1st Gen A/C Overhaul

The A/C compressor in my '02 4 cyl seized up during operation. I'm about to begin the fixin' and I'd like to use this forum to post a decent guide,pictures included, on how to go about the job of replacing the compressor and subsequent components as well as the flushing recharging of the system. This is an attempt to save someone out there the $1000-$1500 you might shell out at a shop for a similar job.

First I'll start with the list of parts and prices:
(All from partsgeek)
A/C Receiver/Dryer (Denso) $21.25 -Necessary replacement Denso is OEM
A/C Compressor (Denso) $204.25 - Necessary replacement Denso is OEM
A/C Expansion Valve (UAC) $9.75 - Debris will be caught in here from the implosion of the compressor
A/C Evaporator (UAC) $34.25 - Some say it can be flushed of debris, some say not. For $35, what the hell.
R134A Refrigerant Oil (Four Seasons) $8.75 - Oil for compressor
A/C O-Ring kit (Santech) $10.25

Before I get started I'd like to ask of anyone who has done a similar job in the past, if they have any thing to add, either to the parts list or helpful hints, to help make this a more complete guide.

More to come

 

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Condensor. Like the evaporator, some feel that it can be flushed, but modern parallel-flor condensors are very hard to flush effectively.

 

Very true, however the cheapest I can find a new aftermarket condensor is around $85. Even OEM used are around that, and I personally would be leery of using any used A/C parts. I'll just be flushing mine to the best of my ability, but i may cave later and end up buying one pending my inspection.

 

You're already at $290 plus $100 or so to have a shop pull a vacuum and reload the R134a. May as well drop the extra $85 and you'll have a 100% new system.

 

Just finished it on my 96. I went ahead and bought the vacuum pump, gauges and 134a fittings, and a book for troubleshooting and reading material because the shop wanted damn close to what I spent on that just to vacuum and fill mine and now I can do A/c in any vehicle I want. The Evaporator removal is the hardest part. Just be very careful when you pull it out as the two aluminum tubes coming out of the firewall you unscrew from the hoses are attached and can be bent/cracked very easily. Make sure you oil the o-rings before you put them on and know they will need to be stretched. That means the fit correctly. Do not skip ANY o-rings, replace them all even if it means going back to the parts store to match one up should you not have it. Don't lose the grommet where the evaporator drain tube exits the firewall or you'll hear helacious engine noise. If you decide to buy a pump and gauges I can help you out on what to buy and how to use them.

 

Thank you very much for the tips, and maybe I'll take you up on that last bit, but for now I was planning on just paying my local shop to vacuum and recharge. Did your compressor go during operation, and what all in the system did you go about replacing/flushing?

Still waiting on the parts to arrive

Thanks again

 

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Yes my compressor took a dump during operation I think because of a lack of oil because the lines were bone dry. Its totally up to you on buying the equipment, I just saw it as an investment because I do a little mechanic work on the side and I got a little better price because I am friends with the owner of a commercial mechanical (heating and a/c) business. I replaced everything you did with the exception of the evaporator which I bought new for $130 which according to your prices i overpaid for as well as the expansion valve which i paid 34 dollars with my parts store discount for. But oh well. I took my condenser out and had my a/c buddy flush the hell out of it which Im pretty sure is just high pressure nitrogen and compressor oil being forced through whatever you are flushing. Maybe take your condenser out and see what your a/c shop will charge you to flush it? Thats all I flushed though since everything else got replaced.

 

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Received my receiver/dryer yesterday along with my o-ring kit and drive belts (I'm replacing them in addition to the a/c system, but won't include them in the parts/price list up top; probably about $25 Total for the 3 Bando belts A/C, PS, WP + Alt --- Dealer wanted $140 while they were swapping my frame)

Partsgeek ships from 4 different warehouses (ABCD) so your order ships in different pieces, and charges shipping from each warehouse: TIP: try to consolidate to as a few different warehouses as you can while ordering the parts, IE: there's another brand of receiver/dryer that's an extra $2 but it's from a warehouse you've already got other items in your shopping cart from. Go ahead and buy it instead because you'll save about 7$ in shipping from another warehouse and still get a better part.

Also went ahead and ordered a condenser from parts geek because the price dropped to $64.38. The retail on it is listed at $170, although i don't know about that. I wont be starting until everything's in, so probably this weekend.

 

please lots of pictures

 

I got impatient waiting for the parts to arrive, so last night and this morning I completely removed and disassembled all A/C components. I took my time, I think I've got about 50 pictures I'll use in my guide when I'm all done, and the dis-assembly probably took about 4 hours of actual work time. I've made more work for myself, one of the bolts was corroded and snapped off inside the receiver, and there was oil all over my A/C pressure switch, so I'll be buying a new one of those ($16 autozone). I won't be putting up the how-to's until I get everything all buttoned up.


Thing covered in green compressor oil is the A/C pressure switch. This switch tells the compressor to stop or start pending on high or low pressures within the system. I believe the leak here and somewhere on the compressor caused loss of oil and low pressure in the system, and the failure of this switch (which should have told the compressor to stop) attributed to the detonation of the compressor; that and lack of oil.

 

Usually, when that switch goes, it goes open and the AC won't come on.

 

http://www.tacomaworld.com/forum/1s...cement-how-seized-compressor.html#post7371373

There she is. Thanks again

 

Help where are you getting those oem parts so cheap? I'm in Arizona and melting fast, i drive a long ways to work and I'm boiling lol my A/C crapped out.

 

All parts are either from partsgeek.com or autozone. Technically none of the parts I used are OEM. The Compressor and the Receiver were both Denso brand; Denso manufactured the original compressors and receivers for Toyota when they built these trucks.

An actual OEM compressor is probably around $700 or so. Not worth it.

 

Awesome writeup. I hope I never have to do this, but if I do, it's good to know it's out there!

 

Denso is oem. Toyots just charges more for it.