ĐÀO TẠO HỆ THỐNG ĐIỀU HÒA Ô TÔ TOYOTA

INSIDE ENGINE COMPARTMENT

TOYOTA

AIR CONDITIONING
ENGLISH

EUROPE,GENERAL,AUSTRALIA


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

: 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 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

2000.8~

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 /
AFTER INSTALLATION

AOAMC-01*

988963-475*

INSTALLATION MANUAL

AAAMB-24*

988963-455*

(INSIDE PASSENGER COMPARTMENT)

© 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

(1)

1ZZ-FE E/G MODEL ONLY
ENGINE COVER

AC3568

-100500107

REMOVAL OF ORIGINAL PARTS

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


(b) Battery and battery tray
BATTERY

FRONT

BATTERY TRAY

AC4368

(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 BOX UPPER COVER
VEHICLE HARNESS

AIR CLEANER HOSE

AC4369

(f)

VSV

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

VSV

CAUTION

HOOK

Do not disconnect the intake hoses from the VSV.

AIR CLEANER BOX
UPPER COVER

FRONT

AC4370

(g) Filter

FILTER

FRONT
AC4371

-200500107


(h) Vehicle harness clamp

VEHICLE HARNESS CLAMP

FRONT

AC4372

AIR CLEANER BOX LOWER COVER

FRONT

(i)

Air cleaner box lower cover

(j)

Air duct

AC4373

AIR DUCT

FRONT
AC4374

(k) Radiator upper supports. (RH,LH)
(l) Front grille

RADIATOR UPPER SUPPORTS (RH,LH)

FRONT GRILLE

AC3569

-300500107

(m) Front fender liner (LH)

NOTE

CLIPS

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

FRONT FENDER
LINER (LH)

SCREWS

AC3570

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

STEERING WHEEL

AC4379




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

VEHICLE WITH SURGE TANK ONLY

SCREW

FRONT BUMPER
AC3571

(p) Surge tank

VEHICLE WITH SURGE TANK ONLY

SURGE TANK
AC3572

-400500107


(q) Under cover (RH)

CLIPS

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

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

VEHICLE HARNESS
(2-P)

AC4384

-500500107

(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

AC4423

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

RADIATOR

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

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

LIQUID TUBE No.1

FRONT

AC4424

-600500107


(4)

COLLARS

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

BUSHINGS

CONDENSER

AC4420

(b) Lean the radiator backward then insert the
condenser in front of radiator.

CONDENSER
RADIATOR

CAUTION
Insert a corrugated board and others before
inserting the condenser to prevent the radiator from
being damaged.

CORRUGATED
BOARD

AC4387

(c) Make sure that the bushings of condenser
positively inserted into the vehicle holes.

VIEWED FROM THE BOTTOM SIDE OF VEHICLE

VIHICLE HOLE

RUBBER CUSHION
CONDENSER

VIHICLE HOLE

CONDENSER

RUBBER CUSHION
AC4388

-700500107


BOLTS (M8

(d) Install the condenser using two bolts.

CONDENSER

32,SILVER)

AC4389

FRONT

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

RADIATOR FAN MOTOR

VEHICLE HARNESS CLIP

VEHICLE HARNESS CLIP

VEHICLE HARNESS
FAN SHROUD
1NZ/2NZ-FE E/G MODEL ONLY

AC4425

(5)
ADJUSTING BOLT

ALTERNATOR BELT
(DISCARD)

LOCK BOLT
AC3573

-800500107

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.

(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]

[4]
ENGINE BLOCK

COMPRESSOR
AC3574

-900500107


1NZ/2NZ-FE E/G MODEL ONLY
COMPRESSOR
DRIVE BELT 10kgf

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

ALTERNATOR
PULLEY

CAUTION
1. The threads on the compressor belt must fit into
grooves on the pulley.

WATER PUMP
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.

COMPRESSOR
PULLEY

CRANKSHAFT PULLEY
ROD
ALTERNATOR
ADJUSTING BAR

(e) Adjust the belt tension as shown in the left
figure.
Belt deflection at Belt tension using
98 N•(10 kgf,22 the belt tension
gauge
lbf) force

FRONT

New Belt
OCV
ALTERNATOR
AC3575

7.0-8.5 mm
539-637 N
(0.28-0.33 inch) (55-65 kgf, 121-143
lbf)

Used Belt
11.0-13.0 mm
245-392 N
(Re-adjustment) (0.44-0.51 inch) (25-40 kgf, 55-88 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

(f)

Tighten the adjusting bolt.

ADJUSTING BOLT

COMPRESSOR DRIVE
BELT

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
AC3576

- 10 00500107





1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY
[(h)~(l)]
(h) Use the following procedure to remove the
alternator belt.

1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY
NOTE
ALTERNATOR BELT
(DISCARD)

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.

FRONT

(i)
BOX-END COMBINATION
WRENCH (19mm)

FRONT
AC3577

- 11 00500107

Remove and discard the alternator belt.


(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)

[3]
ENGINE BLOCK

COMPRESSOR

- 12 00500107

AC3579


(k) Use the following procedure to install the
compressor drive belt.

1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY
NOTE
COMPRESSOR DRIVE
BELT

NOTE
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.

FRONT

BOX-END COMBINATION
WRENCH (19mm)

FRONT
AC3580

(l)

1ZZ/3ZZ/4ZZ-FE, 2ZZ-GE E/G MODEL ONLY
P/S PUMP PULLEY OR
IDLE PULLEY

ALTERNATOR
PULLEY

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

WATER PUMP
PULLEY
TENSIONER
PULLEY

CRANKSHAFT PULLEY

COMPRESSOR
PULLEY

AC3578

(m) Pull the vehicle harness (4-P) down.
VEHICLE HARNESS (4-P)

FRONT
TAPING

AC4394

- 13 00500107


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

Mg/C CONNECTOR
VEHICLE HARNESS
(4-P)

FRONT

COMPRESSOR




AC4395

PIPING LAYOUT
TO PASSENGER COMPARTMENT

PLASTIC CLAMP No.3

BRACKET No.1

PLASTIC CLAMP No.2

SUCTION HOSE

LIQUID TUBE No.2
COMPRESSOR
FRONT

PLASTIC CLAMP No.1

BRACKET No.2

LIQUID TUBE No.1
CONDENSER

DISCHARGE HOSE

(6)
PLASTIC CLAMP No.2

FRONT
AC4397

- 14 00500107

AC4396

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


LIQUID TUBE No.1

PLASTIC CLAMP 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 N•m (55 kgf•cm, 4.0 lbf•ft)
(d) Fasten the liquid tube No.1 to the 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

FRONT

12)

AC4398

(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
PACKING
LIQUID TUBE No.1

CROSS
SECTION

PACKING
PLASTIC CLAMP No.2

FRONT

AC4399

(i)

Route and connect the liquid tube No.2 to the
liquid and 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).

LIQUID TUBE No.2

BRACKET No.1

FRONT
QUICK JOINT (SMALL)

AC4400

- 15 00500107

(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

(n) Connect the suction hose to the compressor
using a bolt.

SUCTION HOSE

Tightening Torque
9.8 N•m (100 kgf•cm, 7.2 lbf•ft)

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

- 16 00500107


PLASTIC CLAMP No.3

(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)

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

5.4 N•m (55 kgf•cm, 4.0 lbf•ft)

25)
DISCHARGE HOSE

FRONT

AC4407

- 17 00500107


(u) Connect the discharge hose to the compressor
using a bolt.

COMPRESSOR

Tightening Torque
9.8N•m (100 kgf•cm, 7.2 lbf•ft)

BOLT(M6

FRONT

DISCHARGE HOSE

35)

AC3584

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

FRONT

TAPING

AC4409

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

VEHICLE HARNESS (4-P)

PRESSURE SWITCH
AC4410

(7)
RELAY BOX COVER

FRONT
AC4411

- 18 00500107

RELAYS

(a) Temporarily remove the relay box cover.


(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)

CAUTION PLATE
(a) Attach the caution plate to the frame.

CAUTION PLATE

NOTE
Affix after completely wiping off dust and oil stains
from the frame.

AC3581

(9)
CLIPS

CLIPS
UNDER COVER (RH)
CLIP

SCREWS
AC4381

- 19 00500107

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





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

VEHICLE WITH SURGE TANK ONLY

SURGE TANK
AC3572

(c) Screw

VEHICLE WITH SURGE TANK ONLY

SCREW

FRONT BUMPER
AC3571

(d) Front fender liner (LH)

CLIPS

FRONT FENDER
LINER (LH)

SCREWS

AC3570

(e) Radiator upper supports (RH,LH)
(f) Front grille

RADIATOR UPPER SUPPORTS (RH,LH)

FRONT GRILLE

AC3582

- 20 00500107

(g) Air duct
AIR DUCT

FRONT
AC4374

(h) Air cleaner box lower cover

AIR CLEANER BOX LOWER COVER

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

CAUTION
FRONT

AC4416

VEHICLE HARNESS CLAMP

FRONT

FILTER

(i)

Vehicle harness clamp

(j)

Filter

AC4417

FRONT
AC4418

- 21 00500107


(k) Reinstall the VSV to the air cleaner box upper
cover.

VSV

VSV
HOOK
AIR CLEANER BOX
UPPER COVER

FRONT

AC4419

(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 BOX UPPER COVER
VEHICLE HARNESS

AIR CLEANER HOSE

AC4369

(o) Battery and battery tray
BATTERY

FRONT

BATTERY TRAY
RIB

AC4368




1ZZ-FE E/G MODEL ONLY [(p)]
(p) Engine cover

1ZZ-FE E/G MODEL ONLY
ENGINE COVER

Tightening Torque
7.0 N•m (71 kgf•cm, 5.1 lbf•ft)

AC3583

- 22 00500107


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.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]

Belt tension
[N (kgf, lbf)]

11.0 - 13.0 mm
(0.44 - 0.51 inch)

245 - 392 N
(25 - 40 kgf, 55 - 88 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.)

- 23 00500107