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Yet another "I'm going to refresh the A/C" thread.
I have finally decided I needed to do something about the lack of aircon in my 1990 C2 Tiptronic. Basically I haven't had aircon for years (17 years of ownership, 12 years sans aircon).......not exactly a necessity when living in a mild climate.
My intention is to remove and replace pretty much everything from the compressor through to the drier, servos, condenser, evaporator and blowers because I suspect most of the O rings and other bits will have dried out. I know this has been documented before, sometimes partially and some resources are very dated with missing photos, so I hope this helps others.
Many thanks to those who have gone before me, these are the resources I constantly referred too:
Obviously the first step is to make sure your system is evacuated to get rid of any remaining R134. A local garage did this (wasn't anything much left in there anyway - ok, nothing.) and I took the opportunity to remove the compressor as the red hose fitting wouldn't quite fit (not enough room between the connection and the oil filter).
I also did my 'best' to use as much petrol as possible on the way home (the long way.....with corners and things) so that the fuel tank would be as low as possible prior to removal.
The OBC claimed I had 60 km worth of fuel left.
Remove the trunk carpet, the spare wheel, battery and anything else in the way. My car is RHD so some bits will be on the 'wrong' side for those LHD countries.
I also removed the small tank on top of the main tank. Not necessary but I intend to replace some of the hoses and want to know where they all go. This is held down with 3 x 10mm bolts. Beware of the black spacers between the two tanks.
Unplug the fuel level sender and unscrew the 50mm hex top. Trying to siphon the last of the petrol out via this hole proved fruitless (not keen on getting high....really, I'm not).
Also discovered the source of the faint petrol smell I would get occasionally when opening the frunk.......the O ring for the fuel level sender was kinked and clearly not sealing well.
Best option is to drain the tank via the petrol pump.
Undo the hose clip on the left side (red circle.....I know sh** photo), pull the hose out while crimping it and make sure you have a suitable container to catch the excess fuel (I had about 8 liters left). Oh yeah, wear eye protection and keep a couple of rags handy. There will be splashes. Undo the return hose (yellow circle) with a 17 mm & 19 mm wrench. There will be some fuel still in this line.
Undo and pull away the fuel filler and overflow pipes.
Remove the 13mm bolt from the tank strap, the plastic protective cover falls out, and then with a bit of wiggling the strap will come free from the other end. The tank should come free with a bit of jiggling although I had to go underneath again and feed the fuel hoses up past the fuel pump a bit. Easy to do as I have a hoist.
Next is the relay/fuse box and the firewall. Remove the 3 screws marked in red and remove that small panel. Underneath that are two 7 mm screws to be removed. Undo the screw fitting marked in yellow and then everything should be able to be pulled aside.
The firewall itself has a few screws down one side (white marking) and an electrical plug in the center (marked in yellow.). It should then come out easily.
Off to a running start! I'm subscribed for pix of the suitcase guts, notably to see how you fix the seals around the mixing servo motor flaps to prevent unwanted heat. I'm also here to help where I can as I've done this in bits and pieces. Last nite I refreshed the servos themselves, which are of a remarkable familiar construction to anyone who has refreshed the AFM, but unlike later I don't believe a new "wiper track" is available as a spare. If I'm wrong please say!
Since you have the tank out do you have any while you're in there tankwork planned? Perhaps check the strainer at the outlet?
Ha, how ironic. I've just had my suitcase completely apart last weekend redoing the flaps, case seal and a bunch of other things like a new evaporator. I'll be doing that write up tomorrow on my "another 64" thread.
Hold my beer......................yes there is a solution for the servos. New bits. Pics/instructions/info coming.
The tank is getting a clean out and a new filter. Pics to come.
I do have the suitcase apart.Once I have posted them feel free to ask for more specific pics if needed.
Ha, how ironic. I've just had my suitcase completely apart last weekend redoing the flaps, case seal and a bunch of other things like a new evaporator. I'll be doing that write up tomorrow on my "another 64" thread.
Too funny! As you have already been there done that, feel free to add, tweak, inform and post pics to supplement my posts.
Semi-naked suitcase with firewall removed. Someone has definitely been here before. The wires to the blowers had been cut and repaired. The fuel hoses look to have been replaced as well, but will redo those and the fuel pump anyway as this must have been worked on about 20 years ago.
I'll be on the lookout for the suitcase pics. I'm trying to understand what makes the L/R heat blockoff flappies stop blocking off the heat. Here are a few pics I've collected from the innernet.
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Yet another "I'm going to refresh the A/C" thread.
