AIR CONDITIONING

ENGLISH

EUROPE

INSIDE PASSENGER COMPARTMENT & INSIDE ENGINE COMPARTMENT

TOYOTA

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 drivers 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

DOCUMENT CODE

DOCUMENT PART NUMBER

GENERAL INFORMATION /
AFTER INSTALLATION

AOAMC-01*

988963-475*

2001 DENSO CORPORATION

All Rights Reserved. This book may not be reproduced or copied,
AAAMC-22

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

-200500075

(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.

(l) Vehicle harness connector (4-p)

(m) Vehicle harness clip

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.

-500500075

(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.

-600500075

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)

-700500075

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.

-800500075

(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)

-900500075

Wrap the packing (Small) to the branch

connector as shown.

- 10 00500075

(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.

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(d) Hood lock

(e) Harness clip & horn connector

(f) Bumper clip (Right & Left)

(g) Center brace tightening bolts.

NOTE
Attach 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.

(i)

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Put the brace as shown.

(j)

(2)

Radiator fan shroud

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

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

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