Hi All,

Need some brain-power help. I have the dreaded A/C Evap leak on my 06 T4R and it looks like I'm in it to fix it myself.

Does anyone have a step-by-step tutorial on this? I couldn't find anything

Do I REALLY need to tear it down to the firewall to get to it?

What else should I replace while I've torn everything apart?

Lessons Learned?

Grab the because I will be the project and need a when I'm done and a big

I'm trying to find something to help you out but not having much luck as of yet.

In the meantime you can check out this video which shows a little bit of what you have to look forwards too in doing this yourself, this video is on a 2007 Toyota FJ Crusier, which I would guess is similar to what you are going to have to do.

https://youtu.be/UKr5LlzM15k

Another video on 2005 4 Runner, not much help in a step by step, but it will show you what it will look like by the time you get the evaporator out, basically nothing left but the firewall where the dash was.

https://youtu.be/ILjLUareKHU

That's NUTS!

Yes I agree, totally NUTS!!
But if you're up to the task you will avoid paying a $2000 to $3000 final bill if you got a Dealer to do the job, not to sure you would save much by getting an independent garage to do the work, if they're good and know what they're doing they will charge similarly to what a Dealer would charge.

Is this your ride or your wife's, I would prefer it being mine and not my wife's if I was in the same situation, I could live without AC if I had too but not the wife, I would never hear the end of it if I didn't fix her AC!!!

If you do decide to do this yourself, PLEASE document it for the forum, maybe as you're doing it and you may also get some technical advice from others if you get stuck on something to help you along the way, as you know there doesn't seem to be a "step by step" totorial for this on the forum and not even the internet, at least not that I could find so far, I'm still looking to try and help you out!!

I've been getting my A/C recharged at cheapest place every now and then - sometimes it last 3 months, sometimes a year or two, they always say they find no leak therefore I assume it's an "evap" leak, not detectible with their $0.02 smoke test?

I've replaced my stock navi, ran mic/antenna wires up pillars, drilled hole into the console to install inputs etc. so I have no qualms about SOME interior dash disassembly but I'm not about to take the WHOLE dash, steering, airbags, etc. out...Am I crazy or is this worth the money? Right now, I'd rather just recharge it as needed for $30 or whatever, even twice a summer if need be.

Is this the symptom you were experiencing? A/C just went out way too often? I only need A/C in summer, live in Kentucky so that may make a difference. Thanks for this post

EDIT: after searching I assume you're getting an actual CEL evap code...? I never got one but there's some issue because I shouldn't get the dreaded smell and hot air from bad A/C as often as I do.. Thanks again for posting any replies/help, if not, i'll just keep recharging as needed, NBD.

way to go dude....wanted to replace it myself, but lack of step by step videos/instructions dissuaded me. grew cold feet when i saw the amount of work involved
i was or rather am in the same boat with you.
after getting pissy refills that lasted barely 3months from technicians.
i learnt how to refill it myself, got a vacuum pump , a kg scale and the other tools, and started taking care of business myself.....
my ac refills lasts me 10 to 12months now, got the truck in 2012, ac issue became pronounced late 2014, and i started diy refill in 2015 i intend to sell the truck in 2 or 3 yrs time, so fingers crossed

nb: if you are in the usa and hvnt done the dashboard replacement recall, you could have the evap replaced for free then.

I discovered mine was leaking a few months after I got my unit. I had bought it in the dead of winter and really couldn't test the ac when it was 11°!

My local garage had a hard time tracking the the leak until they put the light way up under the dash and got a reaction from the dye.

It cost me $900 to have it down. I'm sure the Toyota dealer would have charged triple that.

If you can do itself more power to you! I didn't have the heart to do a dash tear down.


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There have been several fourm members that checked to see if they could have the evaporator replaced for a discounted price during the free dash replacement and the dealers were going to charge them more or less the going rate to do the evaporator, so I wouldn't count on that happening unless you have a dealer that is not of the norm as far as dealers go!!

That being said there's a lot more to take apart doing the evaporator than to do the dash replacement but considering that they would be about a 1/4 of the way there doing the dash they would discount the job of doing the evaporator to some degree.

For anybody who has dealt with this: what's the best way to confirm that it is, in fact, the evaporator leaking? I've got a leak that my mechanic cannot confirm is the evaporator...no dye is showing up at the condensate drain, and looking up under the dash with a UV light doesn't seem to help either. I'm not terribly excited about proceeding with a replacement without absolute confirmation that's the problem.

To confirm evaporator leak you have two choices, (maybe more). Either have dye added to the freon and check with a black light or use a sniffer. Either way you will be checking at the condensation drain underneath the vehicle. You know, where the water drips out when you run the a/c. At least that's how I've always done it. Hope this helps.

Would you say this is most likely an evaporator leak? I just added a couple of cans of freon/dye yesterday and after a night and a drive to work I've got green freon down my step bar on my passenger side and green stuff leaking in my front wheel well. I'm thinking this is my condenser drain tube right above my right front tire.

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Yes that is the AC drain and yes it looks like your evaporator is leaking.

Its not that bad. More time consuming than difficult. I did it to my 05 a couple years ago. i also had a friend to help. him on passenger side, i was on driver side. we followed the factory manual on how to do it. started around 8-9am. had the dash out and evap changed by lunch around 1. then reassembled. we also changed out the compressor, expansion valve(DO THIS!!), and condenser. All was done by 7pm but one bolt on the compressor didn't fit the new compressor. it was too short. So it wasn't until the next day i went to lowes and got a longer bolt. Then i charged it up with about three cans of Freon and its been running fine since.

I will also say the leaking drain is the for sure sign.

I got all the parts from rock auto for around 400 bucks. better than 1500-2500 by having somebody else do it.

proper planning and give yourself time. you'll be fine.

Just curious, why do you advocate replacing the expansion valve? I know it's a cheap part (like $20 on rockauto), but aside from that I don't think they're very prone to failure from my research. Just as a "while you're in there" sort of thing, or do you have experience of those failing on 4th gens?