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INSIDEEN
GINECOMPAR
TMENT
TOYOTA
ENGLISH
AIR CONDITIONING
EUROPE
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2001 DENSO CORPORATION
All Rights Reserved. This book may not be reproduced or copied,
in whole or in part, without the written permission of the publisher.
INTRODUCTION
IMPORTANT NOTICE
DEFINITION OF TERMS
FOREWORDThis manual has been published to explain how to install the air conditioning for TOYOTA COROLLA VERSO.When installing the air conditioning, installation should be performed as described in this manual.
[APPLICATION VEHICLE]
CAUTION
[DOCUMENT CODE AND DOCUMENT PART NUMBER]
This manual has been designed for technicians who are qualified and educated in the proper procedures of vehicle
safety, handling and maintenance; experienced in installation of car air conditioning or who are able to carry out
installation procedures when given instructions by an experienced technician in a supervisory capacity; and arecertified to handling refrigerant.
1. Take special care to ensure that clearance between air conditioning components and other components such as
brake parts, fuel system and electric wires as specified in this manual.
2. If a problem is found with the air conditioning system due to installation, refer back to the manual to correct the
problem(s).
3. Vehicle and air conditioning kit components as well as installation procedures are subject to change without
prior notice. Refer to the latest installation manual and service information. Any changes affecting the above
items will be given in the form of a Installation instructions for air conditioning (Supplement) (issued by
DENSO) or a service bulletin (issued by the manufacturer).
WARNING : Describes precautions that should be observed in order to prevent injury or death to the user
during installation.
CAUTION : Describes precautions that should be observed in order to prevent damage to the vehicle or its
components, which may occur during installation if insufficient care is taken.
NOTE : Provides additional information that facilitates installation work.
FRONT,REAR
LEFT,RIGHT
: Shows the direction when viewed from the drivers seat.
VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITION
COROLLA VERSO ZZE121R 2001.10~ 3ZZ-FE RHD
ZZE122R 1ZZ-FE
1. Carefully read the separate manual"GENERAL INFORMATION/AFTER INSTALLATION" before and after
installation.
2. Refer to the separate manual"INSTALLATION MANUAL(INSIDE PASSENGER COMPARTMENT)" for details on
installation for the passenger compartment side.
MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBER
GENERAL INFORMATION /AFTER INSTALLATION
AOAMC-01* 988963-475*
INSTALLATION MANUAL(INSIDE PASSENGER COMPARTMENT)
AAAMC-28* 988963-509*
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1. INSTALLATION INSIDEPASSENGERCOMPARTMENT
CAUTION
1. Before starting installation, remove the negative
cable from the battery.
2. Before making any hoses and tubes
connections, apply a few drops of compressor
oil to the seat of O-ring and coupling nuts.
3. When tightening and loosening the fittings, use
two wrenches for support.
4. Ensure fender covers are in position.
5. Start the work from the inside passenger
compartment side.
CAUTION
First remove the negative terminal on the battery
and the vehicle harness connection before installing
the equipment.
VEHICLE HARNESS
BATTERY
Disconnect
the negative
cable first.
AC1895
(1) REMOVAL OF ORIGINAL PARTS
1ZZ-FE E/G MODEL ONLY [(a)]
(a) Engine coverENGINE COVER
AC4375
1ZZ-FE E/G MODEL ONLY
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(b) Battery & battery tray
FRONT
AC4368
BATTERY
BATTERY TRAY
(c) Disconnect the vehicle harness from the air
cleaner box upper cover.
(d) Disconnect the air cleaner hose from the air
cleaner box upper cover.(e) Temporarily remove the air cleaner box upper
cover from the air cleaner lower cover.
AC4369
VEHICLE HARNESS
AIR CLEANER BOX UPPER COVER
AIR CLEANER HOSE
(f) Temporarily remove the VSV from the air
cleaner box upper cover.
CAUTION
Do not disconnect the intake hoses from the VSV.
VSV
FRONT
AIR CLEANER BOX
UPPER COVER
VSV
HOOK
AC4370
(g) Filter
FRONT
AC4371
FILTER
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(h) Vehicle harness clamp
FRONTAC4372
VEHICLE HARNESS CLAMP
(i) Air cleaner box lower cover
AC4373
AIR CLEANER BOX LOWER COVER
FRONT
(j) Air duct
FRONT
AC4374
AIR DUCT
(k) Plate
(l) Front grille
AC4376
PLATEFRONT GRILLE
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(m) Radiator upper supports (RH,LH)
AC4377
RADIATOR UPPER SUPPORTS (RH,LH)
(n) Front fender liner (LH)
NOTE
Take care not to remove the front fender liner (LH)
completely.
AC4378
FRONT FENDER
LINER (LH)
CLIPS
SCREWS
(o) Fully turn the steering wheel counterclockwise,
before removing the front fender liner (LH).
AC4379
STEERING WHEEL
VEHICLE WITH SURGE TANK ONLY [(p)~(q)]
(p) Screw
AC4422FRONT BUMPER
SCREW
VEHICLE WITH SURGE TANK ONLY
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(q) Surge tank
AC4380SURGE TANK
VEHICLE WITH SURGE TANK ONLY
(r) Under cover (RH)
SCREWS
AC4381
UNDER COVER (RH)
CLIPS
CLIPS
CLIP
(2) RESISTOR
(a) Install the resistor to the body using two bolts.
RESISTOR
BOLTS
(M6 16)
AC4382
(b) Pull the vehicle harness (2-P) down.
(c) Route the vehicle harness (2-P) to the resistor.
FRONT
AC4383
VEHICLE HARNESS(2-P)
TAPING
TO RESISTOR
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(d) Connect the vehicle harness (2-P) to the
resistor.
RESISTOR
VEHICLE HARNESS
(2-P)
AC4384
(3) LIQUID TUBE
(a) Disconnect the vehicle harness from the radiator
fan motor.
(b) Temporarily remove the vehicle harness clipfrom the fan shroud.
FRONT
FAN SHROUD AC4423
RADIATOR FAN MOTOR
VEHICLE HARNESS
VEHICLE HARNESS CLIP
VEHICLE HARNESS CLIP
(c) Insert the liquid tube No.1 as shown in the left
figure.
FRONT
LIQUID TUBE No.1
RADIATOR
AC4385
(d) Route the liquid tube No.1 under the vehicle
harness, when inserting the liquid tube No.1.
FRONT
AC4386
LIQUID TUBE No.1
VEHICLE HARNESS
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(e) Set the liquid tube No.1 as shown in the left
figure.
LIQUID TUBE No.1
AC4424
FRONT
(4) CONDENSER
(a) Assemble two collars and two bushings to the
condenser.
AC4420CONDENSER
COLLARS
BUSHINGS
(b) Lean the radiator backward then insert the
condenser in front of radiator.
CAUTION
Insert a corrugated board and others before
inserting the condenser to prevent the radiator from
being damaged.
RADIATOR
CORRUGATED
BOARD AC4387
CONDENSER
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(c) Make sure that the bushings of condenser
positively inserted into the vehicle holes.
CONDENSER
CONDENSER
AC4388
VIEWED FROM THE BOTTOM SIDE OF VEHICLE
VIHICLE HOLE
VIHICLE HOLE
RUBBER CUSHION
RUBBER CUSHION
(d) Install the condenser using two bolts.CONDENSER
AC4389
BOLTS (M8 32,SILVER)
(e) Reinstall the vehicle harness clip to the fan
shroud.
(f) Reconnect the vehicle harness to the radiator
fan motor.
FRONT
FAN SHROUD AC4425
RADIATOR FAN MOTOR
VEHICLE HARNESS
VEHICLE HARNESS CLIP
VEHICLE HARNESS CLIP
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(5) COMPRESSOR AND COMPRESSOR DRIVE
BELT
(a) Use the following procedure to remove the
alternator belt.
NOTE
(b) Remove and discard the alternator belt.
Set the box-end combination wrench (19mm) as
shown in the left figure, and remove the alternator
belt from the pulleys while pulling the box-end
combination wrench to the front of the vehicle.
NOTE
FRONT
ALTERNATOR BELT
(DISCARD)
FRONT
AC4390
BOX-END COMBINATION
WRENCH (19mm)
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(c) Install the compressor to the engine block using
three bolts.
CAUTION
Tightening Torque
24.5 Nm (250 kgfcm, 18.1 lbfft)
Tightening order; [1] [2] [3]
COMPRESSOR
ENGINE BLOCK
AC4392
BOLTS(M8 72)
[3]
[1]
[2]
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(d) Use the following procedure to install the
compressor drive belt.
NOTE
Set the box-end combination wrench (19mm) as
shown in the left figure, and install the compressor
drive belt from the pulleys while pulling the box-end
combination wrench to the front of the vehicle.
NOTE
FRONT
COMPRESSOR DRIVE
BELT
FRONT
AC4393
BOX-END COMBINATION
WRENCH (19mm)
(e) Install the compressor drive belt to the pulleys as
shown in the left figure.
AC4391
TENSIONER
PULLEY
P/S PUMPPULLEY
ALTERNATOR
PULLEY
WATER PUMP
PULLEY
COMPRESSOR
PULLEYCRANKSHAFT PULLEY
(f) Pull the vehicle harness (4-P) down.
TAPING
VEHICLE HARNESS (4-P)
FRONT
AC4394
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(g) Connect the vehicle harness (4-P) to the Mg/C
connector.
FRONT
VEHICLE HARNESS
(4-P)
Mg/C CONNECTOR
AC4395COMPRESSOR
PIPING LAYOUT
COMPRESSOR
CONDENSER
LIQUID TUBE No.1
PLASTIC CLAMP No.1
LIQUID TUBE No.2
PLASTIC CLAMP No.2
PLASTIC CLAMP No.3
DISCHARGE HOSE
SUCTION HOSE
BRACKET No.2
BRACKET No.1
FRONT
TO PASSENGER COMPARTMENT
AC4396
(6) PIPING
(a) Install the plastic clamp No.2 to the body.
FRONT
AC4397
PLASTIC CLAMP No.2
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(b) Assemble the plastic clamp No.1 to the
condenser.
(c) Connect the liquid tube No.1 to the condenser
using a bolt.
(d) Fasten the liquid tube No.1 to the plastic clamp
No.1.
Tightening Torque
5.4 Nm (55 kgfcm, 4.0 lbfft)
CONDENSER AC4421
LIQUID TUBE No.1
PLASTIC CLAMP No.1
BOLT(M6 25)
(e) Install the bracket No.1 to the body using a bolt.
FRONT
AC4398
BOLT(M6 12)
BRACKET No.1
(f) Connect the liquid tube No.2 to the liquid tube
No.1.(g) Fasten the liquid tube No.1 to the plastic clamp
No.2.
(h) Attach the packing around connecting portion of
the liquid tube No.1 and liquid tube No.2.
LIQUID TUBE No.2
AC4399PLASTIC CLAMP No.2FRONT
LIQUID TUBE No.1
PACKING
PACKING
CROSSSECTION
(i) Route and connect the liquid tube No.2 to the
liquid & suction tube.
(j) Fasten the liquid tube No.2 to the bracket No.1.
(k) Fasten the liquid tube No.2 using a quick joint
(small).
QUICK JOINT (SMALL) AC4400
LIQUID TUBE No.2
BRACKET No.1
FRONT
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(l) Install the bracket No.2 to the body using a bolt.
CAUTION
Catch the turning stopper to the vehicle hole
surely.
BRACKET No.2
FRONT
AC4401
CAUTION
BOLT(M6 12)
(m) Install the plastic clamp No.3 to the body.
AC4402
PLASTIC CLAMP No.3
FRONT
(n) Connect the suction hose to the compressor
using a bolt.
Tightening Torque
9.8 Nm (100 kgfcm, 7.2 lbfft)
FRONT
SUCTION HOSE
AC4403COMPRESSOR
BOLT(M6 35)
(o) Fasten the suction hose to the bracket No.2
using a nut.
AC4404
SUCTION HOSE
NUT (M6)
FRONT
BRACKET No.2
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(p) Connect the suction hose to the liquid and
suction tube.
(q) Fasten the suction hose to the plastic clamp
No.3.
(r) Fasten the suction hose using a quick joint (big).
QUICK JOINT (BIG)
AC4405
SUCTION HOSE
FRONT
SUCTION HOSE
PLASTIC CLAMP No.3
(s) Insert the discharge hose as shown in the left
figure.
AC3585
FRONT
DISCHARGE HOSE
DISCHARGE HOSE
(t) Connect the discharge hose to the condenser
using a bolt.
Tightening Torque
5.4 Nm (55 kgfcm, 4.0 lbfft)
AC4407
DISCHARGE HOSE
CONDENSER
FRONT
BOLT (M6 25)
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(u) Connect the discharge hose to the compressor
using a bolt.
Tightening Torque
9.8Nm (100 kgfcm, 7.2 lbfft)
FRONTDISCHARGE HOSE AC3584
COMPRESSOR
BOLT(M6 35)
(v) Pull the vehicle harness (4-P) down.
FRONT
TAPING
AC4409
VEHICLE HARNESS (4-P)
(w) Connect the vehicle harness (4-P) to the
pressure switch.
AC4410
VEHICLE HARNESS (4-P)
PRESSURE SWITCH
(7) RELAYS
(a) Temporarily remove the relay box cover.
FRONT
RELAY BOX COVER
AC4411
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(b) Install the Mg/C relay into the relay box.
NOTE
Be sure to install the relay box by supporting the
relay box by hand from the bottom side to prevent
a contact defect.
FRONT
Mg/C RELAY (4-P,BLACK)
AC4412
(c) Reinstall the relay box cover.
FRONT
RELAY BOX COVER
AC4413
(8) CAUTION PLATE
(a) Attach the caution plate to the engine hood.
NOTE
Affix after completely wiping off dust and oil stains
from the engine hood.
AC4414
CAUTION PLATE
ENGINE HOOD
(9) REINSTALLATION OF ORIGINAL PARTS
(a) Under cover (RH)
SCREWS
AC4381
UNDER COVER (RH)
CLIPS
CLIPS
CLIP
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VEHICLE WITH SURGE TANK ONLY [(b)~(c)]
(b) Surge tank
AC4380SURGE TANK
VEHICLE WITH SURGE TANK ONLY
(c) Screw
AC4422FRONT BUMPER
SCREW
VEHICLE WITH SURGE TANK ONLY
(d) Front fender liner (LH)
AC4378
FRONT FENDER
LINER (LH)
CLIPS
SCREWS
(e) Radiator upper supports (RH,LH)
AC4377
RADIATOR UPPER SUPPORTS (RH,LH)
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(f) Front grille
(g) Plate
AC4376
PLATEFRONT GRILLE
(h) Air duct
FRONT
AC4374
AIR DUCT
(i) Air cleaner box lower cover
CAUTION
Make sure to be inserted the air duct into the air
cleaner box lower cover.
AC4416
AIR CLEANER BOX LOWER COVER
FRONT
CAUTION
(j) Vehicle harness clamp
FRONTAC4417
VEHICLE HARNESS CLAMP
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(k) Filter
FRONT
AC4418
FILTER
(l) Reinstall the VSV to the air cleaner box upper
cover.
VSV
FRONT
AIR CLEANER BOX
UPPER COVER
VSV
HOOK
AC4419
(m) Air cleaner box upper cover
(n) Reconnect the vehicle harness to the air cleanerbox upper cover.
(o) Reconnect the air cleaner hose to the air cleaner
box upper cover.
AC4369
VEHICLE HARNESS
AIR CLEANER BOX UPPER COVER
AIR CLEANER HOSE
(p) Battery & battery tray
FRONT
AC4368
BATTERY
BATTERY TRAY
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1ZZ-FE E/G MODEL ONLY [(q)]
(q) Engine cover
Tightening Torque
7.0 Nm (71 kgfcm, 5.1 lbfft)
RIB
ENGINE COVER
AC4415
1ZZ-FE E/G MODEL ONLY
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2. AFTER INSTALLATION
CAUTION
2-1.CHARGING REFRIGERANT (HFC-134a)
For additional information on charging refrigerant using the charging cylinder, refer to "GENERAL INFORMATION/AF-TER INSTALLATION: CHARGING REFRIGERANT (134a)".
CAUTION
2-2.ADJUSTMENT OF ENGINE IDLING SPEED
CAUTION
Refer to the separate manual"GENERAL INFORMATION/AFTER INSTALLATION"for details on what to do after
installation. (Document code: AOAMC-01*/Document part number: 988963-475*)
STANDARD AMOUNT OF REFRIGERANT 490 30 g (1.08 0.7 lbs)
Ensure to fill the refrigerant to the specified amount.
The engine revolution is controlled by a computer, therefore adjustment is not required. (when the air conditioning
system is started, check whether idling revolution increases.)
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3. AMPLIFIER
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4. WIRING DIAGRAM
COMPRESSORMg/C
RELAY
IG
RELAY
IG SW
12V
HEATER
MAIN RELAY
BLOWER
MOTOR
BLOWER
RESISTOR
BLOWER
RESISTOR
LH
RH
BLOWER SW A/C SW
TO GND
TO TAIL RELAY
AC4498
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246108-711
EFI ECUPRESSURE SW
A/C AMP
EVA.THERMISTOR
RESISTOR
FAN RELAY No.2
RADIATOR
FAN MOTOR
FAN RELAY No.1
AC4499
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DENSO CORPORATION
SERVICE DEPARTMENT
Kariya, Aichi, Japan
Frist Issue :SEPTEMBER 2001
Publication No. : AAAMC-29
Printed in Japan
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