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TOYOTA

ENGLISHAIR CONDITIONING

EUROPE

2001 DENSO CORPORATIONAll Rights Reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of the publisher.

INTRODUCTIONIMPORTANT NOTICE

DEFINITION OF TERMS

FOREWORDThis manual has been published to explain how to install the air conditioning for TOYOTA HIACE. 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 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).

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,REARLEFT,RIGHT

: Shows the direction when viewed from the drivers seat.

VEHICLE NAME MODEL CODE PRODUCTION PERIOD ENGINE TYPE STEERING POSITIONHIACE KLH12R,22R 2001.8~ 2KD-FTV RHD

Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation.

MANUAL NAME DOCUMENT CODE DOCUMENT PART NUMBERGENERAL INFORMATION /

AFTER INSTALLATION AOAMC-01* 988963-475*

AAAMC-22

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1. INSTALLATIONCAUTION75

(b) Ash tray

(c) Center panelNOTEAfter removing the two original tapping screws, pullout the left side center panel.1-1. INSTALLATION INSIDE PASSEN-GER COMPARTMENT

groups so that they can be reassembled correctly.

(1) REMOVAL OF PARTS(a) Glove box1. 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

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NOTERemove the center panel from the instrument 75(g) Center lower panel(e) Lower panel (Left side)(f) Tapping screwpanel.

(d) Lower panel (Right side)

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(h) Under coverCAUTION75

NOTE

(n) Blower motor connector (2-p)(o) Blower motor harness bracket

After cutting the boss of the air duct, remove thevehicle harness clip.CAUTIONDo not disconnect the vehicle harness connector.

(l) Vehicle harness connector (4-p)(m) Vehicle harness clip(j) Vehicle computer(k) Power window amplifierBe careful not to shock the air bag harness connector when removing it.

(i) Radio box

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(p) Air duct (discard)NOTE

(q) Blower resister (Reuse)NOTE

1. Remove the air duct with lifting up hook.2. Do not discard three tapping screws and two

bolts.

Do not discard two tapping screws.

(r) Floor hole cover and grommet screw (Discard)75(b) Cut out the carpet as shown.(2) FLOOR CARPET(a) Turn over the carpet.

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(3) COOLING UNIT(a) Assemble the relay and A/C amplifier to the

bracket.75(d) Install the blower motor harness bracket to the cooling unit.(c) Install the bracket to the cooling unit.(b) Cut out the boss of the cooling unit as shown.

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(e) Connect the A/C harness No.1 to the relay (4-p), amplifier (10-p) and the thermistor (2-p).

(f) Reinstall the blower resister to the cooling unit.75

NOTEAlign the drain hose V cut with cooling unit rib.(i) Install the drain hose to the cooling unit using the connector.(h) Install the grommet assy to the cooling unit.(g) Assemble the hole cover bracket and grommet.(with A/C harness No.2)

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NOTEPull out the blower motor connector (2-p) between 75(l) Fully tighten the cooling unit using three original tapping screws and two original bolts.After fastening the hole cover bracket, fully install the cooling unit.

(k) Fasten the hole cover bracket using two bolts.(Engine compartment side)the cooling unit and tubes of cooling unit.

(j) Loosely install the cooling unit.NOTE

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(4) WIRING(a) Install the vehicle harness clip to the cooling

unit.(b) Connect the vehicle harness connector (4-p) to 75(10-p).(f) Connect the A/C harness No.3 (4-p) to the A/C

harness No.2.the blower resister.(c) Install the blower motor connector (2-p) to the

blower motor harness bracket.

(d) Reinstall the power window amplifier and computer as before.

(e) Connect the A/C harness No.3 to the two blower motor connectors (2-p) and A/ C harness No.1

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(5) ECU(a) Disconnect the ECU connector (29-p).(b) Lift up the double casing of ECU connector 75NOTE1. Refer to the next page for connecting the

branch connector.2. Connect the branch connector at 30mm away

from the ECU connector.

(f) Wrap the packing (Small) to the branch connector as shown.(d) Reinstall the double casing as before.

(e) Connect the branch connector of A/C harness No.3 to the original lead wire (WL).(29-p) using the slot screw driver as shown.

(c) Put the lead wire (GY & BW) of A/C harness No.3 into the ECU connector (29-P) as shown.

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(g) Connect the ECU connector (29-p) as before.(h) Fasten the A/C harness No.3 to the vehicle

harness using the plastic tie as shown.-

75(i) Route the A/C harness No.3 as shown.(j) Secure the A/C harness No.3 using the two

plastic ties as shown.

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(k) Disconnect the blower switch connector (8-p).(l) Connect the A/C harness No.3 between the

blower switch and the blower switch connector.-

75ties as shown.(q) Route the A/C harness No.3 as shown.(r) Secure the A/C harness No.3 using the plastic (m) Fasten the A/C switch connector (6-p) to the connector guide.

(n) Cut out the original cover of heater control panel.(o) Connect the A/C harness connector (6-p).(p) Insert the A/C switch to the heater control panel.

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(6) RELAY BOX(a) Temporarily remove the relay and relay box.-

75

Remove the original read wire (YG) as follows.1. Push the projection.2. Pull out the original read wire.(d) Pull out the original read wire (YG).NOTE(c) Remove the cover behind the relay box.(b) Temporarily remove the retainer.

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(e) Disconnect the connector B from the connector A of A/C harness No.3.-

75(h) Insert the terminal (YB) of A/C harness No.3 into the relay box.(g) Connect the connector B to the connector A.(f) Insert the original read wire (YG) to the connector B as shown.

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(i) Reinstall the cover behind the relay box as before.

(j) Reinstall the retainer as before.-

75(k) Reinstall the relay and relay box as before.

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1-2. INSTALLATION INSIDE ENGINE COMPARTMENTCAUTION-

75Remove the earth cable clip from reverse side of air duct.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.

(1) REMOVAL OF PARTS(a) Front grille(b) Under cover

(c) Air ductCAUTION

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(d) Hood lock(e) Harness clip & horn connector-

75(i) Put the brace as shown.NOTEAttach the protective tape to the bumper before removing the center brace.

(h) Pushing down the bumper with both arms, pull the brace out of the radiator support upper.(f) Bumper clip (Right & Left)(g) Center brace tightening bolts.

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(j) Radiator fan shroud

(2) COMPRESSOR(a) Remove and discard the original earth bolt.-

75and spinner handle (09012-12301) to pivot the auto tension pulley.NOTEUse a socket wrench (14 mm), SST (09249-63010)

INTRODUCTIONIMPORTANT NOTICEDEFINITION OF TERMS

FOREWORD1. INSTALLATION1-1. INSTALLATION INSIDE PASSENGER COMPARTMENT(1) REMOVAL OF PARTS(2) FLOOR CARPET(3) COOLING UNIT(4) WIRING(5) ECU(6) RELAY BOX

1-2. INSTALLATION INSIDE ENGINE COMPARTMENT(1) REMOVAL OF PARTS(2) COMPRESSOR(3) CONDENSER & LIQUID TUBE No.1(4) DISCHARGE HOSE(5) RECEIVER AND LIQUID TUBE No.1(6) DISCHARGE AND SUCTION HOSE(7) SUCTION AND LIQUID TUBE(8) A/C HARNESS No.4(9) CAUTION LABEL

2. AFTER INSTALLATION2-1. CHARGING REFRIGERANT (HFC-134a)

3. WIRING DIAGRAM4. A/C AMPLIFIER