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

[Cosmic]

Denso nation wide out of stock

My 03 4Runner has been giving me ac trouble with a slow leak for years. After a recharge it would work perfectly for a few months until one very hot summer day while the truck was parked at work. I came back out after work and as soon as I opened the door I knew something was wrong. There was a strong stink in the 4Runner that smelled alot like freon, and it was. The evaporator or expansion valve finally busted during the hot summer day.

I used a freon sniffer the last time I charged the system and found it would alert from the inside ac vents. This gave me a clue of where my slow leak was.

I'm buying Denso parts since I don't want to do this job more than once. I'm finding the Denso expansion valve is on a national back order. Makes me think I'm just one of many owners dealing with this repair right now. I was told it wouldn't be available until mid November (it's the first of Sept).

Now I'm wondering if it's worth waiting for the Denso part, or take a chance on another brand. I'm thinking this will be a winter project unless I can find a new part #DENSO 475-2060

I would really like to see some of the photos if possible too. Some of the Youtube videos don't show any of the dash removal steps.

 

[alia176]

My 03 4Runner has been giving me ac trouble with a slow leak for years. After a recharge it would work perfectly for a few months until one very hot summer day while the truck was parked at work. I came back out after work and as soon as I opened the door I knew something was wrong. There was a strong stink in the 4Runner that smelled alot like freon, and it was. The evaporator or expansion valve finally busted during the hot summer day.

I used a freon sniffer the last time I charged the system and found it would alert from the inside ac vents. This gave me a clue of where my slow leak was.

I'm buying Denso parts since I don't want to do this job more than once. I'm finding the Denso expansion valve is on a national back order. Makes me think I'm just one of many owners dealing with this repair right now. I was told it wouldn't be available until mid November (it's the first of Sept).

Now I'm wondering if it's worth waiting for the Denso part, or take a chance on another brand. I'm thinking this will be a winter project unless I can find a new part #DENSO 475-2060

I would really like to see some of the photos if possible too. Some of the Youtube videos don't show any of the dash removal steps.

I'm doing the same project on my Subaru SVX and been looking at Amayma for parts. Just for S&G, I looked up an expansion valve and an evap for my '03:

Expansion valve
https://www.amayama.com/en/part/toyota/8851560190
$67

Evaporator
https://www.amayama.com/en/part/toyota/8850135160
$237

Both items from Japan and six days delivery. I have no idea about shipping but you have options. I'll be ordering my SVX A/C parts from them as their prices is stupid good and they're all OEM stuff.

"how to order from them" - https://www.amayama.com/en/txt.help/how-to-buy

Good luck.

 

[ghs215]

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

If someone can point me to a free hosting site for the pictures, I can re-post them. :beer:

 

[Shazley340]

Help!

Congrats on completing this I’ve just started and am stuck trying to get the blower motor box out. There’s no video help available the only one I could find said there’s a clip at the top just push that in and it pops out yeah right I can’t find any clip. Did you take out the central metal bar first and did you remove the steering wheel? Any info would help or suggestions of a manual that covers this Haynes doesn’t. Thanks

 

[ghs215]

Congrats on completing this I’ve just started and am stuck trying to get the blower motor box out. There’s no video help available the only one I could find said there’s a clip at the top just push that in and it pops out yeah right I can’t find any clip. Did you take out the central metal bar first and did you remove the steering wheel? Any info would help or suggestions of a manual that covers this Haynes doesn’t. Thanks

I had to remove the center bar and the steering wheel.

 

[Captsolo]

the unthinkable

I have a 2005 V6 SR5 4runner (140,000 miles). The AC went out at 13 years. I bought to a little junkie AC shop in Nassau where I got charged up last year (with dye), and their tech told me (after checking for green dye with a "black light") to buy a new compressor a few months ago, and he'd install it and recharge whole system (purge the system too) for $200.

I bought a new Denso compressor for $188 (Amazon), and he replaced it and I now have great AC for total of $400 out of pocket. Now going into second month - no leaks. Consistent "cool" - no drop off in temperature or operation.

Took my wife a few hours of "waiting" at shop - which got a whine or two.

For me to diagnose and fix a Toyota 4 runner AC is out of the question. Not for amateurs. You need the right equipment and experience.

Picture of my 4 runner in our driveway at this link (with "starter failure" write up): https://www.linkedin.com/feed/update/urn:li:activity:6458659303145422849/
:uzi:

2005 4runner SR5 V6 4.0 (purchased new)
2015 Camry SE 4 cylinders (purchased new)

Ladies and Gentlemen of the 4Runner World,

I have just done the unthinkable, a complete A/C Evaporator teardown and replacement. OMG is right! Complete with pictures :trophy:

Total Time: 18 hours!
Total People: 2
# of Too many to count :dammit:
# of :beer: Got a kegorator - didn't keep count
Climate Control: 4 Ton A/C on Wheels piped into the rear of 4Runner (check the pics!)
How did we do it? :rtfm:
How many parts left over? NONE! arty:

SEE ALL THE PICS
Home - 2006 4Runner SR5 4x4

 

[himeeto69]

Hopefully I'll never have to do this.

 

[Stackman1]

Strong smell of Freon inside the cab and in the condensate. Is this a clear indication that my leak is in the evaporator or is there a possibility the leak could be somewhere that doesn’t require this nightmare of a procedure?

 

[eleven14]

Strong smell of Freon inside the cab and in the condensate. Is this a clear indication that my leak is in the evaporator or is there a possibility the leak could be somewhere that doesn’t require this nightmare of a procedure?

You'll know shortly if the driver's side starts blowing warm while the passenger side stays cool with the A/C on. Only real way to confirm is dye and/or a freon sniffer in the vents.

 

[Stackman1]

You'll know shortly if the driver's side starts blowing warm while the passenger side stays cool with the A/C on. Only real way to confirm is dye and/or a freon sniffer in the vents.

Yep, that's exactly what it was doing before it stopped blowing cool air completely. So I'm screwed, huh? I'm having a mechanic perform a sniffer check later this week hopefully, but I think I already know the answer.

 

[y=mx+b]

Strong smell of Freon inside the cab and in the condensate. Is this a clear indication that my leak is in the evaporator or is there a possibility the leak could be somewhere that doesn’t require this nightmare of a procedure?

I extended my A/C drain with clear tube here so its easier to see, but if you have dye leaking into the A/C drain, then the evaporator is toast.

 

[eleven14]

Yep, that's exactly what it was doing before it stopped blowing cool air completely. So I'm screwed, huh? I'm having a mechanic perform a sniffer check later this week hopefully, but I think I already know the answer.

Hah, worth confirming but yeah, seems like it. Seems to be a 10ish year/100k+ mile thing on these unfortunately.

 

[Guitarplaya39]

Link doesn't seem to work anymore...

I've been putting this project off for years now :laugh:

 

[hinmo24t]

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

like me lol. test drove it, AC worked, summer after purchase, AC doesnt blow cold, figures.

need to try recharge kit (i duked it out in northeast humidity for years now)
but next summer i need to see if a recharge works (idc if temporary)

eventually id spend a grand on it (this DIY is over my head)
if it turns out to be this whole assembly or w.e.




impressive work

 

[y=mx+b]

I'll get to this eventually too and will make a writeup when it happens. Bummer these pics aren't there anymore. I have to try some more recharges to see how it holds up before diving into replacement, since the past 2 recharges have held for almost a year. But I know my time is soon because of the die in the drain

 

[Stackman1]

I purchased mine in August with 190K and it was filthy on the inside. Don’t think the PO ever cleaned it and the dealer didn’t even clean it up, but I got a good price on it so I was OK with it the way it was. No rust and no fluid leaks.

Spent about 3 months on and off working on it fixing all the minor stuff that needed attention. Removed all the seats and did a thorough cleaning of upholstery and carpet. Compounded, polished and waxed. Installed lift and it turned out excellent. Looks almost brand new.

Had only put about 500 miles on it since purchase and then AC quit. Recharged and it lasted another 500 miles. Now I know why the PO got rid of it.

 

[eleven14]

Huge props to ghs215 for unearthing and sending me his teardown photos of the process, it's by far the best and most thorough documentation I've seen. I'll be replacing mine when all my parts arrive and plan on putting together a proper y=mx+b-style how-to.

Until then, figured these might help someone else. Full album (191 images, sort by "oldest") is here. Teasers below. Cheers!

 

[ghs215]

My Pleasure!

 

[Syr4RinNC]

I may be doing this shortly. Ive got a blinking AC light I cant trouble shoot my way through it - suspect its either the evap core temp sensor or the ac amplifier. Thanks for everyone elses time and documentation - itll help me through it

 

[UURunner]

Where did them pictures go???