Done! A/C Evaporator Teardown - OMG is Right!

[bunzz]

I would seriously think about at least replacing the dryer bag (within the condenser) which should be done anytime major A/C work is done. They are like $12 online.

I poured about 1.5 oz each in each component.

If you are not recharging it yourself, then the place that does it can inject it through an oil charge.

I actually ended up picking up a condenser and dryer, haha. I figured, "why not?":shrug:

Since this thread is a good reference, here are some part numbers for anyone else in the future who might be tackling it. This is for an 08 V6 Sport, but should work for any SR5/Sport V6. Can't speak for the limiteds since they're dual climate.

Evaporator Assembly: 88501-35160
Expansion Valve: 88515-60190

Condenser: 88461-60091
Dryer Cooler: 88474-17010

 

[ghs215]

Out of curiousity, did you replace the heater core?

Nope. It was in perfect condition. :banana:

 

[bunzz]

Nope. It was in perfect condition. :banana:

arty:

I pulled it off over the weekend! Started Friday night ended literally around 12am this morning. No leftover parts (but maybe a broken tab or two:frusty. Vacuumed the system, it held out fine and this morning i took it the shop to get it charged. They found no issues.

I'll post more photos later. Thanks for all your help!

 

[nevada]

Awesome! I love when people DIY themselves! Good job!

After all that hard work I sure hope you went to the dealer and bought an oem part. I could not risk having a after market one leaking and doing that job a second time!

i would tend to agree, except these are known to fail. unless the OEM part has been changed/improved, it may not be the best choice.

 

[Elan750]

After seeing this, its safe to say when mine goes, I'll be opening the windows a lot more often.

 

[bunzz]

After seeing this, its safe to say when mine goes, I'll be opening the windows a lot more often.

I wish that were possible in Florida! Rolling the windows down in the summer is equivalent to turning the heat on for Central Floridians.

Honestly, if you're not in a rush, the job wasn't that bad. It definitely helps to have a second hand, but I did this one solo over the weekend.

 

[bootheel]

Follow the FSM (print out the applicable sections). Only take off what you have to...the FSM may tell you to take off things that don't need to. Take the front seats out.

buy one of these from amazon.

Performance Tool W86556 Clip Removal Plier

#1 - take pictures, lots of them. It will pay dividends when you cant remember which way you took it off.

Well, I'm off on this fun adventure finally. Not sure if we are working too fast, but we have the HVAC box removed in 4hrs. Evaporator and expansion valve are back in the housing and we are going to begin reassembly tomorrow.

 

[bootheel]

Not sure how you could do that with the upper tabs from the bar going into the box and the 2 arms coming down blocking it from being pulled straight out?

We were able to remove the HVAC box without completely removing the crossbar. It was super tight getting those tabs free that slide through the box from the bar, but by just loosening the bar it did work.

 

[bootheel]

Finished up today. Took about 7 hrs for reassembly, along with condenser replacement, vacuum, and charge. Definitely glad that project is over, but it wasn't as bad as I thought it would be. Things we did that vary from the FSM (at least I think because we didn't use the FSM) include loosening the crossbar but not removing, and we didn't remove the front seats. Not sure how much time that saved, but total labor hrs probably were somewhere around 9-10 for just the evaporator.

 

[keakar]

Finished up today. Took about 7 hrs for reassembly, along with condenser replacement, vacuum, and charge. Definitely glad that project is over, but it wasn't as bad as I thought it would be. Things we did that vary from the FSM (at least I think because we didn't use the FSM) include loosening the crossbar but not removing, and we didn't remove the front seats. Not sure how much time that saved, but total labor hrs probably were somewhere around 9-10 for just the evaporator.

I am certain the front seat removal is just to give you room to work and do things plus it helps protect them tears from any sharp edges of things coming out as it all comes apart.

if and when I do this (waiting on the fall so I can do this in 60-70 degree weather for sure) im sure for me the seats will come out and get put in the house to keep them safe and out of the way while I do this.

my plan is that I will fold the rear seats down so I can throw a quilt or something on it and just start sliding stuff into the back compartment area as it all comes out. im sure there is a good bit of dirt and whatever and whatnot on all those parts.

mine needs a can of Freon every 6-7 days so I bought a case of Freon to get me through the rest of summer. I don't have a garage to do this in so im working out in the yard and no place to put anything but in the back cargo area while im working on this. worsty thing is this is my only means of transport so im hitch hiking or calling a taxi/uber service if I need anything from the store until its done.

 

[bootheel]

I am certain the front seat removal is just to give you room to work and do things plus it helps protect them tears from any sharp edges of things coming out as it all comes apart.

if and when I do this (waiting on the fall so I can do this in 60-70 degree weather for sure) im sure for me the seats will come out and get put in the house to keep them safe and out of the way while I do this.

my plan is that I will fold the rear seats down so I can throw a quilt or something on it and just start sliding stuff into the back compartment area as it all comes out. im sure there is a good bit of dirt and whatever and whatnot on all those parts.

mine needs a can of Freon every 6-7 days so I bought a case of Freon to get me through the rest of summer. I don't have a garage to do this in so im working out in the yard and no place to put anything but in the back cargo area while im working on this. worsty thing is this is my only means of transport so im hitch hiking or calling a taxi/uber service if I need anything from the store until its done.

Yeah, mine was leaking down overnight. This was the first time I had pulled the dash on any vehicle. Not gonna lie, it looked overwhelming with the dash pad removed, but take pictures and pay attention to where you remove bolts and wiring harness routing and you will be fine. I did have the help of a friend, so that sped the process up with both of us removing and installing. Good luck!

 

[theteleguy]

Were pics of the process ever posted? the link on OP was broken.

 

[Cerevo]

I registered just so I could post here but I'm about to the point of pulling the dashboard out. I'm having a hard time finding how to get the lines to the evap core on the firewall undone without breaking them. Anyone got a how to for that?
The Evo was so much easier to do this for. Single bolt and the lines were off.

 

[ghs215]

I registered just so I could post here but I'm about to the point of pulling the dashboard out. I'm having a hard time finding how to get the lines to the evap core on the firewall undone without breaking them. Anyone got a how to for that?
The Evo was so much easier to do this for. Single bolt and the lines were off.

Are you talking about the "quick connects" ??

If so, its a biznatch without the "SST" (super secrete tool)

If you understand how the clip works, you will need 2 tiny things 2 jab into the 2 tiny spring locks to move the clip enough to unlock it.

Check this video out
https://www.youtube.com/watch?v=EFWOPu-WbwI

 

[ZiaMan]

.

Hey GHS,
the link to your website is broken/got blocked but my corp network being a parked domain. Do you have a new site?

 

[ghs215]

Hey GHS,
the link to your website is broken/got blocked but my corp network being a parked domain. Do you have a new site?

Look at this pic...
http://www.autobeyours.com/gifs/Tech Tips Prius/AC line removal tool 002.jpg

That little metal thing slides over a plastic ledge when closed. You just have to jam a tiny thing in the slot to push it aside and it opens.

 

[bunzz]

I registered just so I could post here but I'm about to the point of pulling the dashboard out. I'm having a hard time finding how to get the lines to the evap core on the firewall undone without breaking them. Anyone got a how to for that?
The Evo was so much easier to do this for. Single bolt and the lines were off.

They sell a tool at the parts store you can use. It's pretty cheap.

 

[rhassett]

Updated Pics

Hey OP. It seems your photos have moved. Anyway I can get them? My 4runner is starting to blow cool air and im pretty sure this is what I need to do.

Thank you

 

[ghs215]

Hey OP. It seems your photos have moved. Anyway I can get them? My 4runner is starting to blow cool air and im pretty sure this is what I need to do.

Thank you

send me a private message with your email address and I'll sen you a direct download link. I'll get them to you tonight. you want them all or just a few critical ones?

 

[santana]

send me a private message with your email address and I'll sen you a direct download link. I'll get them to you tonight. you want them all or just a few critical ones?

Please make these public again
Would greatly appreciate it as I’m sure many others would