03 Gen4 V8 Ltd - Evaporator replacement
 

I am really, really hating this car. Anything expensive that can go wrong is going wrong in spite of only have 110k miles on it.

Latest I believe is the A/C evaporator I think has let go. Get this horrible smell everything I use the car from the heating system.

When I thought replacing the evaporator on my late 1990 Volvos were bad this is way worse.

From those who have tackled this before, what parts should I replace other than the core and any 'O' ring seals it has. As it is a huge job I do not want to go in there again anytime soon, so is there any thing else that should be done while in there? I have read some other general posts about replacing some valve of some sort not sure what. There does not appear to be any good write ups on the subject or You Tubes.

Should the drier be replaced as well? I have done this on other vehicles as part of the repair.

A 2nd question is to do with the A/C itself. When the A/C was running it makes an annoying whistling noise. Is there a flap somewhere that needs adjustment or replacing?

Any help much appreciated.

Still waiting for my Doug Thorley shortie headers. Ordered mid-May 2022, now told maybe end Jan/early Fed 2023!!

Neil.

Should of added, is there a brand other than OE Toyota anyone would recommend? Up here OE part cheapest price I can find is $750 CDN. I think I have found a place that may be able to supply a Denso one, for around $180 CDN, but if they cannot what other brand(s) should I look at? Nissens?

Thanks,

Neil.

I can't recommend too much..but the one thing I would recommend is to also replace the heater core as it's housed in the same enclosure as the evaporator, if not replaced and it starts leaking later you will have to do the same job again to replace the core.

Not sure on any other brands but I would try your best to get the Denso part if at all possible!

My man, you are in for a world of hurt. I had to replace the evaporator core 2 years ago (18 years of faithful service, can’t complain).

All I can say is go OEM, and replace it all. Servos, heater core, compressor all of it. Make sure you suck the crap out of your lines also.

I know it’s expensive, but don’t **** around. I opted to get the shop in town to do it, taking dashes apart gives me the Heebee jeebee’s.

Thanks guys for input. As I have already replaced the X-REAS suspension and have to pay someone to do the exhaust manifolds as well (about $5000 CDN), paying someone else to do the job would be great, especially using OE parts. However the prices of OE parts for Toyotas are just plain stupid now like most OE parts. Parts alone for the Heating/AC you suggest would be in the $1000's. I still don't know why people think these are worth so much, especially when I clearly paid way too much for the car from a main dealer for a supposedly low mileage, fully serviced (it wasn't) vehicle. For what I have already spent on this car in the last 4 years and only driven about 15k miles, I could have bought a much newer vehicle. I would sell it in a heartbeat if major stuff didn't keep failing which makes it worthless compared to what I have into it.

I will do the work on the AC/heating stuff. The heater matrix does sound like a good idea though.

Thanks,

Neil.

I just did this job on an '05 V6. Replaced evaporator, expansion valve and desiccant element - all Denso sourced from Rock Auto. Used the Four Seasons complete system O-Ring and Seal kit and replaced all the seals where I took anything apart. Did not replace the seals that I didn't touch. Even though it was in good shape, I ended up replacing the condenser because I couldn't get the nylon plug out to replace the desiccant element. It was seized. Your whistling may be debris, missing gasket or bad door seal in the air box or the duct system. You will have it all apart so you can do a good visual inspection and clean it all up. Basically you have to remove all the dash components to the firewall to remove the air box which contains the evaporator. Not a difficult job, just tedious. Info on the job in the Maintenance sticky on this forum. I used the FSM which lays it out step by step but it does bounce you from section to section.

Here's a video on removing the evap core.

https://www.youtube.com/watch?v=A2l_7i59FXQ

You're basically taking the entire dash apart. Yea, I'd only want to do that once.

Thanks guys. Before I jump into this I want to make sure it is the issue. I don't have the kit, so I have booked it into the local dealer where I bought it from and the head mechanic will diagnose for 1/2 hr labor.

Not sure if the 2 are related, but I have noticed since this started (maybe a coincidence), when idling at traffic lights, A/C not on, engine up to temp, the idle speed rises about 200 rpm for a short time and then drops back to normal as if the A/C compressor is kicking in. Still don't understand why such a big engine needs to raise the revs to run the AC compressor?

Really appreciate the help and guidance to a newbie to working on old 4Runner!

Neil.

I did this last year in my '08 V6, it's not that bad just time-consuming. I replaced the evaporator core, expansion valve, seals, Schrader valves and the condenser (came with new drier).

Heater core looked great. Used Denso for evaporator core and condenser. I also had my dealer diagnose it to confirm and to ensure the system had dye for troubleshooting.

Not fun but take your time and label everything well makes it very doable. PM if you get stuck.

Thanks guys. Well took the car to Toyota dealer where I bought it for a diagnostic. They say everything is fine and AC is working fine??? They had a good look around and cannot find any leaks under the car. I am now happy but totally baffled. Smell seems to have dissipated now. I may have dodged a bullet this time, well for now anyway.

I appreciate all the support and input. At least I know what to plan for in the future when it does happen.

Neil.