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TOYOTA
AIR CONDITIONING ENGLISH
EUROPE
T N E M T R A P M O C E N I G N E E D I S N I & T N E M T R A P M O C R E G N E S S A P E D I S N I
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 care to ensure that clearance clearance between between air conditioning conditioning components components and other components components such such as brake parts, fuel system and electric wires as specified in this manual. 2. If a problem is found found with the air condition conditioning ing system system due to installation, installation, refer refer back to the manual manual to correct correct the problem(s). 3. Vehicle Vehicle and air conditio conditioning ning kit components components as well well as installation installation procedure procedures s are subject to change change without 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 that facilitates installation work. 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 HIACE. 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
HIACE
KLH12R,22R
2001.8~
2KD-FTV
RHD
CAUTION Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation. [DOCUMENT CODE AND DOCUMENT PART NUMBER] MANUAL NAME
in whole or in part, without the written permission of the publisher.
1. INSTALLATION CAUTION 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.
1-1. INSTALLATION INSIDE PASSENGER COMPARTMENT
(1)
REMOVAL OF PARTS
(a) Glove box (b) Ash tray
(c) Center panel
NOTE After removing the two original tapping screws, pull out the left side center panel.
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NOTE Remove the center panel from the instrument panel.
(d) Lower panel (Right side)
(e) Lower panel (Left side) (f) Tapping screw
(g) Center lower panel
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(h) Under cover
CAUTION Be careful not to shock the air bag harness connector when removing it.
(i)
Radio box
(j) Vehicle computer (k) Power window amplifier
CAUTION Do not disconnect the vehicle harness connector.
NOTE After cutting the boss of the air duct, remove the vehicle harness clip. (n) Blower motor connector (2-p) (o) Blower motor harness bracket
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(p) Air duct (discard)
NOTE 1. Remove the air duct with lifting up hook. 2. Do not discard three tapping screws and two bolts. (q) Blower resister (Reuse)
NOTE Do not discard two tapping screws.
(r)
(2)
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Floor hole cover and grommet screw (Discard)
FLOOR CARPET (a) Turn over the carpet. (b) Cut out the carpet as shown.
(3)
COOLING UNIT (a) Assemble the relay and A/C amplifier to the bracket.
(b) Cut out the boss of the cooling unit as shown.
(c) Install the bracket to the cooling unit.
(d) Install the blower motor harness bracket to the cooling unit.
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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.
(g) Assemble the hole cover bracket and grommet. (with A/C harness No.2)
(h) Install the grommet assy to the cooling unit.
(i)
Install the drain hose to the cooling unit using the connector.
NOTE Align the drain hose V cut with cooling unit rib.
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NOTE Pull out the blower motor connector (2-p) between the cooling unit and tubes of cooling unit.
(j)
Loosely install the cooling unit.
NOTE After fastening the hole cover bracket, fully install the cooling unit.
(k) Fasten the hole cover bracket using two bolts. (Engine compartment side)
(l)
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Fully tighten the cooling unit using three original tapping screws and two original bolts.
(4)
WIRING (a) Install the vehicle harness clip to the cooling unit. (b) Connect the vehicle harness connector (4-p) to 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 (10-p). (f) Connect the A/C harness No.3 (4-p) to the A/C harness No.2.
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(5)
ECU (a) Disconnect the ECU connector (29-p). (b) Lift up the double casing of ECU connector (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. (d) Reinstall the double casing as before.
(e) Connect the branch connector of A/C harness No.3 to the original lead wire (WL).
NOTE 1. Refer to the next page for connecting the branch connector. 2. Connect the branch connector at 30mm away from the ECU connector.
(f)
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Wrap the packing (Small) to the branch connector 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.
(i) (j)
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Route the A/C harness No.3 as shown. Secure the A/C harness No.3 using the two plastic ties as shown.
(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. (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.
(q) Route the A/C harness No.3 as shown. (r) Secure the A/C harness No.3 using the plastic ties as shown.
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(6)
RELAY BOX (a) Temporarily remove the relay and relay box.
(b) Temporarily remove the retainer.
(c) Remove the cover behind the relay box.
(d) Pull out the original read wire (YG).
NOTE Remove the original read wire (YG) as follows. 1. Push the projection. 2. Pull out the original read wire.
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(e) Disconnect the connector B from the connector A of A/C harness No.3.
(f)
Insert the original read wire (YG) to the connector B as shown.
(g) Connect the connector B to the connector A.
(h) Insert the terminal (YB) of A/C harness No.3 into the relay box.
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(i)
Reinstall the cover behind the relay box as before.
(j)
Reinstall the retainer as before.
(k) Reinstall the relay and relay box as before.
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1-2. INSTALLATION INSIDE ENGINE 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. (1)
REMOVAL OF PARTS
(a) Front grille (b) Under cover
(c) Air duct
CAUTION Remove the earth cable clip from reverse side of air duct.
