Not a whole lot has happened to the 4runner but here are some updates.
Back in April my ac compressor finally seized up. The clutch had ben wobbly and going out for a long time, but it died before I ever changed it. Since it's so hot here I decided to replace the condenser, dryer, expansion valve, and evaporator core while I was doing it. I gotta say, forums are much better than other sites. I would've probably not attempted that without all the threads detailing that. (notice the horribly oil covered valve cover- more on that later)
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The bolts holding the expansion valve on were corroded and pretty stuck, but a wire wheel is a great tool
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I don't quite remember how, but the threads on that 2nd bolt got pretty boogered up, and I couldn't find a replacement locally, so I wound up finally buying a metric tap and die set (I only had imperial) and cleaned it up that way.
I found these very helpful
DIY Complete AC Replacement on 2000 T4R Limited
Replacing the A/C Compressor on a 5VZFE (Tacoma, Tundra, 4Runner) – ADVENTURETACO
I had a shop evacuate the old refrigerant and recharge the system. I picked it up right before they closed, and they said they got it charged fine, but couldn't get the compressor to engage and to check the fuses. Sure enough when the old compressor seized, it blew the fuse. I replaced that and the AC worked, but not near as cold as before.
Since it's way better than no AC, I've just been working on a few things to try and improve cooling, but I need to really tackle it, since it's getting to the 115 degree every day part of the year.
I noticed on a offroad trip that my engine temps were around 215 degrees, which I was not comfortable with since the radiator is only a few years old, and I replaced the thermostat a few months ago (with the jiggle valve in the right position per FSM). I thought after 25 years and 268k miles replacing the fan clutch was probably okay. So a new Aisin FTC-013 clutch went in.
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I also remembered that I hadn't put the lower fan shroud on after I had done the compressor. I had lost one of the clips, and the other one was bent and didn't fit well. After finally getting a replacement I rebent the bad one. This is the shape you're looking for and the shape that I got good purchase with.
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That helped, but only lowered vent temperatures about 5 degrees. Which is worth it, but for comparison yesterday (after new fan clutch) my center vent temperature was at 70, and my mom's highlander and my dads tacoma were both mid 50's. That 15 degrees is huge when it's 110 outside.
My next step is to go get some gauges and double check that the shop filled it correctly, or that it isn't leaking. I haven't found any die with a UV light, and the cooling is consistent, so I don't think there is a leak. My best guess if the charge is correct is that I put too much oil in, as the old interweb says that can also cause poor cooling. That catches up the AC issues to present.