOLING UNIT CASE

FILTER CASE

(b) Vehicle harness clamp

(6) REINSTALLATION OF ORIGINAL PARTS qqqqq

(a) Filter case

OU0041

VEHICLE HARNESS

COOLINGUNIT CASE


DRAIN HOSE

GROMMET

BULKHEAD

AU0661

CAUTION!

Do not bend the drain hose.Make sure the prepared grommet is installedcorrectly.

FRONTAU0660

VEHICLE GROMMET

DRAIN HOSE

VIEWED FROM ENGINE COMPARTMENT

CAUTION!

Take care not to bend the drain hose and makesure that the drain hose comes out from thebulkhead.

(5) DRAIN HOSE

(a) Pass the drain hose through the vehiclegrommet.

AAAMC-94– 56 –

BOX

AU1408

BOX

BOX

INSTRUMENT PANEL

LIFT UP

BOX

BOX INSTALLATIONPORTION

w

e

r

OU0033

e Rotate so that the box is facing the front innumerical order.

r pull towards the box installation portion.

NOTE

Install the box in the following order.q Face the vehicle harness installation portion for

the box towards the front, and set as shown inthe figure on the left.

NOTE

w Lift upwards while pulling the box to the front.

NOTE

(c) Box

AAAMC-94– 57 –

BOXVEHICLE HARNESS

OU0021

t

t Reinstall the vehicle harness to the box andreconnect the connection of the vehicleharness.

NOTE


AU0652

(f) Three bolts (for instrument panel)

(d) Reinstall the vehicle bracket to the cooling unitcase.

(e) Reinstall two vehicle harness clamps to thecooling unit case.

VEHICLE HARNESS

AC9071

COOLING UNIT CASE


FRONT

COOLING UNIT CASE


VEHICLE BRACKET

VIEW:A

VIEW:A

AAAMC-94– 58 –

ECUOU0015

(i) ECU

CAUTION!

Must be inserted in the ECU hole for the coolingunit case.

VIEW : A

VIEW : A

HOOKS

HOOKS


AU1529

BOX OR AUDIO(g) Box or audio

(h) Ashtray or coin holder

Reconnect the connector of the audio to thevehicle harness.

NOTE

AAAMC-94– 59 –

AC9279

TYPE [A] ECU

BLACK

BLACK


TYPE [B] ECU

BLUE

BLUE


PART NUMBER

PART NUMBER

(7) WIRING qqqqq


NOTE

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(7)]


NOTE

TYPE [A] ECU

Part number

TYPE [B] ECU

88605-52130 (246460-7590)

88605-52220 (246470-1330)

DENSO part number inside ( ).

ECU

AC9257


2 ROW 4 ROW



AAAMC-94– 60 –

PLASTICTIES

TO A/C SWITCH AU1151


A/C HARNESS q



A/C HARNESS q (3-P)

FRONT

AU1152

HEATERCONTROLASSY

(e) Pass the A/C harness q through the hole of theheater control assy.

(b) Connect the A/C harness q to the thermistorconnector.

(c) Connect the A/C harness q to the A/C amplifier.(d) Secure the A/C harness q to the vehicle

harness using two plastic ties.

INSTRUMENT PANELA/C HARNESS q

TO A/C AMPLIFIER

AU2908


(a) Insert the A/C harness q to inside of theinstrument panel as shown in the left figure.

TO VEHICLEEARTH TERMINAL


TO A/CSWITCH

TO A/C AMPLIFIER

TO THERMISTORCONNECTOR


FUSE

TO VEHICLE CONNECTOR (22-P)(TO EFI ECU CONNECTOR)

TO VEHICLECONNECTOR(26-P)

TO VEHICLECONNECTOR (6-P)

TO VEHICLE CONNECTOR (6-P)(FOR BLOWER RESISTOR AND BLOWER MOTOR)

AU2905

The figure shows the connections of A/C harnessconnector and terminal in the compartment.

NOTE

AAAMC-94– 61 –

PLASTIC TIES

COOLING UNIT CASE

AU1155

A/C HARNESS q

(h) Secure the A/C harness q to the cooling unitcase using two plastic ties.

AU1154

1A/C HARNESS(6-P)

VEHICLE CONNECTOR

VEHICLE HARNESS

PLASTIC TIE

PLASTIC TIES

AU1153

A/C HARNESS q

PLASTIC TIECOOLINGUNIT CASE

(f) Secure the A/C harness q to the vehicleharness using three plastic ties.

(g) Connect the A/C harness q to the vehicleharness and vehicle connector, then secure thevehicle harness using a plastic tie.

AAAMC-94– 62 –

ECU

AC9269

VEHICLE CONNECTOR (31-P)

VEHICLE CONNECTOR (35-P)

VIEW:A

VIEW:AECU

VIEW:A


PRECISION(-) SCREWDRIVER

VIEW:A

AC9271

TERMINALSTOPPER

GAP

CONNECTOR(31-P)

AC9270

A/C HARNESS 1

LEAD WIRE OF THEVEHICLE HARNESS(WHITE/BLUE)

BRANCH CONNECTOR

BRANCH CONNECTOR

30mm

(j) Lift the terminal stopper of the connector (35-P)with the precision (-) screwdriver.

Insert the precision (-) screwdriver to the gap forthe terminal stopper, and lift the terminal stopper.

NOTE

(i) Connect the A/C harness q to the lead wire(white/blue) of the vehicle harness using thebranch connector.

See the P.1 for the connection of the branchconnector.

NOTE

CAUTION!

Do not mistake the lead wire color.

CAUTION!

To plug branch connector connection and 1-Pterminal of the A/C harness, carry out in to the leftdrawing connector.

AAAMC-94– 63 –

BLACK/WHITE

BLACK AC9273


1-P TERMINAL OFTHE VEHICLEHARNESS(BLACK)


BLACK/WHITE

WHITE/REDAC9272


1-P TERMINAL OFTHE VEHICLEHARNESS(WHITE/RED)

TERMINAL

VINYL TAPE

LEAD WIRE

CUT OFF


(n) Insert the terminal of the A/C harness q to thevehicle connector (35-P).

CAUTION!

Check the wire colors before inserting the terminalof the A/C harness q to the vehicle connector.

(k) Pull out the terminal of two lead wires(black/white and white/red) of the vehicle harnessfrom the vehicle connector (35-P).

(l) Cut off the terminal from two lead wires of thevehicle harness.

(m) Attach the vinyl tape around two lead wires of thevehicle harness.

CAUTION!

Do not mistake the lead wire colors.

VEHICLE WITH THE TERMINAL IS INSERTED INTHE VEHICLE CONNECTOR (35-P) ONLY[(k)~(m)]

ECUVEHICLE HARNESS

AC9275

VIEW:A

VEHICLE CONNECTOR (35-P) (TO EFI ECU CONNECTOR)

VIEW:A

AC9274

TERMINALSTOPPER

(o) Restore the terminal stopper of the connector(35-P).

Check to see that the terminal is locked.

NOTE

(p) Reconnect the vehicle harness to ECU.

AAAMC-94– 64 –

A/C HARNESS q

AU1160

VEHICLE EARTH TERMINAL

PLASTIC TIE

COOLING UNIT CASE

AU1161

A/C HARNESS q

(p) Install the A/C harness q together with vehicleearth terminal.

(q) Secure the excess A/C harness q to the vehicleharness, using a plastic tie.

A/C HARNESS q

PLASTIC TIE

A/C HARNESS q

A/C HARNESS w

AU1162


(r) Connect the A/C harness q to the A/C harnessw.

Perform this work after laying out A/C harness w.

NOTE

(s) Secure the A/C harness q to the vehicleharness using a plastic tie.

CAUTION!

Make sure that the A/C harness w pull out fromthe engine compartment.

A/C AMPLIFIER

SHORT CIRCUIT CONNECTOR

VEHICLE HARNESS

VEHICLE HARNESS(TO A/C AMPLIFIER)

AU2079

VEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(8)]

(8) WIRING wwwww

(a) Remove and discard the short circuit connectorfrom the vehicle harness.

AAAMC-94– 65 –

A/C SWITCHSWITCH MODULE

AU0664

A/C


(b) Temporarily remove the switch module from thecenter cluster panel.

CAUTION!

Do not damage the hooks when removing theswitch module.

(9) A/C SWITCH

VEHICLE WITH HEATER MODEL ONLY[(a)~(h)]

(a) Temporarily remove the control knob from thecenter cluster panel.

AU1539




VEHICLE HARNESS

(b) Connect the vehicle harness to the thermistorconnector.

(c) Connect the vehicle harness to the A/Camplifier.

CAUTION!

Connect when laying out the A/C harness w forvehicles made for Europe.

SWITCH MODULE

CENTER CLUSTER PANEL AD1176

HOOKS

CENTER CLUSTERPANEL

AD1175

CONTROL KNOB(REUSE)

EXCEPT FOR AUSTRALIAN SPEC ONLY[(c)~(d)]

(c) Remove and discard the original cover from theswitch module.

(d) Assemble the A/C switch to the switch module.

AAAMC-94– 66 –

(g) Reinstall the switch module to the center clusterpanel.

CAUTION!

The hooks must be inserted when installing theswitch module.

(h) Reinstall the control knob (reuse) to the centercluster panel.

CAUTION!

Do not connect the vehicle harness (3-P) to theA/C switch.

VEHICLE WITHOUT A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(i)]

(i) Connect the A/C harness q to the A/C switch.

A/C HARNESS 1 (3-P)

AD1171

A/C SWITCH



SWITCH MODULEA/C SWITCH


AC9063

SWITCH MODULE

CENTER CLUSTER PANEL AD1176

HOOKS

CENTER CLUSTERPANEL

AD1175

CONTROL KNOB(REUSE)

AUSTRALIAN SPEC ONLY [(e)~(f)](e) Remove and discard the original cover from the

switch module.(f) Assemble the A/C switch to the switch module.

AAAMC-94– 67 –

FRONT

HEATER CONTROL ASSY

CONTROL DIAL ASSY

NOTE

AU0675

VIEW : A

q

HEATERCONTROL ASSY

CAUTION

VIEW : A

BALL

CONTROL DIALASSY

w

180°

(m) Insert the control dial assy to the heater controlassy.

Assemble the control dial assy by inserting the ballinto the heater control assy from directly above.

NOTE

CAUTION!


(n) Rotate the control dial assy until the ball isdirectly underneath.

BALL

CONTROL DIAL

AU0674

SPRING

CONTROL DIAL

AU0673

(l) Install the ball to the control dial.

CAUTION!


VEHICLE WITHOUT HEATER MODEL ONLY[(k)~(r)]

(k) Install the spring to the control dial.



AU1522

A/C SWITCHVEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(j)]

(j) Connect the vehicle harness to the A/C switch.

AAAMC-94– 68 –


AU2083

HEATER CONTROL ASSY


AU2073

HEATER CONTROL ASSY

VIEWED FROM BACK SIDEOF HEATER CONTROL ASSY

HEATER CONTROL ASSY

TEMPERATURECONTROLRESISTOR HARNESS

VIEW : B

CAUTION

AU0677

TAPPINGSCREW( 3 8)

VIEW : B

(r) Connect the vehicle harness to the connector ofthe temperature control resistor.

(p) Route the temperature control resistor harnessas shown in the left figure.

CAUTION!

The pawl for the temperature control resistorharness must be installed on the heater controlassy.

(q) Pull out the vehicle harness which is affixed withtape through the opening.

HEATER CONTROL ASSY

CONTROL DIAL ASSY

w

q

AU0676

BALL

LOCK

CONTROL DIAL ASSY

FACE SIDE (o) Push in the control dial assy once.The operator will watch the pushed-in status,and rotate clockwise until the lock is engaged.

AAAMC-94– 69 –

AD1177

CENTER CLUSTERPANEL


HOOKS

HOOKS


VEHICLE WITHOUT HEATER MODEL ONLY [(v)](v) Reinstall the control knob (reuse), then install

the control knob (included in kit).

When installing the control knob (included in kit),set it to "MAX COOL".

NOTE

VEHICLE WITH HEATER MODEL ONLY [(u)](u) Reinstall two control knobs to the center cluster

panel.

(s) Reinstall the center cluster panel.(t) Reinstall the center cluster lower panel.

Insert the center cluster lower panel onto thereinforcement.

NOTE

AD1173

CENTER CLUSTERPANEL

CONTROLKNOBS(REUSE)

AD1182

CONTROLKNOB(REUSE)

SILVER OR GRAY

CONTROL KNOB(INCLUDED IN KIT) CENTER CLUSTER

PANEL

CAUTION!

Note that assording to the vehicle type, the usecontrol knob differs.

AAAMC-94– 70 –

METER PANEL

HOOKS

HOOKS

AU0668

(d) Meter panel

Reconnect the connector of the meter panel to thevehicle harness.

NOTE

OU0007

ECU HARNESS COVER

(b) ECU harness cover

(10) REINSTALLATION OF ORIGINAL PARTS wwwww

VEHICLE WITH A/C CIRCUIT BUILT IN THEVEHICLE HARNESS ONLY [(a)]

(a) Reconnect the vehicle harness to ECU.

METER

AU0649

(c) Meter

Reconnect the connector of the meter to thevehicle harness.

NOTE

ECUVEHICLE HARNESS

AC9275

AAAMC-94– 71 –

GLOVE BOX

AU0669

(e) Glove box

HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(LH)


CAUTION


(h) Cowl side panel (RH)(i) Scuff plate (RH)

CAUTION!


(f) Cowl side panel (LH)(g) Scuff plate (LH)

CAUTION!


HOOKS

HOOK

HOOK

SCUFF PLATE

SCUFF PLATE(RH)

COWL SIDEPANEL

CAUTION


AU0647

AAAMC-94– 72 –

[MEMO]

AAAMC-94

Printed in Japan

DENSO CORPORATION

SERVICE DEPARTMENT

Kariya, Aichi, Japan

First Issue : NOVEMBER 2002

Publication No. : AAAMC-94

AAAMC-94988963-6050

BOLT LENGTH RULER (mm)

BOLT DIAM. & HEX. HEAD (mm)

(mm)20 1030405060708090

M14M12M10M8M6M5

Airco Passenger Kit RHD Aaamc94

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