Sup guys, I'm thinking about trying to replace my evaporator core myself. There's not much online about the details, but I'm going to see how far I can get and try to document as much as I can. I'm going to start tomorrow hopefully and at least get the dash out. I've just recently graduated college and have more than enough time on my hands, so I'm fine with it taking multiple days to complete.

Hopefully I can get it done within a week.

Be sure to label everything you take apart and photos as well so you don't have too much trouble reassembling it all!

Hey guys, day one on the evaporator core replacement is coming to a close. I'm waiting to pick up the new core tomorrow. I'll post some pics of what I had to do and show where I'm at now. I have pretty much every bolt/screw in a labeled bag.

Removed lower cover under steering wheel
Imgur: The magic of the Internet

Removed metal piece under that
Imgur: The magic of the Internet

Popped off center console bezels (Ignore extra wires)
Imgur: The magic of the Internet

Removed rest of center console
Imgur: The magic of the Internet

Removed Center dash cubby and hvac controls
Imgur: The magic of the Internet

Removed Center dash bezel
https://imgur.com/wiiiLHv

Removed Radio
https://imgur.com/gEBmMcP

Removed trim around gauges (no bolts)
https://imgur.com/Sp9FTnR

Removed trim piece under glove box, glove box and cubby above glove box (was intimidated by gauges at first)
https://imgur.com/3WQr16j

Finally removed gauges (two bolts at top release wire harness)
https://imgur.com/htARDkN
https://imgur.com/7hetsZY

Next, removed passenger side air vent and took out all bolts holding the actual dash in place so as to get it fully removed
https://imgur.com/Yqu5aAy

Had to get some deep well sockets to release steering column so I could get the dash brace to move.
https://imgur.com/EYFpkQJ

At this point, I was a little frustrated and the pictures are less frequent. I disconnected the fuse box, ecm, and anything else that the large brace was connected to. There are a few bolts on either side that are accessible from the door jam that I removed and/or loosened to help free the brace. There are also brackets going to either side of the trans tunnel that needed to be removed.

After I had some play in the brace, I went around the heater box and evaporator and unbolted anything that was holding them in. I managed to get each of them out finally.
https://imgur.com/EfyyBI7
https://imgur.com/oA9SvLK
https://imgur.com/FGnooHK
https://imgur.com/1RguBgH

The evaporator has screws running down the middle that need to be removed in order to get inside to the core. I had to remove a servo in order to rotate a fin to pull it apart.
https://imgur.com/BNz7xzl


Here is the busted core, which i will be replacing and reassembling tomorrow.
https://imgur.com/cwMUG6y


If there is anything that is unclear or any questions, just let me know. I know that I didn't do the best job documenting the process, but I figured it's a lot better than anything I've been able to find. I'm flying mostly blind on this but it's coming along alright.

I’m doing this exact same repair very soon. Thanks for the tread. I looked through the factory service manual and I’m not looking forward to doing this but I also didn’t want to part with $1000 to have a repair shop do it. Looking forward to seeing your progress.

It definitely can look and feel intimidating at times. I don't have any special tools and I have rarely looked to the FSM for guidance honestly. Just make sure you have some deep well sockets as there's plenty of nuts where you'll need them. I worked in a mechanic shop last summer and winter break during school so I felt pretty confident going in, but just make sure to take your time and keep everything organized. I managed to get the evaporator out completely in about 3 1/2 hours. I figure I can get everything re-assembled in 4-5 hours hopefully

Just finished getting everything put back together and A/C charged up. Blowing cold and will update in a day or two to report if it's staying cold. If anybody wants I can post the few pictures that I have but it was basically going in the reverse order of taking it apart. I kinda got carried away and didn't take too many pictures along the way of reassembly, so I apologize for that.

Only big hiccup was getting the main brace that goes across the entire width of the car back in place but it wasn't anything major. Overall took me probably 5 hours to completely reassemble and have it parked back in the driveway, totaling about 8 1/2 hours of work in all.

I haven't read your process in it's entirety but I will when I have more time, but did you also replace the heater core while you had it apart?

Nope, my mechanic told me he heard what sounded like knocking when I left it or him to diagnose a/c problem. I was going to have another shop do the work and fork over $1000+ but I decided if it was gonna kick the bucket sooner before later then I would try to do it myself. I really want to spend as little as I can on it for the time being just so I don’t end up dumping a bunch of money into it the. The motor blowing

8 1/2 hours total, that’s pretty good. I’ve set aside a whole weekend to do this job haha. I like to consider myself mechanically inclined but with something that deep in the bowels of the dash I want to really take my time. Looking forward to the update to see if it’s still working well for you.

I really appreciate you taking the time to grab pics for this, thats awesome! A tip is that you can embed the images from imgur into your post using the html link in imgur and pasting it into the forum. It will look like this when you paste the text into the edit window:
You can change the size at the bottom of the imgur window, I like medium and large thumbnails. If you want to change size on the fly, change the letter at the end of the src section to t=small, m=med, L=large, h=huge. Hopefully the asterisk is lined up correctly over the letter I'm referencing, I think it should be monospaced text.
And then when you preview or submit, it will look like this:

Everything has to come apart

I replaced the AC compressor on my 2005 4runner, and it's been holding the "cool" for two years. The new compressor at Amazon was $200.

Compressors have a hundred rubber seals in them, that is why when they fail and leak the refrigerant you buy only new replacement compressor.

puttin my truck back together after installing new evaporator. there is a wiring connector on passnger A pillar that i can't find the other side for. anyone know what it is for?

This guy does a 2006 4runner evaporator replacement in 15 minutes in this youtube.

I have a 2005 4runner an mine needs a new Denso evaporator - $101 at Amazon

youtube 2005 4runner evaporator AC - Bing video

well i found what i was looking for and i got it all back together, but for some reason the truck doesn't start. Im almost 100% sure i got all the electrical connectors back together.i'm about to freak. the truck will turn over but just won't start. anyone have a clue what it could be?