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100 series Air Con pipe repair

warrenpfo

Well-Known Member
Joined
Jul 21, 2010
Messages
2,895
As most of you know our 100's have a rear air con unit which has 2 pipes running from the engine bay to the rear. One small and one large running under the driver’s side.

It is a common fault that due to the salt on our roads the smaller of the two pipes corrodes over time and needs replacing. The way the 100's are made you have to lift the body to replace the pipes which Toyota want £1600 to do. Here is what i did:

I took the car to get it pressure tested at Pirtek in Reading and got under the car to establish that i had 4 pin holes and that the previous owner must have had it fixed by a fast and dirty chap as there where two push fit joins in the pipe work that where not fit for purpose.

I asked the chap at Pirtek if he could vacuum out anything still in the lines and he told me that there was no need as anything that was in the pipe work would have worked its way out over time and I was free to dismantle if i wanted to.

When i got home i went to work with a pair of side cutters and ended up with this:
6005873747_29c49e67d2.jpg

The length of pipe from the rear to the front is made up of 2 sections and i made sure that i left enough space at each end to work with:
6006412520_49c2302841.jpg

If you are careful you end up with 2 male and 2 female ends, one set you can keep as spare for future use if needed:
6005876327_4f303230fd.jpg

I cleaned up the pipework with and oven cleaning pad and boxed them up and sent them to Burgaflex (http://www.burgaflex.co.uk/contact.php#)

I dealt with a chap called Robert option #2 on the phone he is the technical guru. After a brief discussion and a few measurements i received a parcel at my front door 2 weeks later:
6006399364_5f44c9548a.jpg
6005860369_a5e34415a1.jpg
6005863771_7f18a7f910.jpg
6005863771_7f18a7f910.jpg

I fitted the hose yesterday and a great chap called Mike from Air Medic came round today to pressure test it and fill the system. He being the expert was very impressed with the workmanship and i can’t say enough about the service i received from Burgaflex. Ok i know it’s not alu pipe and will not last as long but Mike said it should do 5 years and might then need to be replaced. The way it has been manufactured all i will need to do is order a section of hose and swap out the old one.

The best part is that the hose only cost me £86 delivered to my door.

Fantastic product for what is a common problem. Hope it helps someone else down the road.
 
Hi Warren

Thats brilliant, If I could not get mine repaired, I was going down that route,
But can this post be locked (or what ever they call it)

as if mine goes again that's what I am doing.

{Admin - long quote removed and thread added to 100 series FAQ}
 
air con repair on my lexus lx470

Hi Warren

Thats brilliant, If I could not get mine repaired, I was going down that route,
But can this post be locked (or what ever they call it)

as if mine goes again that's what I am doing.

{Admin - long quote removed and thread added to 100 series FAQ}

Hi Warren

I have recently bought a Lexus LX470 which is the equivalent to the Amazon 4.7 (2000) Same proplem with air con pipe.
I have requested Burgaflex to quote me exactly as yours. Will keep you posted once the job is done.

Thanks a million for the post
 
Hi Warren,

thanks for for the post and the details of Burgaflex. Out of interest when you were a Pirtek would they not make what you wanted or were they to expensive?
 
Pirtek specialize in hydraulic hoses and not AC hoses so they could make the hose but the hose its self was not capable of holding the gas so it was a non start.
 
Thanks for this great advice, I'm about to cut my old one out and replace.
Interested to know if the fix from 2011 is still working?
 
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Did the aircon at the front still work , as my pipes have been disconnected but aircon at front works
 
As most of you know our 100's have a rear air con unit which has 2 pipes running from the engine bay to the rear. One small and one large running under the driver’s side.

It is a common fault that due to the salt on our roads the smaller of the two pipes corrodes over time and needs replacing. The way the 100's are made you have to lift the body to replace the pipes which Toyota want £1600 to do. Here is what i did:

I took the car to get it pressure tested at Pirtek in Reading and got under the car to establish that i had 4 pin holes and that the previous owner must have had it fixed by a fast and dirty chap as there where two push fit joins in the pipe work that where not fit for purpose.

I asked the chap at Pirtek if he could vacuum out anything still in the lines and he told me that there was no need as anything that was in the pipe work would have worked its way out over time and I was free to dismantle if i wanted to.

When i got home i went to work with a pair of side cutters and ended up with this:
View attachment 69967

The length of pipe from the rear to the front is made up of 2 sections and i made sure that i left enough space at each end to work with:
View attachment 69968

If you are careful you end up with 2 male and 2 female ends, one set you can keep as spare for future use if needed:
View attachment 69969

I cleaned up the pipework with and oven cleaning pad and boxed them up and sent them to Burgaflex (http://www.burgaflex.co.uk/contact.php#)

I dealt with a chap called Robert option #2 on the phone he is the technical guru. After a brief discussion and a few measurements i received a parcel at my front door 2 weeks later:
View attachment 69970
View attachment 69971
View attachment 69972
View attachment 69973

I fitted the hose yesterday and a great chap called Mike from Air Medic came round today to pressure test it and fill the system. He being the expert was very impressed with the workmanship and i can’t say enough about the service i received from Burgaflex. Ok i know it’s not alu pipe and will not last as long but Mike said it should do 5 years and might then need to be replaced. The way it has been manufactured all i will need to do is order a section of hose and swap out the old one.

The best part is that the hose only cost me £86 delivered to my door.

Fantastic product for what is a common problem. Hope it helps someone else down the road.
Do happen to have the lengths by any chance
 
Hi all . I know this thread is very old but I'm in the same position no Air con at the back but the front is knackered also. Is there a quick fix for both ends using this type of pipework as described as above. ????
 
hi repaired mine with 10mm copper pipe and 10mm to 8mm reducer compression fittings been ok last 12 months
 
Mine is still bust and the garage that I use say its not worth repairing due to the costs
Do you live near the Peak District ?
 
No i live in the midlands like you i priced up to do a proper job but ridiculous prices that's why i decided to try gas pipe and fittings i left original pipe in place just routed the gas pipe as best i could by the original left a bit of original pipe on so i had something to connect to. Hardest part of job was routing the pipe total cost of repair was around 25 pounds
 
Thanks for that i might encourage a mechanic to do the same for me. Is there anyway I can test the other components of the ac first to make sure they're working first ??
 
My aircon specialist fitted flexible pipes fro to rear all good 2 years
 
How much did he charge and did he just have to fit new pipes ? Thanks
 
It was St Helens . I think around £300-350. He did a really good job
 
0C160CD7-485E-42EE-B1E9-B51A9AB3E377.png
 
Would you be able to let me have his contact details please as I miss the ac . Would I need to check out my compressor etc first?
 
Oops I've just seen the link Cool Wheels. Ill give them a call tomorrow and report back . Thanks once again
 
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