fraggle

Have new bolts ready, you don't want sketchy ones going back in.

bureau13

Hmmm...that's actually a good point...although I didn't THINK the bolts were actually the problem....maybe they were.

FredR

Jeff,

You will just have to chase down the source of the leak- nothing more frustrating than having slow leak sure in the knowledge that it is going to go flat. I am a little intrigued as to why you would conduct [pressure test with air- worried about moisture content? I am not sure I understand this given the system is open to air when joints are broken etc. If you can do a pressure test and chase leaks with soapy water all well and good- the only thing you cannot test this way is the evaporator and if nothing else leaks well....we know where to look suspiciously.

My compressor was the source of an annoying leak but it was not the dynamic shaft seal it was the body seals that were leaking- do you know if these were changed/are holding up?

Good to read that Jake had success with his expansion valve removal. Just goes to show the importance of stepping back and thinking about problems before diving in and ripping everything out.

Good luck finding the leak

Regards

Fred

bureau13

Hmmm, maybe you're right...I was thinking I wouldn't want to put more moisture in the system, but as you say...it's no longer sealed up. I also do not have the new drier installed yet, so no worries about ruining that one.

The compressor is a factory reconditioned unit and looked brand new. I did put brand new o-rings on with the service valves.

Someone else suggested I could pressurize it with R134a w/ dye, since I'm not actually running it, and then evacuate it after I use a detector to find the leak. Not sure if that's a great idea either. I'm tempted to take it somewhere and just have them find the leak, if they'll do that.

FredR

The dye with UV light to spot the leaks is the best system I have seen used to find leaks in places you can see.

I take it your hoses have been rebuilt or replaced and the expansion valve is new? Just remember the compressor having been rebuilt should be tight but...? When the above are all good and the joint seals have been refreshed that only leaves the pipes, the condenser and the evaporator.

I take it you have no rear a/c?

Rgds

Fred

bureau13

No rear AC. Regardless of what may or may not have been good before I touched it, I'm am sure something that I've touched is the source of this massive leak. There was still pressure in the system when I disconnected it, after well over a year (at least) of non-use. So, even though I haven't rebuilt the hoses*, unless my twisting things around during compressor install caused one of them to spring a leak (which admittedly is a possibility) I suspect an o-ring or something that I've already swapped out is the problem, since it's such a large leak.

*There's probably a better than even chance that the old original hoses would have leaked out freon faster than I would want, but this is something different. I held vacuum for less than 30 seconds, after all my "fixing."

FredR

How long was the system stood static in the pressurised condition? Our experience over here is that if the system is left static for too long and then started up, the oil layer dries out and upon starting the lack of lube at the seal face causes the seal to fail. This is why I recommend folks to use the a/c for a few minutes at start up at least once a month even during winter. This simple procedure seems to work but of course in our conditions the seal face is likely to dry out quicker.

Over here a/c's end to be used most of the year so they get some clog but seal problems, although they can and do occur, are quite rare in my experience.

Rgds

Fred

bureau13

I really do not know...when I got the car last summer, there was no belt on the compressor at all. I know the car had been sitting for quite a while, and I'm betting that the compressor was making noise when the car was being driven, so they cut it off. Just a guess though. I was surprised that there was any pressure in the system, given that it could well have been years without use. I just got the compressor and put it on a week ago though, so the compressor itself is (well, should be) fine.

I still haven't put a belt on it, actually. I want the thing to at least hold a vacuum before I (a) replace the drier, and (b) take all my other belts off so I can put a belt on the compressor.

FredR

Just done my belts and some wiring r/r myself plus a few more while you are at its- not much fun working flat on your back in 40C heat and being on the wrong side of 60. The few muscles I have left are well toned though!

Rgds

Fred

bureau13

No kidding...I REALLY wish I had a lift these days...