Luvmyalltrac
Member
Ok, should have proofread before posting. That last paragraph got jumbled up a bit.
ST185 AC system overhaul with photos
- Thread starter Luvmyalltrac
- Start date
Luvmyalltrac
Member
Thanks Roreri! I am pleased it went well. Again, my success was heavily dependent on the facilities, tools and knowledge of my good friend, Noah! That is his 1970,72? Dodge Demon in the background of my avatar.
grip-addict
Member
Would you happen to have the part numbers handy and be willing to share them please? I found the major stuff on rockauto, but Incidentals and gaskets from oreillys I wonder about. The one near me is quite unreliable.
Mine at least gets cool after a r134 charge, but the pressure does not last thru the night
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Mine at least gets cool after a r134 charge, but the pressure does not last thru the night
.Attachments
Luvmyalltrac
Member
Sorry, for slow response. my work weeks have been in the high 60’s to 70+ hours, so just don’t have much free time. I got my compressor, expansion valve/ evap core, and the drier from Rock Auto. The o-Ring was just a generic assortment kit from O‘reilly, as were the gallon jug of flush and the pag46 oil. So my question is, “what part numbers do you want, if you already found the major parts on Rock Auto?”. I will be happy to help, just not clear on what you want.Would you happen to have the part numbers handy and be willing to share them please? I found the major stuff on rockauto, but Incidentals and gaskets from oreillys I wonder about. The one near me is quite unreliable.
Mine at least gets cool after a r134 charge, but the pressure does not last thru the night
Luvmyalltrac
Member
Would you happen to have the part numbers handy and be willing to share them please? I found the major stuff on rockauto, but Incidentals and gaskets from oreillys I wonder about. The one near me is quite unreliable.
Mine at least gets cool after a r134 charge, but the pressure does not last thru the night
Luvmyalltrac
Member
Major parts list from Rockauto as requested. 
RedCelicaTRD
Moderator
You appear to have left off the part number for “Visa”. If you could provide that I’m sure all members would benefit.
🥸
🥸
Luvmyalltrac
Member
I’m sure😁
I'm tacking this project myself, and need a sanity check on something. Does anything plug into the connector highlighted below? I can't find the mating plug for this anywhere. I also can't find it on the 1992 wiring diagram. I took lots of photos for reference as well, but none of my photos show this connector. I'll be adding some notes to this thread once I finish my project soon.
Luvmyalltrac
Member
I am not certain, but I will take a look at mine tomorrow. I do seem to remember one unused connector, but it has been to long for me to say for certain without looking. I will post a response as soon as I can.
Luvmyalltrac
Member
Apologies for the delay. Above is a photo that shows nothing connected to that same harness on my car with a complete and working AC system.-Tim
I just finished refurbishing the AC system on my 92 All-trac after I lost my refrigerant due to a leak. The previous owner converted it to R-134a. Given that I have still have R-12 available, I decided to flush all the lines and bring it back to the factory-spec R-12 refrigerant.
The original compressor was leaking from the shaft seal. I got a new Denso compressor. I leared that R-12 mineral oil ND-Oil 6 is still available in Japan, but can't be shipped to the USA since 2011 due to a missing environmental data sheet. The service manual says that Suniso 5GS is also compatible, so I acquired some of that. I also added some UV dye to the compressor to make any future leaks more obvious.
The condenser appears to be no longer available. However, I had a new condenser in my parts stash acquired from Toyota back in 2014, when they were still available.
The power steering cooler and transmission cooler both need to be moved out of the way to remove the condenser. You don't need to disconnect either one, just unbolt them from the lower radiator support.
There isn't much room to work to unbolt the AC lines at the firewall. I think I used several different brands of wrenches, all with slightly different angles, to accomplish the task. I installed a new Denso evaporator and expansion valve.
My evaporator hosing gaskets were in rough shape. I found some from another model I was able to make work. Toyota part number 88578-60130. They are very fat when new, but are very soft and compress down to size once the housing is installed in the car. I learned that the All-trac only uses the black-wire thermistor. The green-wire thermistor is used by the GT and GT-S ECU, but not on the All-trac. In theory, you could leave the green thermistor out with no ill effects.
When doing this job, I learned that my external temperature sensor wire was broken due to rubbing on a bracket. I wonder how long this has been broken for. I repaired the wires and installed a new connector. The original connector was discontinued, so I found a similar connector that worked.
The information in this thread was helpful in completing this project. I'll complete a second post with additional information that may be helpful to others, as I'm hitting the attachment limit for this post.
The original compressor was leaking from the shaft seal. I got a new Denso compressor. I leared that R-12 mineral oil ND-Oil 6 is still available in Japan, but can't be shipped to the USA since 2011 due to a missing environmental data sheet. The service manual says that Suniso 5GS is also compatible, so I acquired some of that. I also added some UV dye to the compressor to make any future leaks more obvious.
The condenser appears to be no longer available. However, I had a new condenser in my parts stash acquired from Toyota back in 2014, when they were still available.
The power steering cooler and transmission cooler both need to be moved out of the way to remove the condenser. You don't need to disconnect either one, just unbolt them from the lower radiator support.
There isn't much room to work to unbolt the AC lines at the firewall. I think I used several different brands of wrenches, all with slightly different angles, to accomplish the task. I installed a new Denso evaporator and expansion valve.
My evaporator hosing gaskets were in rough shape. I found some from another model I was able to make work. Toyota part number 88578-60130. They are very fat when new, but are very soft and compress down to size once the housing is installed in the car. I learned that the All-trac only uses the black-wire thermistor. The green-wire thermistor is used by the GT and GT-S ECU, but not on the All-trac. In theory, you could leave the green thermistor out with no ill effects.
When doing this job, I learned that my external temperature sensor wire was broken due to rubbing on a bracket. I wonder how long this has been broken for. I repaired the wires and installed a new connector. The original connector was discontinued, so I found a similar connector that worked.
The information in this thread was helpful in completing this project. I'll complete a second post with additional information that may be helpful to others, as I'm hitting the attachment limit for this post.
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If you convert to R-134, HNBR o-rings are preferred. Prior to 1992, Toyota used NBR o-rings. Starting in 1992, Toyota switched from NBR o-rings to HNBR o-rings. Toyota's NBR o-rings were originally black. Their HNBR o-rings are brown. My 92 had a mix of black and brown o-rings, so it was produced during the transition. Current replacement o-rings from Toyota are brown HNBR o-rings. Aftermarket HNBR o-rings are generally, but not always, green.
I found a TSB AC92-004 that specifies the color and material change for the o-rings:
There are some 'hidden' o-rings that aren't on the diagrams.
Where the high-side service port screws into the block joint above the receiver/drier:
Where the lead-filled fuse bolt screws into the block joint above the receiver/drier:
Where the pressure relief valve screws into the compressor manifold:
Toyota part numbers for o-rings:
Evaporator x Expansion valve: Qty 2 of 90099-14045
Expansion valve x Tube Assy: 90099-14045 and 90099-14044
Tube Assy x Liquid pipe: 90099-14044
Tube Assy x Suction pipe: 90099-14045
Pressure Switch x Liquid pipe: 90099-14056 (*1)
Suction pipe x Suction hose: 90099-14045
Suction hose x Compressor manifold: 90099-14045
Discharge hose x Compressor manifold: 90099-14046
Discharge hose x Condenser: 90099-14046
Condender x Liquid pipe A: 90099-14046
Liquid pipe x Receiver/drier: 90099-14044
Receiver drier x Liquid pipe B: 90099-14044
Liquid pipe B x Liquid pipe: 90099-14044
Liquid pipe B x High-side service valve: 90099-14056 (*1)
Compressor manifold x Pressure relief safety valve: 90099-14056 (*1)
Liquid pipe B x Fuse bolt: 88475-12020 (*2)
Compressor manifold x compressor: Not available separately from Toyota. Use Honda #38839-PR7-A01:
*1. Toyota claims that 90099-14056 is a 9.25mm ID x 12.81mm OD o-ring. This equates to a #012 standard o-ring, which is nominally 3/8" size. However, Toyota's o-ring is on the thin side. I ended up using TSI part #77147, which is a little thicker than the Toyota o-ring.
*2. This part number is for the fuse bolt and the o-ring, and it's not cheap. It is a 8.8mm ID x 1.9mm thick o-ring:
The Toyota suction hose has some heat insulation around it. Mine was pretty degraded. Aftermarket hoses don't come with the heat insulation. I used Thermo-Tec Thermo-Flex Aluminum Heat Shield Sleeve 17150, which is an exact match to the factory insulation in size, and very close in overall appearance.
I have a low-milage GT-S, and I used that for reference to see how the compressor wires are routed. Here's how they go:
I found a TSB AC92-004 that specifies the color and material change for the o-rings:
There are some 'hidden' o-rings that aren't on the diagrams.
Where the high-side service port screws into the block joint above the receiver/drier:
Where the lead-filled fuse bolt screws into the block joint above the receiver/drier:
Where the pressure relief valve screws into the compressor manifold:
Toyota part numbers for o-rings:
Evaporator x Expansion valve: Qty 2 of 90099-14045
Expansion valve x Tube Assy: 90099-14045 and 90099-14044
Tube Assy x Liquid pipe: 90099-14044
Tube Assy x Suction pipe: 90099-14045
Pressure Switch x Liquid pipe: 90099-14056 (*1)
Suction pipe x Suction hose: 90099-14045
Suction hose x Compressor manifold: 90099-14045
Discharge hose x Compressor manifold: 90099-14046
Discharge hose x Condenser: 90099-14046
Condender x Liquid pipe A: 90099-14046
Liquid pipe x Receiver/drier: 90099-14044
Receiver drier x Liquid pipe B: 90099-14044
Liquid pipe B x Liquid pipe: 90099-14044
Liquid pipe B x High-side service valve: 90099-14056 (*1)
Compressor manifold x Pressure relief safety valve: 90099-14056 (*1)
Liquid pipe B x Fuse bolt: 88475-12020 (*2)
Compressor manifold x compressor: Not available separately from Toyota. Use Honda #38839-PR7-A01:
*1. Toyota claims that 90099-14056 is a 9.25mm ID x 12.81mm OD o-ring. This equates to a #012 standard o-ring, which is nominally 3/8" size. However, Toyota's o-ring is on the thin side. I ended up using TSI part #77147, which is a little thicker than the Toyota o-ring.
*2. This part number is for the fuse bolt and the o-ring, and it's not cheap. It is a 8.8mm ID x 1.9mm thick o-ring:
The Toyota suction hose has some heat insulation around it. Mine was pretty degraded. Aftermarket hoses don't come with the heat insulation. I used Thermo-Tec Thermo-Flex Aluminum Heat Shield Sleeve 17150, which is an exact match to the factory insulation in size, and very close in overall appearance.
I have a low-milage GT-S, and I used that for reference to see how the compressor wires are routed. Here's how they go:
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RedCelicaTRD
Moderator
Very nice. I believe the condenser is originally a Denso unit and is still available online, but not available through Toyota.
Luvmyalltrac
Member
YYonline, Excellent information! Thank you for adding it to my thread!