Airco Passenger Kit RHD Aaamc94

INSIDE PASSENGER COMPARTMENT
AIR CONDITIONING
ENGLISH
EUROPE,GENERAL,AUSTRALIA
INSTALLATION
MANUAL
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 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 drivers seat. LEFT, RIGHT
FOREWORD
This 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]
VEHICLE NAME YARIS/ECHO PRODUCTION PERIOD 1999.8~ STEERING POSITION RHD
! CAUTION
1. Carefully read the separate manual "GENERAL INFORMATION/AFTER INSTALLATION" before and after installation. 2. Refer to the separate manual "INSTALLATION MANUAL (INSIDE ENGINE COMPARTMENT)" for details on installation for the engine compartment side.
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.
AAAMC-94
Instruction of branch connector connection

q Set the wire harness to which you are connecting on the insulator assembly. CAUTION Put the press connection vehicle harness firmly into the guide groove. CONNECTING WIRE HARNESS GUIDE GROOVE TERMINAL CONNECTING WIRE HARNESS w Fold the connector about the A section.
INSULATOR ASSEMBLY
A SECTION
CAUTION 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. 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. PIVOT B TEMPORARILY FASTENING LOCK SECTION A PIVOT
PERMANENT FASTENING LOCK SECTIONS
CAUTION CAUTION 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.
CAUTIONS FOR BRANCH CONNECTOR CONNECTIONS 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. CAUTION Do not reuse a used branch connector. BRANCH CONNECTOR
MUST NOT BE DISCONNECTED. INSULATE VINYL TAPE OR THE LIKE.
A SECTION CONNECTING WIRE HARNESS
PRODUCT SIDE WIRE HARNESS
AU1130
AAAMC-94
NOTE
According to the vehicle production period, the ECU vehicle connector shape differs as in the left drawing. The following procedure is divided into the TYPE [A] VEHICLE and TYPE B VEHICLE.
ECU
! CAUTION
In case of TYPE [A] VEHICLE, refer to 1. INSTALLATION INSIDE PASSENGER COMPARTMENT (1) and perform the operation. In case of TYPE [B] VEHICLE, refer to 2. INSTALLATION INSIDE PASSENGER COMPARTMENT (2) and perform the operation.
TYPE [A] VEHICLE
TYPE [B] VEHICLE
VEHICLE CONNECTOR
VEHICLE CONNECTOR
NOTE Concerning ECU confirmation, confirm after (1) REMOVAL OF PARTS (a) to (p) has been performed.
2 ROW 4 ROW
AC9257
AAAMC-94
1. INSTALLATION INSIDE PASSENGER COMPARTMENT (1)

!
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.
COWL SIDE PANEL (RH) HOOKS
(1)
HOOK CAUTION
REMOVAL OF PARTS (a) Scuff plate (RH) (b) Cowl side panel (RH)
SCUFF PLATE
! CAUTION A hook is interconnected to the cowl side panel, therefore, be careful when removing to prevent damage.
AU0647
SCUFF PLATE (RH)
COWL SIDE HOOK PANEL
HOOK CAUTION
COWL SIDE PANEL (LH) HOOKS
(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 prevent damage.
SCUFF PLATE
HOOK COWL SIDE PANEL
SCUFF PLATE (LH)

GLOVE BOX
AU0646
(e) Glove box

BOSS w PUSH
BOSS e q PUSH
NOTE Remove the glove compartment in the following order. q Press in the sides of the glove compartment. w Bypass the bosses. e Lift.
PULL UP
OU0026
AAAMC-94
METER PANEL HOOKS
(f)
Meter panel
! CAUTION
Attach the cloth tape as shown, before removing the meter panel. NOTE Disconnect the connector of the meter panel from the vehicle harness.
HOOKS CLOTH TAPE
AU0648
METER
(g) Meter NOTE Disconnect the connector of the meter from the vehicle harness.
AU0649
CENTER CLUSTER PANEL
VEHICLE WITH HEATER MODEL ONLY [(h)] (h) Control knobs (reuse)
CONTROL KNOBS (REUSE)

AU0650
VEHICLE WITHOUT HEATER MODEL ONLY [(i)] (i) Control knob (reuse) and original cover (discard)
CONTROL KNOB (REUSE)
ORIGINAL COVER (DISCARD)

AU0679
AAAMC-94
CENTER CLUSTER PANEL CLOTH TAPE
HOOKS
(j) Center cluster panel (k) Center cluster lower panel

!
CAUTION
Attach the cloth tape as shown, before removing the center cluster panel. NOTE
HOOKS CENTER CLUSTER LOWER PANEL
OU0038
Disconnect the connector of the center cluster panel from the vehicle harness.
NOTE
c CAUTION
Disconnect the connector of the center cluster panel from the vehicle harness. VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]
x VEHICLE HARNESS (3-P)
CAUTION
Connect the vehicle harness (3-P) to the original location in recovery.
z CENTER CLUSTER PANEL

AC9921
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY VEHICLE WITH HEATER MODEL ONLY NOTE
VEHICLE HARNESS (3-P)
A vehicle harness from the A/C switch is connected to the center cluster panel. Be sure to remove this harness before proceeding with the work.

AU0651
VIEW : A BOX OR AUDIO
(l) Ashtray or coin holder (m) Box or audio NOTE Disconnect the connector of the audio from the vehicle harness.
HOOKS
HOOKS
AU1529
VIEW : A ASHTRAY OR COIN HOLDER
AAAMC-94
HEATER CONTROL ASSY
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY VEHICLE WITH HEATER MODEL ONLY NOTE Pull the vehicle harness for the A/C switch to the front.
OU0030
(n) Three bolts (for instrument panel)
BOLTS (FOR INSTRUMENT PANEL)
AU0652
(o) ECU harness cover
ECU HARNESS COVER
OU0007
(p) ECU NOTE Disconnect the vehicle harness from ECU.
ECU
OU0015
AAAMC-94
! CAUTION
VEHICLE HARNESS
Be careful when removing ECU to prevent damage.
ECU
AU0654
COOLING UNIT CASE
(r) Vehicle bracket (s) Two vehicle harness clamps NOTE Rotate the clamp counter-clockwise once and remove the vehicle harness clamp.
VIEW:A VEICLE HARNESS CLAMPS VEHICLE HARNESS VIEW:A COOLING UNIT CASE VEHICLE BRACKET
FRONT
VEHICLE HARNESS CLAMP

AC9070
(r)
!
Vehicle harness clamp
CAUTION
VEHICLE HARNESS
Vehicle harness clamp must be removed with needle-nose pliers to prevent breakage of the clamp.
COOLING UNIT CASE
OU0040
AAAMC-94
(s) Box (t) Vehicle harness clamps NOTE Disconnect the connection of the vehicle harness, then temporarily remove the vehicle harness from the box.
BOX VEHICLE HARNESS
CAUTION
VEHICLE HARNESS CLAMPS
AU1404
w q
1. The clamps for the vehicle harness must be removed with needle-nose pliers to prevent breakage of the clamps. 2. Moving the storage tray simplifies removal of the vehicle harness clamps. (Refer to the following illustrations) 3. Be careful when moving the small parts box to prevent damage to other vehicle parts.
BOX
NOTE 1 Press-in the box one time to the vehicle front in numerical order, insert the needle-nose pliers from the bottom, and remove the vehicle harness q by tilting.
FRONT
VEHICLE HARNESS q
NOTE 2 Remove vehicle harness w in the same position as NOTE 1 .

BOX
FRONT VEHICLE HARNESS w
NOTE 3 Tilt the box to the front, insert the needle-nose pliers from the side, and remove the vehicle harness e.
BOX
FRONT
VEHICLE HARNESS e
OU0046
AAAMC-94
COOLING UNIT CASE DRAIN HOSE FLOOR CARPET
(u) Temporarily pull the floor carpet down, then temporarily remove the silencer mat. NOTE The floor carpet and silencer mat must be removed as far as necessary. (To simplify removal of the cooling unit case) (v) Drain hose (pull up the vehicle hole.)
SILENCER MAT
AU1406
COOLING UNIT CASE FRS/REC CONTROL BOX
(w) Remove and discard the lock clamp from connection part of the cooling unit case and FRS/REC control box. NOTE Push upward with a (-) screwdriver to remove the lock clamp.
LOCK CLAMP (DISCARD)
OU0028
VEHICLE HARNESS (6-P) (FOR BLOWER RESISTOR)
(x) Vehicle harness for blower resistor connection (Remove the connection for the cooling unit case.)
COOLING UNIT CASE

OU0029
FILTER CASE
(y) Filter case

KONB
NOTE Hold the left and right knobs at both ends of the filter case at the same time, and pull out the knob to the front.
KONB
OU0048
COOLING UNIT CASE
PULL
AAAMC-94
FROM METER OPENING AREA
FILTER CASE FITTING PLACE HOOK CAUTION 2
HOOK
COOLING UNIT CASE
TAPPING SCREW NUT (REUSE) (DISCARD)
FROM BOX OPENING AREA
CAUTION 2 TAPPING SCREW (REUSE) NUT (REUSE) COOLING UNIT CASE

AU2837
NUT (DISCARD) TAPPING SCREW (REUSE) COOLING UNIT CASE
CLOTH TAPE
CAUTION 1
(z) Cooling unit case

!
CAUTION
1. Attach the cloth tape as shown, before removing the cooling unit case. 2. Follow the instructions specified in NOTE because the pawl of cooling unit case and the filter case installation portion are easily damaged.
AAAMC-94
10
NOTE
CAUTION HOOK HOOK
Remove the cooling unit case in the following procedures. q Remove the catch of pawl.
!
CAUTION
Unhook the catch of pawl and keep as it is. (Do not pull the pawl forcibly because it is easily damaged.)
COOLING UNIT CASE

FILTER CASE INSTALLATION SECTION CAUTION 1 w CAUTION 2
AU2364
NOTE
CAUTION 1 w
w Lift the filter case installation section upward so that the pawls do not interfere with the case and place the cooling unit case downward. e Pull the whole cooling unit case toward you through the pawls.
!
HOOK
CAUTION
COOLING UNIT CASE
COOLING UNIT AU2929 CASE
COOLING UNIT CASE
1. Move both the filter case installation section and cooling unit case slowly so that stress is not applied only to the pawl. 2. Never hold the middle part of filter case installation section with hands because it is easily damaged. NOTE r Pull out the cooling unit from the stud bolts.
r
AU2702
11
AAAMC-94
NOTE t Lower the cooling unit case midway and hold it. (Do not lower all the way to the bottom.)
t
w
COOLING UNIT CASE COOLING UNIT CASE
NOTE y Take out the right side of the cooling unit case while pulling the instrument panel towards you.
INSTRUMENT PANEL
y PULL
COOLING UNIT CASE
INSTRUMENT PANEL
NOTE u Then, pull out the left side of the cooling unit case while pulling the instrument panel towards you, and remove the unit.
PULL
AU2838
VIEWED FROM METER OPENING AREA A/C AMPLIFIER
(2)
AMPLIFIER (a) Install the A/C amplifier to the FRS/REC control box using a tapping screw.
FRS/REC CONTROL BOX
FRONT
TAPPING SCREWS ( 4 10, SILVER)

AU0686
AAAMC-94
12
(3)
COOLING UNIT (a) Remove and discard the original packing from the cooling unit case.
COOLING UNIT CASE
ORIGINAL PACKING (DISCARD)
AU0658
COOLING UNIT UPPER CASE
COOLING UNIT LOWER CASE
(b) Temporarily remove the cooling unit upper case from the cooling unit lower case.
AU1542
PLATE (DISCARD)
(c) Remove and discard the plate from the cooling unit lower case.
TAPPING SCREW (DISCARD)
AU2072
13
AAAMC-94
(d) Cut the shaded portion shown in the illustration for the cooling unit upper case and cooling unit lower case.
CUT OUT COOLING UNIT LOWER CASE
CUT OUT
OU0031
THERMISTOR HARNESS
THERMISTOR HOLDER
(e) Assemble the thermistor harness to the thermistor holder. NOTE After the above is assembled, pull the tubing on the thermistor harness up to the thermistor holder.
THERMISTOR HOLDER
AU0681
TUBE
PULL UP
(f)
INSULATOR
Install the insulator to the cooling unit lower case.
OU0010
AAAMC-94
14
EVAPORATOR COOLING UNIT LOWER CASE
(g) Install the evaporator to the cooling unit lower case.
OU0011
(h) Reinstall the cooling unit upper case to the cooling unit lower case.
AU1542
VIEW : A
(i)
Install the thermistor assy to the cooling unit case.
COOLING UNIT CASE

VIEW : A CLAMP
THERMISTOR ASSY
AU1533
(j)
CLAMP
Secure the thermistor harness to the cooling unit case.
COOLING UNIT CASE
THERMISTOR HARNESS
AU1534
15
AAAMC-94
(k) Attach the packing on the cooling unit case.
COOLING UNIT CASE
PACKING (INCLUDED IN KIT)
AU0659
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]
!
CAUTION
At this point, discontinue the work inside passenger compartment and move to the engine compartment.
AAAMC-94
16
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(NOTE)]
FROM INSIDE ENGINE COMPARTMENT
NOTE Make sure the A/C harness w is pulled out from the engine compartment.
A/C HARNESS 2
A/C HARNESS 2
NOTE Pull out the A/C harness w toward you.
FRONT
AU0687
(4)
COOLING UNIT CASE
REINSTALLATION OF THE COOLING UNIT NOTE
Use the following procedure to install the cooling unit case. q Insert the left side of the cooling unit case in the instrument panel.
NOTE
w
REINFORCEMENT
w Slide the cooling unit case edge towards the reinforcement while pulling the instrument panel towards you. e Insert the right side of the cooling unit case in the instrument panel.
COOLING UNIT CASE
OU0017
17
AAAMC-94
COOLING UNIT CASE BOSS FRS/REC CONTROL BOX
HEATER UNIT COOLING UNIT CASE INSERT t
AU0670
NOTE r With the cooling unit case pulled out to the front, lift upwards. (Lift so that the head portion of the cooling unit case is higher than the gap for the FRS/REC control box and heater unit.) t Push in towards the vehicle front, then the boss for the cooling unit case must be inside the hole for the FRS/REC control box. Align the hole in the cooling unit case with the stud bolt and insert.
AAAMC-94
18
COOLING UNIT CASE
NOTE y Put on the cooling unit case so that the stud bolts are inserted.
y
AU2839
FILTER CASE INSTALLATION SECTION CAUTION 1
CAUTION 2 CAUTION 1 u u
NOTE u Lift the filter case installation section upward so that the pawls do not interfere with the case and place the cooling unit case downward. i Push the whole cooling unit case behind through the pawls.
HOOK
! CAUTION
u
COOLING UNIT CASE
CAUTION HOOK HOOK
1. Move both the filter case installation section and cooling unit case slowly so that stress is not applied only to the pawl. 2. Never hold the middle part of filter case installation section with hands because it is easily damaged. NOTE o Engage the pawl catch and fix it.
! CAUTION
Engage the pawl catch only. (Do not pull the pawl forcibly because it is easily damaged.)
COOLING UNIT CASE
AU2841
19
AAAMC-94
COOLING UNIT CASE
TAPPING SCREW NUT (REUSE) (INCLUDED IN KIT)
TAPPING SCREW (REUSE)
NUT (REUSE) COOLING UNIT CASE NUT (INCLUDED IN KIT) TAPPING SCREW (REUSE) COOLING UNIT CASE
AU2842
CLOTH TAPE
(a) Reinstall the cooling unit case using three nuts and three tapping screws.
!
CAUTION
Be careful not to pinch the vehicle harness when reinstalling the cooling unit case.
AAAMC-94
20
VIEWED FROM ENGINE COMPARTMENT VEHICLE GROMMET
(5)
DRAIN HOSE (a) Pass the drain hose through the vehicle grommet.
! CAUTION
Take care not to bend the drain hose and make sure that the drain hose comes out from the bulkhead.
DRAIN HOSE FRONT
AU0660
CAUTION
DRAIN HOSE
Do not bend the drain hose. Make sure the prepared grommet is installed correctly.
BULKHEAD
GROMMET
AU0661
(6)
FILTER CASE
REINSTALLATION OF ORIGINAL PARTS q (a) Filter case
AU1535
COOLING UNIT CASE
(b) Vehicle harness clamp

VEHICLE HARNESS
COOLING UNIT CASE
OU0041
21
AAAMC-94
(c) Box
BOX
AU1408
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 in the figure on the left.
BOX
INSTRUMENT PANEL
NOTE w Lift upwards while pulling the box to the front.
LIFT UP w
BOX
NOTE
BOX r
e Rotate so that the box is facing the front in numerical order. r pull towards the box installation portion.
BOX INSTALLATION PORTION e

OU0033
AAAMC-94
22
NOTE t Reinstall the vehicle harness to the box and reconnect the connection of the vehicle harness.
t VEHICLE HARNESS BOX
OU0021
COOLING UNIT CASE
(d) Reinstall the vehicle bracket to the cooling unit case. (e) Reinstall two vehicle harness clamps to the cooling unit case.
FRONT

AC9071
(f)
Three bolts (for instrument panel)
AU0652
23
AAAMC-94
(g) Box or audio NOTE Reconnect the connector of the audio to the vehicle harness.
HOOKS
(h) Ashtray or coin holder
HOOKS
AU1529
(i)
!
ECU
CAUTION
Must be inserted in the ECU hole for the cooling unit case.
ECU
OU0015
AAAMC-94
24
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(7)] (7) WIRING q NOTE According to the vehicle production period, the ECU vehicle connector shape differs as in the left drawing.
ECU
TYPE [A] VEHICLE
TYPE [B] VEHICLE
VEHICLE CONNECTOR
VEHICLE CONNECTOR
2 ROW
4 ROW
AC9257
TYPE [A] ECU
NOTE
A/C HARNESS (INSIDE PASSENGER COMPARTMENT) PART NUMBER BLACK
According to the vehicle production period, the ECU vehicle connector shape differs as in the left drawing. Part number TYPE [A] ECU TYPE [B] ECU 88605-52130 (246460-7590) 88605-52220 (246470-1330) DENSO part number inside ( ).
BLACK
TYPE [B] ECU
A/C HARNESS (INSIDE PASSENGER COMPARTMENT) PART NUMBER BLUE
BLUE
AC9279
25
AAAMC-94
A/C HARNESS (INSIDE PASSENGER COMPARTMENT)

TO A/C AMPLIFIER TO VEHICLE CONNECTOR (6-P) (FOR BLOWER TO A/C HARNESS TO VEHICLE RESISTOR AND CONNECTOR BLOWER MOTOR) (INSIDE ENGINE COMPARTMENT) (26-P)
NOTE The figure shows the connections of A/C harness connector and terminal in the compartment.
FUSE TO A/C SWITCH TO THERMISTOR CONNECTOR

AU2905
TO VEHICLE CONNECTOR (6-P) TO VEHICLE CONNECTOR (22-P) TO VEHICLE (TO EFI ECU CONNECTOR) EARTH TERMINAL
TO A/C AMPLIFIER
(a) Insert the A/C harness q to inside of the instrument panel as shown in the left figure.
INSTRUMENT PANEL
A/C HARNESS q
AU2908
TO A/C HARNESS (INSIDE ENGINE COMPARTMENT)
VIEWED FROM METER OPENING AREA THERMISTOR CONNECTOR (2-P) A/C AMPLIFIER (14-P)
(b) Connect the A/C harness q to the thermistor connector. (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.
PLASTIC TIES A/C HARNESS q TO A/C SWITCH

AU1151
FRONT
(e) Pass the A/C harness q through the hole of the heater control assy.
HEATER CONTROL ASSY
A/C HARNESS q (3-P)
AU1152
AAAMC-94
26
COOLING UNIT CASE
(f)
PLASTIC TIE
Secure the A/C harness q to the vehicle harness using three plastic ties.
A/C HARNESS q
PLASTIC TIES
AU1153
PLASTIC TIE
A/C HARNESS 1 (6-P)
(g) Connect the A/C harness q to the vehicle harness and vehicle connector, then secure the vehicle harness using a plastic tie.
VEHICLE CONNECTOR VEHICLE HARNESS

AU1154
COOLING UNIT CASE
(h) Secure the A/C harness q to the cooling unit case using two plastic ties.
A/C HARNESS q
PLASTIC TIES
AU1155
BRANCH CONNECTOR
LEAD WIRE OF THE VEHICLE HARNESS (WHITE/BLUE)
(i)
Connect the A/C harness q to the lead wire (white/blue) of the vehicle harness using the branch connector.
!
CAUTION
Do not mistake the lead wire color.

30mm
A/C HARNESS 1
CONNECTOR (26-P)
NOTE See the P.1 for the connection of the branch connector.
AU1156
BRANCH CONNECTOR
27
AAAMC-94
(j)
VEHICLE CONNECTOR (22-P)
Lift the terminal stopper of the connector (22-P) with the precision (-) screwdriver. NOTE
Insert the precision (-) screwdriver to the gap for the terminal stopper, and lift the terminal stopper.
VIEW:A PRECISION (-) SCREWDRIVER GAP
AU1157
VIEW:A
TERMINAL STOPPER
VEHICLE CONNECTOR (22-P) (TO EFI ECU CONNECTOR)
1-P TERMINAL OF THE VEHICLE HARNESS (BLACK/WHITE)
VEHICLE WITH THE TERMINAL IS INSERTED IN THE VEHICLE CONNECTOR (22-P) ONLY [(k)~(m)]
(k) Pull out the terminal of two lead wires (black/white and white/red) of the vehicle harness from the vehicle connector (22-P). (l) Cut off the terminal from two lead wires of the vehicle harness. (m) Attach the vinyl tape around two lead wires of the vehicle harness.
LEAD WIRE VINYL TAPE CUT OFF 1-P TERMINAL OF THE VEHICLE HARNESS (WHITE/RED) TERMINAL
AU2366
BLACK/WHITE
CAUTION
WHITE/RED
Do not mistake the lead wire colors. (n) Insert the terminal of the A/C harness q to the vehicle connector (22-P).
!
1-P TERMINAL OF THE A/C HARNESS 1 (BLACK/WHITE) VEHICLE CONNECTOR (22-P) BLACK/WHITE
1-P TERMINAL OF THE A/C HARNESS 1 (BLACK)
CAUTION
Check the wire colors before inserting the terminal of the A/C harness q to the vehicle connector.
BLACK
VIEW:A PUSH PUSH
AU1158
(o) Restore the terminal stopper of the connector (22-P). NOTE Check to see that the terminal is locked.
VIEW:A
TERMINAL STOPPER
AU1159
PRECISION (-) SCREWDRIVER
AAAMC-94
28
(p) Reconnect the vehicle harness to ECU.
ECU
VEHICLE HARNESS
AU0667
(q) Install the A/C harness q together with vehicle earth terminal.
VEHICLE EARTH TERMINAL
A/C HARNESS q
AU1160
COOLING UNIT CASE
(r)
Secure the excess A/C harness q to the vehicle harness, using a plastic tie.
A/C HARNESS q
PLASTIC TIE
AU1161
FROM INSIDE ENGINE COMPARTMENT A/C HARNESS q
(s) Connect the A/C harness q to the A/C harness w.

!
CAUTION
Make sure that the A/C harness w pull out from the engine compartment.
PLASTIC TIE
(t)
Secure the A/C harness q to the vehicle harness using a plastic tie. NOTE
A/C HARNESS w A/C HARNESS q

AU1162
Perform this work after laying out A/C harness w. 29
AAAMC-94
A/C AMPLIFIER
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(8)] (8) WIRING w
SHORT CIRCUIT CONNECTOR
(a) Remove and discard the short circuit connector from the vehicle harness.
VEHICLE HARNESS
VEHICLE HARNESS (TO A/C AMPLIFIER)

AU2079
(b) Connect the vehicle harness to the thermistor connector. (c) Connect the vehicle harness to the A/C amplifier.
!
CAUTION
Connect when laying out the A/C harness w for vehicles made for Europe.
VEHICLE HARNESS
AU1539
(9)
A/C SWITCH VEHICLE WITH HEATER MODEL ONLY [(a)~(h)] (a) Temporarily remove the control knob from the center cluster panel.

AU0662
(b) Temporarily remove the switch module from the center cluster panel.
! CAUTION
Do not damage the hooks when removing the switch module.
HOOKS
SWITCH MODULE CENTER CLUSTER PANEL

AU0663
AAAMC-94
30
A/C SWITCH ORIGINAL COVER (DISCARD)
SWITCH MODULE
(c) Remove and discard the original cover from the switch module. (d) Assemble the A/C switch to the switch module.
A/C
AU0664
(e) Reinstall the switch module to the center cluster panel.
! CAUTION
The hooks must be inserted when installing the switch module.
HOOKS

AU0663
(f)
Reinstall the control knob (reuse) to the center cluster panel.

AU0662
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(g)] (g) Connect the A/C harness q to the A/C switch.
!
CAUTION
A/C HARNESS 1 (3-P) A/C SWITCH
Do not connect the vehicle harness (3-P) to the A/C switch.

AD1171
31
AAAMC-94
A/C SWITCH
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(h)] (h) Connect the vehicle harness to the A/C switch.

AU1522
SPRING
VEHICLE WITHOUT HEATER MODEL ONLY [(i)~(p)] (i) Install the spring to the control dial.
CONTROL DIAL
AU0673
(j)
BALL
Install the ball to the control dial.
! CAUTION
Do not drop the ball.
CONTROL DIAL
AU0674
FRONT
CONTROL DIAL ASSY q NOTE
(k) Insert the control dial assy to the heater control assy. NOTE Assemble the control dial assy by inserting the ball into the heater control assy from directly above. (l) Rotate the control dial assy until the ball is directly underneath.
!
VIEW : A
VIEW : A BALL CAUTION w
HEATER CONTROL ASSY
180 CONTROL DIAL ASSY
CAUTION
AU0675
HEATER CONTROL ASSY
AAAMC-94
32
FACE SIDE
CONTROL DIAL ASSY
(m) Push in the control dial assy once. The operator will watch the pushed-in status, and rotate clockwise until the lock is engaged.
HEATER CONTROL ASSY
LOCK
BALL CONTROL DIAL ASSY

AU0676
VIEWED FROM BACK SIDE OF HEATER CONTROL ASSY TAPPING SCREW ( 3 8) VIEW : B VIEW : B TEMPERATURE CONTROL RESISTOR HARNESS
(n) Route the temperature control resistor harness as shown in the left figure.
!
CAUTION
The pawl for the temperature control resistor harness must be installed on the heater control assy.
CAUTION HEATER CONTROL ASSY

AU0677
(o) Pull out the vehicle harness which is affixed with tape through the opening.
VEHICLE HARNESS (2-P) HEATER CONTROL ASSY

AU2083
HEATER CONTROL ASSY
(p) Connect the vehicle harness to the connector of the temperature control resistor.
AU2073
33
AAAMC-94
HOOKS
(q) Reinstall the center cluster panel. (r) Reinstall the center cluster lower panel. NOTE Insert the center cluster lower panel onto the reinforcement.
CENTER CLUSTER LOWER PANEL HOOKS
REINFORCEMENT OU0039 CENTER CLUSTER LOWER PANEL
VEHICLE WITH HEATER MODEL ONLY [(s)] (s) Reinstall two control knobs to the center cluster panel.

AU0650
CONTROL KNOB (INCLUDED IN KIT)
VEHICLE WITHOUT HEATER MODEL ONLY [(t)] (t) Reinstall the control knob (reuse), then install the control knob (included in kit). NOTE When installing the control knob (included in kit), set it to "MAX COOL".
!
CAUTION
AD1172
Note that assording to the vehicle type, the use control knob differs.
AAAMC-94
34
(10) REINSTALLATION OF ORIGINAL PARTS w VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(a)] (a) Reconnect the vehicle harness to ECU.
ECU
VEHICLE HARNESS
AU0667
(b) ECU harness cover
ECU HARNESS COVER
OU0007
(c) Meter
METER
NOTE Reconnect the connector of the meter to the vehicle harness.
AU0649
METER PANEL HOOKS
(d) Meter panel NOTE Reconnect the connector of the meter panel to the vehicle harness.
HOOKS
AU0668
35
AAAMC-94
GLOVE BOX
(e) Glove box
AU0669
HOOK CAUTION
(f) Cowl side panel (LH) (g) Scuff plate (LH)
! CAUTION
Make sure the clips are engaged with the cowl side panel and scuff plate.
SCUFF PLATE

SCUFF PLATE (LH)
AU0646
HOOK CAUTION
(h) Cowl side panel (RH) (i) Scuff plate (RH)
! CAUTION
SCUFF PLATE
AU0647
SCUFF PLATE (RH)
AAAMC-94
36
2. INSTALLATION INSIDE PASSENGER COMPARTMENT (2)

!
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)
HOOK CAUTION
REMOVAL OF PARTS (a) Scuff plate (RH) (b) Cowl side panel (RH)
SCUFF PLATE
! CAUTION A hook is interconnected to the cowl side panel, therefore, be careful when removing to prevent damage.
AU0647
SCUFF PLATE (RH)
HOOK CAUTION
(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 prevent damage.
SCUFF PLATE
SCUFF PLATE (LH)

GLOVE BOX
AU0646
(e) Glove box

BOSS w PUSH
BOSS e q PUSH
NOTE Remove the glove compartment in the following order. q Press in the sides of the glove compartment. w Bypass the bosses. e Lift.
PULL UP
OU0026
37
AAAMC-94
METER PANEL HOOKS
(f)
Meter panel
! CAUTION
Attach the cloth tape as shown, before removing the meter panel. NOTE Disconnect the connector of the meter panel from the vehicle harness.
HOOKS CLOTH TAPE
AU0648
METER
(g) Meter NOTE Disconnect the connector of the meter from the vehicle harness.
AU0649
VEHICLE WITH HEATER MODEL ONLY [(h)] (h) Control knobs (reuse)
AD1173
VEHICLE WITHOUT HEATER MODEL ONLY [(i)] (i) Control knob (reuse) and original cover (discard)

AD1180
AAAMC-94
38
CENTER CLUSTER PANEL CLOTH TAPE HOOKS
(j) Center cluster panel (k) Center cluster lower panel

!
CAUTION
Attach the cloth tape as shown, before removing the center cluster panel. NOTE
HOOKS CENTER CLUSTER LOWER PANEL
Disconnect the connector of the center cluster panel from the vehicle harness.
AD1174
NOTE
c CAUTION
Disconnect the connector of the center cluster panel from the vehicle harness. VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]
x VEHICLE HARNESS (3-P)
CAUTION
Connect the vehicle harness (3-P) to the original location in recovery.
z CENTER CLUSTER PANEL

AC9921
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY VEHICLE WITH HEATER MODEL ONLY NOTE
A vehicle harness from the A/C switch is connected to the center cluster panel. Be sure to remove this harness before proceeding with the work.

AU0651
(l) Ashtray or coin holder (m) Box or audio NOTE Disconnect the connector of the audio from the vehicle harness.
HOOKS
HOOKS
AU1529
39
AAAMC-94
HEATER CONTROL ASSY
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY VEHICLE WITH HEATER MODEL ONLY NOTE Pull the vehicle harness for the A/C switch to the front.
OU0030
(n) Three bolts (for instrument panel)
AU0652
(o) ECU harness cover
ECU HARNESS COVER
OU0007
(p) ECU NOTE Disconnect the vehicle harness from ECU.
ECU
AC9267
AAAMC-94
40
! CAUTION
VEHICLE HARNESS
Be careful when removing ECU to prevent damage.
ECU
AU0654
COOLING UNIT CASE
(r) Vehicle bracket (s) Two vehicle harness clamps NOTE Rotate the clamp counter-clockwise once and remove the vehicle harness clamp.
FRONT

AC9070
(r)
!
Vehicle harness clamp
CAUTION
VEHICLE HARNESS
Vehicle harness clamp must be removed with needle-nose pliers to prevent breakage of the clamp.
COOLING UNIT CASE
OU0040
41
AAAMC-94
(s) Box (t) Vehicle harness clamps NOTE Disconnect the connection of the vehicle harness, then temporarily remove the vehicle harness from the box.
BOX VEHICLE HARNESS
CAUTION
VEHICLE HARNESS CLAMPS
AU1404
w q
1. The clamps for the vehicle harness must be removed with needle-nose pliers to prevent breakage of the clamps. 2. Moving the storage tray simplifies removal of the vehicle harness clamps. (Refer to the following illustrations) 3. Be careful when moving the small parts box to prevent damage to other vehicle parts.
BOX
NOTE 1 Press-in the box one time to the vehicle front in numerical order, insert the needle-nose pliers from the bottom, and remove the vehicle harness q by tilting.
FRONT
VEHICLE HARNESS q
NOTE 2 Remove vehicle harness w in the same position as NOTE 1 .

BOX
FRONT VEHICLE HARNESS w
NOTE 3 Tilt the box to the front, insert the needle-nose pliers from the side, and remove the vehicle harness e.
BOX
FRONT
VEHICLE HARNESS e
OU0046
AAAMC-94
42
COOLING UNIT CASE DRAIN HOSE FLOOR CARPET
(u) Temporarily pull the floor carpet down, then temporarily remove the silencer mat. NOTE The floor carpet and silencer mat must be removed as far as necessary. (To simplify removal of the cooling unit case) (v) Drain hose (pull up the vehicle hole.)
SILENCER MAT
AU1406
COOLING UNIT CASE FRS/REC CONTROL BOX
(w) Remove and discard the lock clamp from connection part of the cooling unit case and FRS/REC control box. NOTE Push upward with a (-) screwdriver to remove the lock clamp.
LOCK CLAMP (DISCARD)
OU0028
VEHICLE HARNESS (6-P) (FOR BLOWER RESISTOR)
(x) Vehicle harness for blower resistor connection (Remove the connection for the cooling unit case.)
COOLING UNIT CASE

OU0029
FILTER CASE
(y) Filter case

KONB
NOTE Hold the left and right knobs at both ends of the filter case at the same time, and pull out the knob to the front.
KONB
OU0048
COOLING UNIT CASE
PULL
43
AAAMC-94
FILTER CASE FITTING PLACE HOOK CAUTION 2
HOOK
COOLING UNIT CASE
TAPPING SCREW NUT (REUSE) (DISCARD)
CAUTION 2 TAPPING SCREW (REUSE) NUT (REUSE) COOLING UNIT CASE

AU2837
NUT (DISCARD) TAPPING SCREW (REUSE) COOLING UNIT CASE
CLOTH TAPE
CAUTION 1
(z) Cooling unit case

!
CAUTION
1. Attach the cloth tape as shown, before removing the cooling unit case. 2. Follow the instructions specified in NOTE because the pawl of cooling unit case and the filter case installation portion are easily damaged.
AAAMC-94
44
NOTE
CAUTION HOOK HOOK
Remove the cooling unit case in the following procedures. q Remove the catch of pawl.
!
CAUTION
Unhook the catch of pawl and keep as it is. (Do not pull the pawl forcibly because it is easily damaged.)
COOLING UNIT CASE

FILTER CASE INSTALLATION SECTION CAUTION 1 w CAUTION 2
AU2364
NOTE
CAUTION 1 w
w Lift the filter case installation section upward so that the pawls do not interfere with the case and place the cooling unit case downward. e Pull the whole cooling unit case toward you through the pawls.
!
HOOK
CAUTION
COOLING UNIT CASE
COOLING UNIT CASE
1. Move both the filter case installation section and cooling unit case slowly so that stress is not applied only to the pawl. 2. Never hold the middle part of filter case installation section with hands because it is easily damaged. NOTE r Pull out the cooling unit from the stud bolts.
r
AU2702
45
AAAMC-94
NOTE t Lower the cooling unit case midway and hold it. (Do not lower all the way to the bottom.)
t
w
COOLING UNIT CASE COOLING UNIT CASE
NOTE y Take out the right side of the cooling unit case while pulling the instrument panel towards you.
INSTRUMENT PANEL
y PULL
COOLING UNIT CASE
INSTRUMENT PANEL
NOTE u Then, pull out the left side of the cooling unit case while pulling the instrument panel towards you, and remove the unit.
PULL
AU2838
VIEWED FROM METER OPENING AREA A/C AMPLIFIER
(2)
AMPLIFIER (a) Install the A/C amplifier to the FRS/REC control box using a tapping screw.
FRS/REC CONTROL BOX
FRONT
TAPPING SCREWS ( 4 10, SILVER)

AU0686
AAAMC-94
46
(3)
COOLING UNIT (a) Remove and discard the original packing from the cooling unit case.
COOLING UNIT CASE
ORIGINAL PACKING (DISCARD)
AU0658
(b) Temporarily remove the cooling unit upper case from the cooling unit lower case.

PLATE (DISCARD)
AD1181
(c) Remove and discard the plate from the cooling unit lower case.
TAPPING SCREW (DISCARD)
AU2072
47
AAAMC-94
(d) Cut the shaded portion shown in the illustration for the cooling unit upper case and cooling unit lower case.
CUT OUT COOLING UNIT LOWER CASE
CUT OUT
OU0031
THERMISTOR HARNESS
THERMISTOR HOLDER
(e) Assemble the thermistor harness to the thermistor holder. NOTE After the above is assembled, pull the tubing on the thermistor harness up to the thermistor holder.
THERMISTOR HOLDER
AU0681
TUBE
PULL UP
(f)
INSULATOR
Install the insulator to the cooling unit lower case.
OU0010
AAAMC-94
48
EVAPORATOR COOLING UNIT LOWER CASE
(g) Install the evaporator to the cooling unit lower case.
OU0011
(h) Reinstall the cooling unit upper case to the cooling unit lower case.

VIEW : A
AD1181
(i)
Install the thermistor assy to the cooling unit case.
COOLING UNIT CASE

VIEW : A CLAMP
THERMISTOR ASSY
AU1533
(j)
CLAMP
Secure the thermistor harness to the cooling unit case.
COOLING UNIT CASE
THERMISTOR HARNESS
AU1534
49
AAAMC-94
(k) Attach the packing on the cooling unit case.
COOLING UNIT CASE
PACKING (INCLUDED IN KIT)
AU0659
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(CAUTION)]
!
CAUTION
At this point, discontinue the work inside passenger compartment and move to the engine compartment.
AAAMC-94
50
FROM INSIDE ENGINE COMPARTMENT
NOTE Make sure the A/C harness w is pulled out from the engine compartment.
A/C HARNESS 2
A/C HARNESS 2
NOTE Pull out the A/C harness w toward you.
FRONT
AU0687
(4)
COOLING UNIT CASE
REINSTALLATION OF THE COOLING UNIT NOTE
Use the following procedure to install the cooling unit case. q Insert the left side of the cooling unit case in the instrument panel.
NOTE
w
REINFORCEMENT
w Slide the cooling unit case edge towards the reinforcement while pulling the instrument panel towards you. e Insert the right side of the cooling unit case in the instrument panel.
COOLING UNIT CASE
OU0017
51
AAAMC-94
COOLING UNIT CASE BOSS FRS/REC CONTROL BOX
HEATER UNIT COOLING UNIT CASE INSERT t
AU0670
NOTE r With the cooling unit case pulled out to the front, lift upwards. (Lift so that the head portion of the cooling unit case is higher than the gap for the FRS/REC control box and heater unit.) t Push in towards the vehicle front, then the boss for the cooling unit case must be inside the hole for the FRS/REC control box. Align the hole in the cooling unit case with the stud bolt and insert.
AAAMC-94
52
COOLING UNIT CASE
NOTE y Put on the cooling unit case so that the stud bolts are inserted.
y
AU2839
FILTER CASE INSTALLATION SECTION CAUTION 1
CAUTION 2 CAUTION 1 u u
NOTE u Lift the filter case installation section upward so that the pawls do not interfere with the case and place the cooling unit case downward. i Push the whole cooling unit case behind through the pawls.
HOOK
! CAUTION
u
COOLING UNIT CASE
CAUTION HOOK HOOK
1. Move both the filter case installation section and cooling unit case slowly so that stress is not applied only to the pawl. 2. Never hold the middle part of filter case installation section with hands because it is easily damaged. NOTE o Engage the pawl catch and fix it.
! CAUTION
Engage the pawl catch only. (Do not pull the pawl forcibly because it is easily damaged.)
COOLING UNIT CASE
AU2841
53
AAAMC-94
COOLING UNIT CASE
TAPPING SCREW NUT (REUSE) (INCLUDED IN KIT)
TAPPING SCREW (REUSE)
NUT (REUSE) COOLING UNIT CASE NUT (INCLUDED IN KIT) TAPPING SCREW (REUSE) COOLING UNIT CASE
AU2842
CLOTH TAPE
(a) Reinstall the cooling unit case using three nuts and three tapping screws.
!
CAUTION
Be careful not to pinch the vehicle harness when reinstalling the cooling unit case.
AAAMC-94
54
VIEWED FROM ENGINE COMPARTMENT VEHICLE GROMMET
(5)
DRAIN HOSE (a) Pass the drain hose through the vehicle grommet.
! CAUTION
Take care not to bend the drain hose and make sure that the drain hose comes out from the bulkhead.
DRAIN HOSE FRONT
AU0660
CAUTION
DRAIN HOSE
Do not bend the drain hose. Make sure the prepared grommet is installed correctly.
BULKHEAD
GROMMET
AU0661
(6)
FILTER CASE
REINSTALLATION OF ORIGINAL PARTS q (a) Filter case
AU1535
COOLING UNIT CASE
(b) Vehicle harness clamp

VEHICLE HARNESS
COOLING UNIT CASE
OU0041
55
AAAMC-94
(c) Box
BOX
AU1408
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 in the figure on the left.
BOX
INSTRUMENT PANEL
NOTE w Lift upwards while pulling the box to the front.
LIFT UP w
BOX
NOTE
BOX r
e Rotate so that the box is facing the front in numerical order. r pull towards the box installation portion.
BOX INSTALLATION PORTION e

OU0033
AAAMC-94
56
NOTE t Reinstall the vehicle harness to the box and reconnect the connection of the vehicle harness.
t VEHICLE HARNESS BOX
OU0021
COOLING UNIT CASE
(d) Reinstall the vehicle bracket to the cooling unit case. (e) Reinstall two vehicle harness clamps to the cooling unit case.
FRONT

AC9071
(f)
Three bolts (for instrument panel)
AU0652
57
AAAMC-94
(g) Box or audio NOTE Reconnect the connector of the audio to the vehicle harness.
HOOKS
(h) Ashtray or coin holder
HOOKS
AU1529
(i)
!
ECU
CAUTION
Must be inserted in the ECU hole for the cooling unit case.
ECU
OU0015
AAAMC-94
58
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(7)] (7) WIRING q NOTE According to the vehicle production period, the ECU vehicle connector shape differs as in the left drawing.
ECU
TYPE [A] VEHICLE
TYPE [B] VEHICLE
VEHICLE CONNECTOR
VEHICLE CONNECTOR
2 ROW
4 ROW
AC9257
TYPE [A] ECU
NOTE
A/C HARNESS (INSIDE PASSENGER COMPARTMENT) PART NUMBER BLACK
According to the vehicle production period, the ECU vehicle connector shape differs as in the left drawing. Part number TYPE [A] ECU TYPE [B] ECU 88605-52130 (246460-7590) 88605-52220 (246470-1330) DENSO part number inside ( ).
BLACK
TYPE [B] ECU
A/C HARNESS (INSIDE PASSENGER COMPARTMENT) PART NUMBER BLUE
BLUE
AC9279
59
AAAMC-94
A/C HARNESS (INSIDE PASSENGER COMPARTMENT)

TO A/C AMPLIFIER TO VEHICLE CONNECTOR (6-P) (FOR BLOWER TO A/C HARNESS TO VEHICLE RESISTOR AND CONNECTOR BLOWER MOTOR) (INSIDE ENGINE COMPARTMENT) (26-P)
NOTE The figure shows the connections of A/C harness connector and terminal in the compartment.
FUSE TO A/C SWITCH TO THERMISTOR CONNECTOR

AU2905
TO VEHICLE CONNECTOR (6-P) TO VEHICLE CONNECTOR (22-P) TO VEHICLE (TO EFI ECU CONNECTOR) EARTH TERMINAL
TO A/C AMPLIFIER
(a) Insert the A/C harness q to inside of the instrument panel as shown in the left figure.
INSTRUMENT PANEL
A/C HARNESS q
AU2908
TO A/C HARNESS (INSIDE ENGINE COMPARTMENT)
(b) Connect the A/C harness q to the thermistor connector. (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.
PLASTIC TIES A/C HARNESS q TO A/C SWITCH

AU1151
FRONT
(e) Pass the A/C harness q through the hole of the heater control assy.
HEATER CONTROL ASSY
A/C HARNESS q (3-P)
AU1152
AAAMC-94
60
COOLING UNIT CASE
(f)
PLASTIC TIE
Secure the A/C harness q to the vehicle harness using three plastic ties.
A/C HARNESS q
PLASTIC TIES
AU1153
PLASTIC TIE
A/C HARNESS 1 (6-P)
(g) Connect the A/C harness q to the vehicle harness and vehicle connector, then secure the vehicle harness using a plastic tie.
VEHICLE CONNECTOR VEHICLE HARNESS

AU1154
COOLING UNIT CASE
(h) Secure the A/C harness q to the cooling unit case using two plastic ties.
A/C HARNESS q
PLASTIC TIES
AU1155
61
AAAMC-94
! CAUTION
To plug branch connector connection and 1-P terminal of the A/C harness, carry out in to the left drawing connector.
ECU
VIEW:A
VIEW:A
ECU VEHICLE CONNECTOR (35-P)

AC9269
BRANCH CONNECTOR
LEAD WIRE OF THE VEHICLE HARNESS (WHITE/BLUE)
(i)
Connect the A/C harness q to the lead wire (white/blue) of the vehicle harness using the branch connector.
!
CAUTION
Do not mistake the lead wire color.

30mm CONNECTOR (31-P) A/C HARNESS 1
AC9270 BRANCH CONNECTOR
NOTE See the P.1 for the connection of the branch connector.
(j)
Lift the terminal stopper of the connector (35-P) with the precision (-) screwdriver. NOTE
VIEW:A VIEW:A PRECISION (-) SCREWDRIVER

AC9271
TERMINAL STOPPER
Insert the precision (-) screwdriver to the gap for the terminal stopper, and lift the terminal stopper.
GAP
AAAMC-94
62
1-P TERMINAL OF THE VEHICLE HARNESS (BLACK/WHITE) LEAD WIRE VINYL TAPE CUT OFF TERMINAL 1-P TERMINAL OF THE VEHICLE HARNESS (WHITE/RED) WHITE/RED
VEHICLE WITH THE TERMINAL IS INSERTED IN THE VEHICLE CONNECTOR (35-P) ONLY [(k)~(m)]
(k) Pull out the terminal of two lead wires (black/white and white/red) of the vehicle harness from the vehicle connector (35-P). (l) Cut off the terminal from two lead wires of the vehicle harness. (m) Attach the vinyl tape around two lead wires of the vehicle harness.
VEHICLE CONNECTOR (35-P) (TO EFI ECU CONNECTOR) BLACK/WHITE
CAUTION
AC9272
Do not mistake the lead wire colors. (n) Insert the terminal of the A/C harness q to the vehicle connector (35-P).
1-P TERMINAL OF THE VEHICLE HARNESS (BLACK/WHITE)
! CAUTION
Check the wire colors before inserting the terminal of the A/C harness q to the vehicle connector.
BLACK/WHITE
VEHICLE CONNECTOR (35-P) (TO EFI ECU CONNECTOR) 1-P TERMINAL OF THE VEHICLE HARNESS (BLACK)
AC9273
BLACK
(o) Restore the terminal stopper of the connector (35-P). NOTE Check to see that the terminal is locked.
VIEW:A VIEW:A
TERMINAL STOPPER
AC9274
(p) Reconnect the vehicle harness to ECU.
VEHICLE HARNESS ECU

AC9275
63
AAAMC-94
(p) Install the A/C harness q together with vehicle earth terminal.
VEHICLE EARTH TERMINAL
A/C HARNESS q
AU1160
COOLING UNIT CASE
(q) Secure the excess A/C harness q to the vehicle harness, using a plastic tie.
A/C HARNESS q
PLASTIC TIE
AU1161
FROM INSIDE ENGINE COMPARTMENT A/C HARNESS q
(r)
Connect the A/C harness q to the A/C harness w.
CAUTION
Make sure that the A/C harness w pull out from the engine compartment.
PLASTIC TIE
(s) Secure the A/C harness q to the vehicle harness using a plastic tie. NOTE
A/C HARNESS w A/C HARNESS q

AU1162
Perform this work after laying out A/C harness w. VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(8)] (8) WIRING w
A/C AMPLIFIER
SHORT CIRCUIT CONNECTOR
(a) Remove and discard the short circuit connector from the vehicle harness.
VEHICLE HARNESS
VEHICLE HARNESS (TO A/C AMPLIFIER)

AU2079
AAAMC-94
64
(b) Connect the vehicle harness to the thermistor connector. (c) Connect the vehicle harness to the A/C amplifier.
! CAUTION
Connect when laying out the A/C harness w for vehicles made for Europe.
VEHICLE HARNESS
AU1539
(9)
A/C SWITCH VEHICLE WITH HEATER MODEL ONLY [(a)~(h)] (a) Temporarily remove the control knob from the center cluster panel.
AD1175
(b) Temporarily remove the switch module from the center cluster panel.
!
CAUTION
Do not damage the hooks when removing the switch module.

HOOKS

AD1176
A/C SWITCH ORIGINAL COVER (DISCARD)
SWITCH MODULE
EXCEPT FOR AUSTRALIAN SPEC ONLY [(c)~(d)] (c) Remove and discard the original cover from the switch module. (d) Assemble the A/C switch to the switch module.
A/C
AU0664
65
AAAMC-94
A/C SWITCH
SWITCH MODULE
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.
AC9063
(g) Reinstall the switch module to the center cluster panel.
! CAUTION
The hooks must be inserted when installing the switch module.
HOOKS

AD1176
(h) Reinstall the control knob (reuse) to the center cluster panel.
AD1175
VEHICLE WITHOUT A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(i)] (i) Connect the A/C harness q to the A/C switch.
!
CAUTION
A/C HARNESS 1 (3-P) A/C SWITCH
Do not connect the vehicle harness (3-P) to the A/C switch.

AD1171
AAAMC-94
66
A/C SWITCH
VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(j)] (j) Connect the vehicle harness to the A/C switch.

AU1522
SPRING
VEHICLE WITHOUT HEATER MODEL ONLY [(k)~(r)] (k) Install the spring to the control dial.
CONTROL DIAL
AU0673
(l)
BALL
Install the ball to the control dial.
! CAUTION
CONTROL DIAL
AU0674
FRONT
CONTROL DIAL ASSY q NOTE
(m) Insert the control dial assy to the heater control assy. NOTE Assemble the control dial assy by inserting the ball into the heater control assy from directly above. (n) Rotate the control dial assy until the ball is directly underneath.
!
VIEW : A
VIEW : A BALL CAUTION w
HEATER CONTROL ASSY
180 CONTROL DIAL ASSY
CAUTION
AU0675
HEATER CONTROL ASSY
67
AAAMC-94
FACE SIDE
CONTROL DIAL ASSY
(o) Push in the control dial assy once. The operator will watch the pushed-in status, and rotate clockwise until the lock is engaged.
HEATER CONTROL ASSY
LOCK
BALL CONTROL DIAL ASSY

AU0676
VIEWED FROM BACK SIDE OF HEATER CONTROL ASSY TAPPING SCREW ( 3 8) VIEW : B VIEW : B TEMPERATURE CONTROL RESISTOR HARNESS
(p) Route the temperature control resistor harness as shown in the left figure.
!
CAUTION
The pawl for the temperature control resistor harness must be installed on the heater control assy.
CAUTION HEATER CONTROL ASSY

AU0677
(q) Pull out the vehicle harness which is affixed with tape through the opening.
VEHICLE HARNESS (2-P) HEATER CONTROL ASSY

AU2083
HEATER CONTROL ASSY
(r)
Connect the vehicle harness to the connector of the temperature control resistor.
AU2073
AAAMC-94
68
CENTER CLUSTER PANEL HOOKS
(s) Reinstall the center cluster panel. (t) Reinstall the center cluster lower panel. NOTE Insert the center cluster lower panel onto the reinforcement.
HOOKS
AD1177
CENTER CLUSTER LOWER PANEL
CENTER CLUSTER LOWER PANEL
VEHICLE WITH HEATER MODEL ONLY [(u)] (u) Reinstall two control knobs to the center cluster panel.
AD1173
CONTROL KNOB (INCLUDED IN KIT)
VEHICLE WITHOUT HEATER MODEL ONLY [(v)] (v) Reinstall the control knob (reuse), then install the control knob (included in kit). NOTE
SILVER OR GRAY
When installing the control knob (included in kit), set it to "MAX COOL".
CAUTION
Note that assording to the vehicle type, the use control knob differs.
AD1182
69
AAAMC-94
(10) REINSTALLATION OF ORIGINAL PARTS w VEHICLE WITH A/C CIRCUIT BUILT IN THE VEHICLE HARNESS ONLY [(a)] (a) Reconnect the vehicle harness to ECU.
VEHICLE HARNESS ECU

AC9275
(b) ECU harness cover
ECU HARNESS COVER
OU0007
(c) Meter
METER
NOTE Reconnect the connector of the meter to the vehicle harness.
AU0649
METER PANEL HOOKS
(d) Meter panel NOTE Reconnect the connector of the meter panel to the vehicle harness.
HOOKS
AU0668
AAAMC-94
70
GLOVE BOX
(e) Glove box
AU0669
HOOK CAUTION
(f) Cowl side panel (LH) (g) Scuff plate (LH)
! CAUTION
SCUFF PLATE

SCUFF PLATE (LH)
AU0646
HOOK CAUTION
(h) Cowl side panel (RH) (i) Scuff plate (RH)
! CAUTION
SCUFF PLATE
AU0647
SCUFF PLATE (RH)
71
AAAMC-94
[MEMO]
AAAMC-94
72
DENSO CORPORATION SERVICE DEPARTMENT

Kariya, Aichi, Japan
First Issue
: NOVEMBER 2002
Publication No. : AAAMC-94
Printed in Japan
AAAMC-94
BOLT LENGTH RULER (mm)
90
80
70
60
50
40
30
20
10
(mm)
BOLT DIAM. & HEX. HEAD (mm)
M5
M6
M8
M10
M12
M14
AAAMC-94 988963-6050

Airco Passenger Kit RHD Aaamc94

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Airco Passenger Kit RHD Aaamc94

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INSIDE PASSENGER COMPARTMENT

Instruction of branch connector connection

PERMANENT FASTENING LOCK SECTIONS

A SECTION CONNECTING WIRE HARNESS

PRODUCT SIDE WIRE HARNESS

TYPE [A] VEHICLE

TYPE [B] VEHICLE

1. INSTALLATION INSIDE PASSENGER COMPARTMENT (1)

COWL SIDE PANEL (RH) HOOKS

SCUFF PLATE (RH)

COWL SIDE HOOK PANEL

COWL SIDE PANEL (LH) HOOKS

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

HOOK COWL SIDE PANEL

SCUFF PLATE (LH)

(e) Glove box

METER PANEL HOOKS

CENTER CLUSTER PANEL

CONTROL KNOBS (REUSE)

CENTER CLUSTER PANEL

CONTROL KNOB (REUSE)

ORIGINAL COVER (DISCARD)

CENTER CLUSTER PANEL CLOTH TAPE

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

x VEHICLE HARNESS (3-P)

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

z CENTER CLUSTER PANEL

CENTER CLUSTER PANEL

VIEW : A BOX OR AUDIO

VIEW : A ASHTRAY OR COIN HOLDER

HEATER CONTROL ASSY

VEHICLE HARNESS (3-P)

(n) Three bolts (for instrument panel)

BOLTS (FOR INSTRUMENT PANEL)

(o) ECU harness cover

ECU HARNESS COVER

(p) ECU NOTE Disconnect the vehicle harness from ECU.

Be careful when removing ECU to prevent damage.

COOLING UNIT CASE

VEHICLE HARNESS CLAMP

VEHICLE HARNESS CLAMP

Vehicle harness clamp

COOLING UNIT CASE

VEHICLE HARNESS CLAMPS

NOTE 2 Remove vehicle harness w in the same position as NOTE 1 .

FRONT VEHICLE HARNESS w

COOLING UNIT CASE DRAIN HOSE FLOOR CARPET

COOLING UNIT CASE FRS/REC CONTROL BOX

LOCK CLAMP (DISCARD)

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

COOLING UNIT CASE

(y) Filter case

COOLING UNIT CASE

FROM METER OPENING AREA

FILTER CASE FITTING PLACE HOOK CAUTION 2

COOLING UNIT CASE

TAPPING SCREW NUT (REUSE) (DISCARD)

FROM BOX OPENING AREA

CAUTION 2 TAPPING SCREW (REUSE) NUT (REUSE) COOLING UNIT CASE

NUT (DISCARD) TAPPING SCREW (REUSE) COOLING UNIT CASE

(z) Cooling unit case

COOLING UNIT CASE

COOLING UNIT CASE

COOLING UNIT AU2929 CASE