Air Conditioning Unit (For Manual Air Conditioning System) Removal


  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. DISCONNECT SUCTION TUBE SUB-ASSEMBLY (w/ Air Conditioning System)

  4. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning System)

  5. DISCONNECT WATER HOSE SUB-ASSEMBLY

  6. DISCONNECT WATER HOSE SUB-ASSEMBLY B

  7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

  8. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER

  9. REMOVE NO. 2 HEATER TO REGISTER DUCT

  10. REMOVE NO. 1 HEATER TO REGISTER DUCT

  11. REMOVE NO. 3 HEATER TO REGISTER DUCT

  12. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY

  13. DISCONNECT STEERING COLUMN ASSEMBLY

  14. REMOVE ECM

  15. REMOVE NO. 1 AIR DUCT

  16. REMOVE NO. 2 AIR DUCT

  17. REMOVE NO. 4 AIR DUCT

  18. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (w/ Air Conditioning System)

  19. REMOVE NO. 1 COOLER UNIT DRAIN HOSE

  20. REMOVE INSTRUMENT PANEL REINFORCEMENT

  21. REMOVE AIR CONDITIONING UNIT ASSEMBLY

Air Conditioning Unit (For Manual Air Conditioning System) -- Removal



1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

  1. Start up the engine.

  1. Turn the A/C switch ON.

  1. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

  1. Stop the engine.

  1. Using SST, discharge the refrigerant gas.

    SST
    09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.


3. DISCONNECT SUCTION TUBE SUB-ASSEMBLY (w/ Air Conditioning System)


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the bolt and disconnect the suction tube.

    NOTICE:
    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal
    1. Do not use a screwdriver or similar tool to disconnect the tube.
    1. Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  1. Remove the 2 O-rings from the suction tube.



4. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (w/ Air Conditioning System)
HINT:
Use the same procedures described for the suction tube.


5. DISCONNECT WATER HOSE SUB-ASSEMBLY


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Using pliers, grip the claws of the clip and slide the clip to detach the water hose.

    HINT:
    Collect the engine coolant in a container.


6. DISCONNECT WATER HOSE SUB-ASSEMBLY B
HINT:
Use the same procedures described for the water hose.


7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY UPPER

  1. Remove the instrument panel upper (Toyota Fortuner RM000000SQC007X_01_0111.html).



8. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER

  1. Remove the instrument panel lower (Toyota Fortuner RM000000SQH004X_01_0029.html).



9. REMOVE NO. 2 HEATER TO REGISTER DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the clip and duct.



10. REMOVE NO. 1 HEATER TO REGISTER DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Detach the 3 claws and remove the duct.



11. REMOVE NO. 3 HEATER TO REGISTER DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Detach the 4 claws and remove the duct.



12. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the 3 nuts, 2 bolts, 2 clamps and instrument panel brace.

  1. Disconnect the connectors and remove the instrument panel junction block.



13. DISCONNECT STEERING COLUMN ASSEMBLY


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the 3 bolts and cover.

  1. Remove the 3 bolts and pull out the steering column together with the steering sliding with coupling yoke.



14. REMOVE ECM
For 1GR-FE, refer to the following procedures (Toyota Fortuner RM000000VW200DX.html).
For 1KD-FTV, refer to the following procedures (Toyota Fortuner RM0000013Z0004X.html).


15. REMOVE NO. 1 AIR DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Detach the 2 claws and remove the duct.



16. REMOVE NO. 2 AIR DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Detach the 2 claws and remove the duct.



17. REMOVE NO. 4 AIR DUCT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Detach the 2 claws and remove the duct.



18. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (w/ Air Conditioning System)


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Detach the clamp.

  1. Disconnect the connector.

  1. Remove the screw and A/C amplifier.



19. REMOVE NO. 1 COOLER UNIT DRAIN HOSE


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Remove the drain hose.



20. REMOVE INSTRUMENT PANEL REINFORCEMENT


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Disconnect the connector, 2 clamps and wire harness.



    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Disconnect the connector and wire harness.

  1. Detach the 3 clamps.



    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the 2 bolts and disconnect the ground wires from the instrument panel reinforcement.



    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal

  1. Remove the grommet from the vehicle body.

  1. Release the 12 clamps.



  1. Disconnect the connectors.


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal



  1. Remove the 3 bolts.


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal



  1. Remove the 7 bolts and instrument panel reinforcement.


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50.Air Conditioning.Air Conditioning Unit (For Manual Air Conditioning System).Air Conditioning Unit (For Manual Air Conditioning System) Removal



21. REMOVE AIR CONDITIONING UNIT ASSEMBLY


    Toyota Fortuner. Ggn50, 60 Kun51, 61 Tgn51 Lan50

  1. Remove the bolt, nut and A/C unit.