DIY Complete AC Replacement on 2000 T4R Limited

[BamaDrewski]

Can anyone shed some light on how much oil needs to be in the compressor? The book that came with my new denso compressor says to pour out the oil form the old compressor and match the amount with the new one. It barley had any in it and i had a line leak last year so i am sure i lost some.

Compressor Priming

I purchased the compressor from Amazon. It’s the Deno 10PA version and is an exact match to the original one on the truck. You have to relieve the pressure on the unit when it arrives, take off the shipping plate and pour out the factory oil. It had 100cc’s in it. I replaced it with PAG46 (with dye) from Advance. YOU MUST REUSE THE OLD COMPRESSOR MANIFOLD PLATE. Simply take off the old plate, clean it up, replace the compressor gasket (comes with the compressor) and use the old compressor bolts to attach the old manifold plate to the new compressor.

Everything is back in. From here, take it to a shop and have them vacuum down the system for about an hour. The system only takes about 1.5lbs of R134a and a good shop can make sure it is "metered in" in the right amount and flow. With all new components, there is no need to use that "leak seal" stuff. Hope this has been a helpful write-up. Feel free to contact me with any questions.

 

[Noonan11]

Thanks for the write up. I’m just about to do the same thing on my AC system. I lost all my Freon after recharging my system a little over a month ago. Just decided it was easier to replace all of the key components and do it myself. This is a pretty big job for me, I think, so appreciate the info!

 

[BamaDrewski]

Thanks for the write up. I’m just about to do the same thing on my AC system. I lost all my Freon after recharging my system a little over a month ago. Just decided it was easier to replace all of the key components and do it myself. This is a pretty big job for me, I think, so appreciate the info!

If I can help you though it....let me know. Just PM me....

 

[BamaDrewski]

Thanks for the write up. I’m just about to do the same thing on my AC system. I lost all my Freon after recharging my system a little over a month ago. Just decided it was easier to replace all of the key components and do it myself. This is a pretty big job for me, I think, so appreciate the info!

You will never regret "re-building" the entire AC system. As I mentioned in a previous post, it is not difficult but it is time-consuming. I am geeked up that this post was helpful. Again, if I can do anything to help, PM me on this site. I do not check it often so forgive me if you message me and I do not respond immediately. I also have a spreadsheet of all the items (+part numbers and vendors) I purchased and where I purchased them from. As strong as our rigs are, by investing in good Denso parts and TAKING YOUR TIME, you will have a virtually new system that serves you for years to come!

 

[BamaDrewski]

Thanks for the write up. I’m just about to do the same thing on my AC system. I lost all my Freon after recharging my system a little over a month ago. Just decided it was easier to replace all of the key components and do it myself. This is a pretty big job for me, I think, so appreciate the info!

For what it is worth, I did this complete rebuild on the AC 4 years ago and it still blows at 38 degrees on the coldest setting. I have a spreadsheet of the components (with part numbers) and where I bought them. If you need it, PM me and I will email it to you (or anyone who wants the info).

 

[octanejunkie]

Here is the breakdown of the costs for everything. My buddy has a SnapOn system that vacuums, adds oil, checks for leaks, puts in R134a and he did it for free. I am now getting frostbite in my truck!

Item Part # Brand Amazon
AC Compressor with Clutch 88310-35770-84 Denso $195.71
Condenser 477-0518 Denso $62.68
Evaporator Core 88501-35050 Denso $133.62
Expansion Valve 88515-22240 Denso $28.12
Pressure Switch 88645-04040 Santech $16.90
Receiver/Drier 88471-34010 Denso $17.82
O-Ring Kit FourSeasons $12.00
Aerosol AC PRO Flush AC Pro $18.00

TOTAL $594.84

Updated Amazon prices (many with new part numbers)

Item Part # Brand Amazon
AC Compressor with Clutch Denso 471-1164 Denso $190.78
Condenser 477-0518 Denso $58.02
Evaporator Core 476-0019 Denso $121.15
Expansion Valve 475-0505 Denso $27.33
Pressure Switch 88645-04040 Denso $25 eBay (couldn't find on Amazon)
Receiver/Drier 478-0500 Denso $14.08
O-Ring Kit FourSeasons 26749 $12.08
Aerosol AC PRO Flush AC Pro $18.00 (auto part store?)

Surprisingly, most of these parts actually went down in price!

 

[BamaDrewski]

Updated Amazon prices (many with new part numbers)

Item Part # Brand Amazon
AC Compressor with Clutch Denso 471-1164 Denso $190.78
Condenser 477-0518 Denso $58.02
Evaporator Core 476-0019 Denso $121.15
Expansion Valve 475-0505 Denso $27.33
Pressure Switch 88645-04040 Denso $25 eBay (couldn't find on Amazon)
Receiver/Drier 478-0500 Denso $14.08
O-Ring Kit FourSeasons 26749 $12.08
Aerosol AC PRO Flush AC Pro $18.00 (auto part store?)

Surprisingly, most of these parts actually went down in price!

Nice work man. According to the new prices, the total for the parts listed comes to $466.84. That is definitely a nice savings over what I paid 4 years ago! (and yes, the AC PRO FLUSH was bought at Advance Auto Parts)

 

[96RedRunner]

[MENTION=25434]BamaDrewski[/MENTION] [OP], Have you dug into what part of system failed? Taking system apart did you to see any gritty particles inside hoses, tubing? If you did your drier went to pieces, like mine did n screwed the pooch for whole system.

The drier is a good maintenance to-do for those that have the original drier or 150k plus miles.

 

[BamaDrewski]

[MENTION=25434]BamaDrewski[/MENTION] [OP], Have you dug into what part of system failed? Taking system apart did you to see any gritty particles inside hoses, tubing? If you did your drier went to pieces, like mine did n screwed the pooch for whole system.

The drier is a good maintenance to-do for those that have the original drier or 150k plus miles.

As i was replacing the system with all new parts, I did not spend time looking for failed components. There was no reason to spend time nor effort on that.

 

[Noonan11]

I got the new expansion valve and evaporator put in tonight. Would’ve never figured out how to get that bottom line apart with that weird clip! I’m going to do the condenser and dryer on Sunday and then the compressor mid next week. Hope to have it charged up and working by Memorial Day. That’s the goal anyways. Hopefully everything works. I know a shop charges a lot do this job!

 

[BamaDrewski]

I got the new expansion valve and evaporator put in tonight. Would’ve never figured out how to get that bottom line apart with that weird clip! I’m going to do the condenser and dryer on Sunday and then the compressor mid next week. Hope to have it charged up and working by Memorial Day. That’s the goal anyways. Hopefully everything works. I know a shop charges a lot do this job!

Sounds like you are making good progress man! Was the evaporator core case really nasty inside? Mine was not too bad but I cleaned it regardless. I think you will really be pleased with the final result. I am OCD so I made sure to clean out the aluminum lines I took out while doing the work....not sure if it made a difference but my AC is cold as an outhouse toilet seat in an Eskimo Alaskan winter.....4+ years and running after all the work....

 

[Meetball]

First post on this forum, but I've scoured it quite a bit over the years.

You did the whole system replacement, what about the two lines from the expansion valve that run through the firewall? Were they included in what you bought, or did you purchase them separately? I have a slow leak and will be replacing my evap. core and expansion valves, and I can't seem to find the hoses anywhere.


Found the part I was looking for. It's #88710-35380, and called a tube assembly. I really cannot afford to replace every piece in the entire system, so has anyone ever heard of this part failing?

 

[BamaDrewski]

First post on this forum, but I've scoured it quite a bit over the years.

You did the whole system replacement, what about the two lines from the expansion valve that run through the firewall? Were they included in what you bought, or did you purchase them separately? I have a slow leak and will be replacing my evap. core and expansion valves, and I can't seem to find the hoses anywhere.


Found the part I was looking for. It's #88710-35380, and called a tube assembly. I really cannot afford to replace every piece in the entire system, so has anyone ever heard of this part failing?

I did not replace the tubes through the firewall. I simply made sure to spray the cleaner through them and let them dry. Aluminum tubes rarely fail but in my case, I did have a "knick" in the line and had a buddy tig-weld a spot of aluminum to stop it up........

 

[Noonan11]

Got the condenser and dryer in this morning. Pretty easy job, just a ton of bolts to take off and then reinstall. Only issue I had was two of my clips that hold the grill on broke. Cable ties to the rescue until I can get new ones.

 

[Noonan11]

Here’s a couple photos of the evaporator. Mine was filled with 19 years of nastiness. Glad I decided to just replace all these major components as they looked pretty bad after 217k of use... The only non OEM part I used was the evaporator. Got some other brand off Amazon that all had 5 star reviews. Decided to roll the dice on that part based on the reviews. Fit perfect and no issues during the install.

 

[BamaDrewski]

Here’s a couple photos of the evaporator. Mine was filled with 19 years of nastiness. Glad I decided to just replace all these major components as they looked pretty bad after 217k of use... The only non OEM part I used was the evaporator. Got some other brand off Amazon that all had 5 star reviews. Decided to roll the dice on that part based on the reviews. Fit perfect and no issues during the install.

Great pics! man, that evap core was definitely ready to be replaced. I am sure the air in your rig will also smell much better now. Nice job!

 

[BamaDrewski]

Great pics! man, that evap core was definitely ready to be replaced. I am sure the air in your rig will also smell much better now. Nice job!

One question: How did you end up cleaning up/out the evaporator core case? (I rinsed my out and then put it in the dishwasher...LOL...but it WORKED!)

 

[Noonan11]

I used about a tree and a half of paper towels and glass cleaner to wipe it all out. It was a mess! Get back from Chicago tomorrow night then hope to finish this up Thursday and be fishing all weekend, weather permitting! Thanks for the help!

 

[BamaDrewski]

I used about a tree and a half of paper towels and glass cleaner to wipe it all out. It was a mess! Get back from Chicago tomorrow night then hope to finish this up Thursday and be fishing all weekend, weather permitting! Thanks for the help!

Man, that's awesome and I do hope the write-up was helpful. I don't know about you, but I live in Alabama where it gets pretty freaking hot in the summer. Having a new system that you know is gonna work is awesome in the hot summer! Nice job!

 

[Meetball]

Well, I finally got it all apart, and it is nasty. Add to the fact that I will have to get a new tube assembly

https://parts.olathetoyota.com/oem-parts/toyota-tube-assembly-8871035380/?c=Zz1odmFjJnM9ZXZhcG9yYXRvci1jb21wb25lbnRzJmk9ODQxNDEwMDUmcj0xMCZhPXRveW90YSZvPTRydW5uZXImeT0yMDAwJnQ9bGltaXRlZCZlPTMtNGwtdjYtZ2Fz

because when I removed the 2 bolts holding it all together, they had seized to the threaded aluminum inserts and stripped them out.......:ybrick:

So rather than take a chance, it's getting replaced too.

BTW, the link is to the dealership I bought the part from and they beat my local place by $20 including shipping and will have it here in three days instead of next week.