Complete A/C system replacement? (1 Viewer)

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culturedredneck

culturedredneck

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Sep 28, 2005
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Location
Knoxville, TN
Hi All,

After sweltering through the first half of the summer with no A/C, I took my 97 FZJ80 into a local shop to have the A/C issue diagnosed. The compressor would kick on for a couple minutes and then kick off. After lots of research on this forum I thought maybe either an expansion valve or the engine temp cutoff relay. Lacking a place or tools to do repairs myself at the moment, I dropped it off for what I thought would be a relatively simple fix.

They found a couple of leaks and replaced the dryer and a leaky tube and then called back to say the expansion valve also needed replacing. As I had already bought this part previously, I had them go ahead and do it. THEN they called back and said, "We have some really really bad news, are you sitting down?" Turns out when they went to replace the expansion valve they noticed a substantial amount of debris inside the lines, and my entire A/C system would need to be replaced. In his words, 'The shop manager said in 35 years of doing this he's never seen one this bad." They even sent me photos. Its to the point they cant even put freon in the system to try and recharge it. They said I was looking between 3-4k and acted like he wasnt super pumped to do it. Which is fine, since Im not about to pay 4k for A/C.

So, question is, what do I do now? Sell the car? Wait until Im in a better spot to do the repairs myself? Try and get a second opinion? Try and flush out the system?

Its the only car between my wife and I, and while we don't need it that often (we live in Washington, DC) we do need a car that has A/C.

I would appreciate an opinions if anyone else has found themselves in a similar place. Thanks!!!

97FZJ80 A/C

97FZJ80 A/C

 
That looks like some type of 'stop leak' crud, which if throughout your entire system....is indeed a problem.

Most likely your hard lines can be flushed out, but the evaporator (pictured), condenser, drier and most likely your compressor will have to be replaced.

If no hoses or hard lines are required then you should be able to do the job for about $800.00 (in parts), including Flushing Agent. If you are not set up to recharge the system....then take it to a shop and have them do it after you flush the system and install the new parts.

You'll need a source of compressed air to flush the lines.

97 1997 Toyota Land Cruiser A/C Accumulator - Climate Control - Action Crash, Spectra Premium - PartsGeek

97 1997 Toyota Land Cruiser A/C Compressor - Climate Control - Delphi, Denso, Four Seasons, GPD, UAC - PartsGeek

97 1997 Toyota Land Cruiser A/C Condenser - Climate Control - APDI, Action Crash, Denso, Spectra Premium - PartsGeek

97 1997 Toyota Land Cruiser A/C Evaporator - Climate Control - Denso, GPD, Nissens, UAC, Front - PartsGeek

97 1997 Toyota Land Cruiser A/C Expansion Valve - Climate Control - Action Crash, Denso, Four Seasons, GPD, Metrix, UAC - PartsGeek

97 1997 Toyota Land Cruiser A/C O-Ring Kit - Climate Control - Action Crash, Santech - PartsGeek

https://www.amazon.com/Refrigeration-Technologies-RT201B-NYLOG-GASKET-SEALANT/dp/B008HOSQQQ

Great Deal on Mastercool 91046-A at ToolPan.com

Supercool AC Flush, Solvent Based, 1 Gal. 22779 | Zoro.com
 
Last edited:
4K for the whole ac system is crazy! You could have the Cruiser painted for that price
 
$4k? What are they going to install A gold plated AC!
 
@culturedredneck give the guys at Ironpigoffroad a call. Talk to Lance and see if he will do the A/C work. I am not sure if he has the machine or not. If not you could at least have him replace all the parts and then take it back to your A/C guy just to have the system pressurized. The A/C system in these trucks is kind of a pain to get at from behind the glovebox but it is not a $4000 job. I did the entire system minus the lines, using all Toyota parts except for the evaporator. There used to be an A/C vendor on mud that could get Denso evaporators same as OEM just cheaper.
 
A month ago I replaced my entire 1993 system and thereby converted it to R134a for $529 shipped from Rockauto. Denso condensor and evaporator, brand new (not reman'd) 4seasons compressor, dryer and expansion valve with two year warranty. The job really isn't that hard. Research first.
I took it to a shop I like for servicing and now she blows snow.
 
scottryana said:
@culturedredneck give the guys at Ironpigoffroad a call. Talk to Lance and see if he will do the A/C work. I am not sure if he has the machine or not. If not you could at least have him replace all the parts and then take it back to your A/C guy just to have the system pressurized. The A/C system in these trucks is kind of a pain to get at from behind the glovebox but it is not a $4000 job. I did the entire system minus the lines, using all Toyota parts except for the evaporator. There used to be an A/C vendor on mud that could get Denso evaporators same as OEM just cheaper.
Click to expand...

Correct.

^^^^^ The evaporator is not much fun to get out, it is housed in a plastic shell that fits fairly tightly behind the glove compartment, but if I can do it (6'-5" 260 lbs. 62 yrs old), most anyone else should be able to. Once you find all the little hidden screws/nuts and remove the unit, it is easy to work on. Going back in...is actually a bit easier. Working in the small space provided (basically the floorboard at the front passenger seat), is the hardest part.

The condenser is not a big deal, or the drier. Flushing the lines (correctly) will take more time than any other part of the job. Use a NEW expansion valve on the evaporator. I recommend using 'nylog' on all your fittings...along with new O-rings of course.

I wouldn't re-use the compressor, new ones (or re-mans) are not that expensive. The system uses 8 ozs. of PAG 46 oil and 1.8 lbs. of R134A.

I can't imagine anyone quoting 4K for the job unless they REALLY didn't want the business.
 
First off, thanks for all the replies. Already feeling better about this whole mess. Hearing the mechanic say that it was the worst he's seen in 35 years definitely caused a moment of panic. The car was recently purchased and more of a passion splurge than a sound financial decision so the thought of replacing the entire A/C system was a bit of a shock. Most frustrating part being I don't have a place or tools to do much right now so I'm dependent on local mechanics for anything major and being new in the area, I haven't found one I like yet.

This shop was alright. I knew I'd be over paying a bit but I'm headed away next weekend for the wife's b-day and A/C sure sounded nice for the long ride. The manager at the shop printed off several pages of parts, highlighting and circling everything I would need to get, prices of everything included. Nearly 3k worth of parts. They're buying OEM everything, and it ain't cheap. I told him I'd try to source my own parts and he agreed that was probably the best plan. Even he thought 4k was crazy.

I picked it up from the mechanics today with a new evaporator, dryer, 1 new tube and new expansion valve so maybe a little head start on replacing stuff.

@flintknapper Thanks a ton for listing those parts out, that's a huge help.

@Rivman1243 Funny you should mention paint.... it needs a paint job pretty bad!

@scottryana Thanks for the lead on iron pigs offroad, I had looked for a LC specialist in my area and hadn't found them. A bit out of the way, but for a large job like this might be what I need. In any case I'll give them a call.

Question now is, do I try anything else before I start digging into the system? Is it worth taking it to a place that specializes in A/C repair and trying a full system flush before I start replacing parts? Or is it pretty certain that its past the point of no return....
 
As affordable as good parts can be had, just replace it all. Labor is your biggest consideration.
 
culturedredneck said:
First off, thanks for all the replies. Already feeling better about this whole mess. Hearing the mechanic say that it was the worst he's seen in 35 years definitely caused a moment of panic. The car was recently purchased and more of a passion splurge than a sound financial decision so the thought of replacing the entire A/C system was a bit of a shock. Most frustrating part being I don't have a place or tools to do much right now so I'm dependent on local mechanics for anything major and being new in the area, I haven't found one I like yet.

This shop was alright. I knew I'd be over paying a bit but I'm headed away next weekend for the wife's b-day and A/C sure sounded nice for the long ride. The manager at the shop printed off several pages of parts, highlighting and circling everything I would need to get, prices of everything included. Nearly 3k worth of parts. They're buying OEM everything, and it ain't cheap. I told him I'd try to source my own parts and he agreed that was probably the best plan. Even he thought 4k was crazy.

I picked it up from the mechanics today with a new evaporator, dryer, 1 new tube and new expansion valve so maybe a little head start on replacing stuff.

@flintknapper Thanks a ton for listing those parts out, that's a huge help.

@Rivman1243 Funny you should mention paint.... it needs a paint job pretty bad!



@scottryana Thanks for the lead on iron pigs offroad, I had looked for a LC specialist in my area and hadn't found them. A bit out of the way, but for a large job like this might be what I need. In any case I'll give them a call.

Question now is, do I try anything else before I start digging into the system? Is it worth taking it to a place that specializes in A/C repair and trying a full system flush before I start replacing parts? Or is it pretty certain that its past the point of no return....
Click to expand...



Since you already have a new Evaporator and Expansion Valve (presumably all mounted back in place), I'd source a new Condenser and drier, have a good A/C shop/person flush all the lines, install new parts, empty the compressor of oil and inspect (though I'd replace it), put it all back together with new o-rings, add PAG oil, pump it down and recharge. You'll probably be good to go.

The place that quoted you 4K is sourcing all OEM parts at the highest list price possible and still expecting it to 'come back' so they are padding it.

Realistically....its a $1500.00 job (+ or - a hundred or so).
 
With another summer approaching, and still no AC, Im going to try and tackle this job myself in the coming weeks. Thanks again to everyone who chimed in with advice and parts references.

I searched but couldn't find anything, is there a thread where someone has done this before and possibly detailed the process? If not, I might try and do this.

Any mechanically inclined individuals in the Knoxville, Tennessee area want to spend an afternoon helping point s*** out to me? Probably sometime around June 19th ish. Plenty of beer...

Kohl
 
I just did this in April. I replaced everything except the hard lines. It was not difficult for this shade tree mechanic. I think in all it cost me around $520, including paying a shop $120 for vacuum, test, and charge. If you do every component, I don't think there is a big need for a flush.

Try this for the evaporator:
A/C system - how to remove the cooling unit, evaporator, expansion valve

EDIT: the evaporator is the only part that is somewhat difficult. Everything else I did is pretty intuitive. Condenser was just a bunch of little screws. Compressor was four bolts and a plug. Drier was removing the sidemarker and three screws.
 
FYI, I found a receipt in the glovebox on mine from the PO that had a new compressor, drier, and expansion valve, and one new hose for $2300 at the Toyota dealer 5 years ago.
 
Going to get cranking on this next week, am ordering all of the parts today. My instinct is to hold off on the hard lines and just replace the Accumulator, Compressor, Evaporator and o-rings. According the the receipt the shop gave me, they replaced the Receiver Dryer, Condenser, and the line running from the Dryer to Condenser. I know they had to pull the evaporator because that where they found the stop leak, but Im not sure if they ended up installing the expansion valve that I provided or not. Ill have to check. In either case I wasn't billed for an evaporator, so Ill probably have to replace it.

The removing/ reinstall of parts doesn't have me worried, its the flushing of the lines and charging/ recharging the system. When it comes to flushing out the lines, would I do this while all the old components are bolted on, or would I remove the lines individually and blast them clean with compressed air? Its currently all charged up (although not circulating freon), should step one be taking it to a shop and having them decharge everything?

Thanks,
Kohl
 
yes.
1. take it in to be evacuated. ask when you take it back to them if they will give you "credit" since they are taking good refrigerant from you which they charge a lot for.
2. remove the new condensor and drier/accumulator. remove all the old components that are getting replaced which should be everything else.
3. then flush each hose/tube
4. reinstall all parts.
5. take back to same shop to pull vacuum and confirm no leaks, then they recharge.
6. beer. see, always somehow step 6.
 
culturedredneck said:
Going to get cranking on this next week, am ordering all of the parts today. My instinct is to hold off on the hard lines and just replace the Accumulator, Compressor, Evaporator and o-rings. According the the receipt the shop gave me, they replaced the Receiver Dryer, Condenser, and the line running from the Dryer to Condenser. I know they had to pull the evaporator because that where they found the stop leak, but Im not sure if they ended up installing the expansion valve that I provided or not. Ill have to check. In either case I wasn't billed for an evaporator, so Ill probably have to replace it.

The removing/ reinstall of parts doesn't have me worried, its the flushing of the lines and charging/ recharging the system. When it comes to flushing out the lines, would I do this while all the old components are bolted on, or would I remove the lines individually and blast them clean with compressed air? Its currently all charged up (although not circulating freon), should step one be taking it to a shop and having them decharge everything?

Thanks,
Kohl
Click to expand...
The lawful thing to do is have a shop evacuate the system so the freon is not released into the atmosphere.

It stands to reason that clearing all lines with compressed air would work best without components connected.

Are you sure the system is sealed and holding a charge? You may want to have a shop fill it with dye and test it for leaks so you know if any hard lines have a hole or crack in them.
 
@baldilocks, It seems to be holding a charge, just not circulating. The shop I took it to did a dye test and found a small leak from the Condenser and the line running from the dryer to condenser. He replaced these parts, charged it back up and didn't find any leaks. When it was charged, but wouldn't blow cold, thats when he dug further and found the clog.

I'll take it to a shop and have them evac everything. Then maybe I can blast out any remaining bits of stop leak when Im replacing parts. I'd hate to leave some crud in there that gums up the new parts...

Kohl
 
No prob. I had crappy or no a/c the last 2 summers. First summer it was the corroded auto a/c amp, fixed that. Last summer i did a ton of work to the front end and replaced the condensor and drier. Great a/c last summer. Now 2 weeks ago it only blows ambient air. So this summer i will replace the compressor, evap core, and expansion valve. Hopefully thats the end of my annual a/c issues
 
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