Replace air conditioner evaporator

[esman Lurker Find all posts View Profile Close esman]

Hi,

I spend days looking on line about DIY replacement of air con evaporator. I was quoted $1500 because dash removal was required..

Prado GRJ120 2003 GX

Ended up trying myself as I had removed my centre console before to replace my stereo.

YOU DO NOT NEED TO REMOVE THE DASH TO REPLACE THE AIR CON EVAPORATOR!!!!!

All you need to do is remove the glove box to expose the fan inlet module. There are 2 nuts and 2 bolts to remove to allow removal of the assembly (fan and plastic housing - Need to wriggle a bit to get it out). On the side of the air on box there are about 6-7 screws that need to be removed to expose the evaporator (this is just behind the heater coil).

You also need to remove the under dash covers on the drivers side so you can access the other side of the air con box.

Unscrew the 2 allen key bolts holding evaporator inlet and outlet pipes. Slide old evaporator out and replace with new one ( I paid $220{cool drive, Darwin} for a new evaporator, $480 from Toyota. I have been told that they are the same, but not sure about that).

Should only take about 4-5 hours first time (2-3 hours to do again - removal and installation)

I am only posting this because I could not find any help in replacing the evaporator without spending 6-7 hours removing the entire dash.

Happy to help anyone looking at doing this themselves. CAN BE DONE IN ONE DAY AND SAVE YOURSELF $1500.

Cheers
Andrew Es

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Hi,

I spend days looking on line about DIY replacement of air con evaporator. I was quoted $1500 because dash removal was required..

Ended up trying myself as I had removed my centre console before to replace my stereo.

YOU DO NOT NEED TO REMOVE THE DASH TO REPLACE THE AIR CON EVAPORATOR!!!!!

All you need to do is remove the glove box to expose the fan inlet module. There are 2 nuts and 2 bolts to remove to allow removal of the assembly (fan and plastic housing - Need to wriggle a bit to get it out). On the side of the air on box there are about 6-7 screws that need to be removed to expose the evaporator (this is just behind the heater coil).

You also need to remove the under dash covers on the drivers side so you can access the other side of the air con box.

Unscrew the 2 allen key bolts holding evaporator inlet and outlet pipes. Slide old evaporator out and replace with new one ( I paid $220{cool drive, Darwin} for a new evaporator, $480 from Toyota. I have been told that they are the same, but not sure about that).

Should only take about 4-5 hours first time (2-3 hours to do again - removal and installation)

I am only posting this because I could not find any help in replacing the evaporator without spending 6-7 hours removing the entire dash.

Happy to help anyone looking at doing this themselves. CAN BE DONE IN ONE DAY AND SAVE YOURSELF $1500.

Cheers
Andrew Es

Great 1st post!
Yes my air-con specialist ( I sublet air-con work) he uses cool drive & says its the goods.

[prado2004 Advanced Member Find all posts View Profile Close prado2004]

Hi,

I spend days looking on line about DIY replacement of air con evaporator. I was quoted $1500 because dash removal was required..

Ended up trying myself as I had removed my centre console before to replace my stereo.

YOU DO NOT NEED TO REMOVE THE DASH TO REPLACE THE AIR CON EVAPORATOR!!!!!

All you need to do is remove the glove box to expose the fan inlet module. There are 2 nuts and 2 bolts to remove to allow removal of the assembly (fan and plastic housing - Need to wriggle a bit to get it out). On the side of the air on box there are about 6-7 screws that need to be removed to expose the evaporator (this is just behind the heater coil).

You also need to remove the under dash covers on the drivers side so you can access the other side of the air con box.

Unscrew the 2 allen key bolts holding evaporator inlet and outlet pipes. Slide old evaporator out and replace with new one ( I paid $220{cool drive, Darwin} for a new evaporator, $480 from Toyota. I have been told that they are the same, but not sure about that).

Should only take about 4-5 hours first time (2-3 hours to do again - removal and installation)

I am only posting this because I could not find any help in replacing the evaporator without spending 6-7 hours removing the entire dash.

Happy to help anyone looking at doing this themselves. CAN BE DONE IN ONE DAY AND SAVE YOURSELF $1500.

Cheers
Andrew Es

Mine was replaced a few months back by an a/c guy and yes no dash removal required. He charged about $200 labour to do it so I was happy to pay it.

[Turbo Piston Senior Member Find all posts View Profile Close Turbo Piston]

Good to know, thanks

[TBL Lurker Find all posts View Profile Close TBL]

Just did mine. Was quoted $2000 for the job. Found this post. Stripped everything out an about 1.5 hours. Got a aftermarket evaporator from Covs (Perth) for $180. Installed it, put everything back together in about 1.5 hours. Taking it for regas next week ($200).

esman, you are a legend for saving me 1600 of Australias finest dollars.

P.S. One thing to note though. When you have removed all the covers and cubby on the passenger side. There is a section of plastic trim that runs around the bottom of the cubby hole. This had previousley been cut out of my car and this made the removal of the fan housing substantially easier. I assume that prior to me owning it someone had done some work in this area before. Anyway this is not exposed once all the covers are back on and although it has one less attachment screw it has not caused any issues in the 3 years I have owned the car.

[topic97 Senior Member Find all posts View Profile Close topic97]

Great 1st post!
Yes my air-con specialist ( I sublet air-con work) he uses cool drive & says its the goods.

Yeah i'm a qualified automotive aircon tech(out of the business now for a few years), we had been using cooldrive for the good part of 15 years & havent had a drama with their stuff.

If you have a Toyota & you take it to an aircon place & they quote you exorbitant prices for removal of the dash to get the evaporator out, turn around and walk straight out.
Pretty much all toyotas have an evaporator box that can be removed seperately to the rest of the hvac box.
All you need to do is remove the glovebox & a few bolts & the pipes from the engine bay and its out!

[245coop Lurker Find all posts View Profile Close 245coop]

Thanks esman,
been without a/c since returning from Fraser over the Sept school holidays. Unable to find leak first time around, gassed her up, lasted about a week and a half. Take it back and they inform me the dash needs to come apart for the evap to be done. Remembered seeing this thread and decided to look after it myself. Just over an hour and all sorted. Back for regas this week.
cheers

Brandon

[prado2004 Advanced Member Find all posts View Profile Close prado2004]

yep redcliffe auto electrics did this in brissy through the glovebox

Address: 220 Anzac Ave, Redcliffe QLD 4020
Phone07) 3284 8459

[jmichaels Junior Member Find all posts View Profile Close jmichaels]

Hello Andrew,

I will be doing this project on Friday(December 11). Hopefully, you get this message in time to offer further advice.

Purchased a new evaporator(60,000Ksh) from Toyota. Didn't trust the second-hand unit dealers here in Nairobi, Kenya.

Do you have a step-by-step list OR photos?

Appreciate any learnings you can pass my way.


Regards,

Hi,

I spend days looking on line about DIY replacement of air con evaporator. I was quoted $1500 because dash removal was required..

Prado GRJ120 2003 GX

Ended up trying myself as I had removed my centre console before to replace my stereo.

YOU DO NOT NEED TO REMOVE THE DASH TO REPLACE THE AIR CON EVAPORATOR!!!!!

All you need to do is remove the glove box to expose the fan inlet module. There are 2 nuts and 2 bolts to remove to allow removal of the assembly (fan and plastic housing - Need to wriggle a bit to get it out). On the side of the air on box there are about 6-7 screws that need to be removed to expose the evaporator (this is just behind the heater coil).

You also need to remove the under dash covers on the drivers side so you can access the other side of the air con box.

Unscrew the 2 allen key bolts holding evaporator inlet and outlet pipes. Slide old evaporator out and replace with new one ( I paid $220{cool drive, Darwin} for a new evaporator, $480 from Toyota. I have been told that they are the same, but not sure about that).

Should only take about 4-5 hours first time (2-3 hours to do again - removal and installation)

I am only posting this because I could not find any help in replacing the evaporator without spending 6-7 hours removing the entire dash.

Happy to help anyone looking at doing this themselves. CAN BE DONE IN ONE DAY AND SAVE YOURSELF $1500.

Cheers
Andrew Es

[ernieprado Lurker Find all posts View Profile Close ernieprado]

Hi there,

I tried to do this in my KZJ120 Prado 2003. But couldn't actually go further than removing the fan with the plastic housing. I was wondering if someone has any pictures of the process. I am attaching some myself, probably someone can point out where to go next.

Thank!

[topic97 Senior Member Find all posts View Profile Close topic97]

Hi there,

I tried to do this in my KZJ120 Prado 2003. But couldn't actually go further than removing the fan with the plastic housing. I was wondering if someone has any pictures of the process. I am attaching some myself, probably someone can point out where to go next.

Thank!

[ATTACH=CONFIG]21987[/ATTACH][ATTACH=CONFIG]21988[/ATTACH]

Ahh, Left hand drive vehicle?
Looks like youll have to go in the other side.

I havent had any experience with LHD Prados, but a lot of the car companies that sell converted vehicles wont actually convert the HVAC boxes - which means your evaporator will most likely still be on the left side of the vehicle under the steering column.

That big vacant space is where the steering column usually sits on the RHD prados.

So drop the covers around your steering column and it should give you a better idea.

[Mule Member Find all posts View Profile Close Mule]

Excuse my ignorance but exactly what is it that goes wrong with the evaporators, Corrosion, valves or what?

[ernieprado Lurker Find all posts View Profile Close ernieprado]

Thank you Topic97,
I will give it a try and will let you know the outcome later.

Mule,
In my case, i've been told there is a leak due to corrosion and apparently is very common in my model (prado kzj120 2003)

[Mule Member Find all posts View Profile Close Mule]

Mule,
In my case, i've been told there is a leak due to corrosion and apparently is very common in my model (prado kzj120 2003)[/QUOTE]

Thanks

[topic97 Senior Member Find all posts View Profile Close topic97]

Excuse my ignorance but exactly what is it that goes wrong with the evaporators, Corrosion, valves or what?

The alloy has a limited lifespan before it starts to break down because its so light & under so much pressure, and the oodles of moisture they create doesnt help all of this.
They split, or can rub holes too.