Johannvb

My air conditioning is not working and my specialist has informed me that I have a leak in my condensor and that the system is not holding a charge.

I am planning to replace the condensor myself and was hoping you guys can help me on my way. I have searched this forum and the web, but cannot locate a DIY for replacing the condensor.

Can someone please point me in the right direction?

I would also like some help with regards, to what I should replace while I am busy. For example O-rings, dryers etc. And how can I test if the system is holding pressure without having it filled with refrigerant?

I know my way around cars and am a competent mechanic. My knowledge of air conditioning systems is however non existent so all help will be greatly appreciated.

Vandit

I used the $99 Behr OE unit from PelicanParts. It is a newer design (from 993) using a serpentine layout rather than the tube/fin layout of the OE 964 unit. The design makes it thicker than the unit you're replacing. You have to bend, widen, and generally open up the channel on the frame bracket where it sits. It should fit, just take your time and be patient.

As far as O-rings, they are quite a bit. I have a list of what I ordered from Pelican. I will find it and post. I bought more than I needed, but they're cheap so no worries. I replaced all when I did my evaporator and condenser in August 2014.

I used Nylog Blue lubricant on all o-rings during assembly.

Vandit

Remove the whole front bumper and forward left fender liner. It's right there once you do that. Good access.

As far as testing the system, AutoZone rents the vacuum pump. You also need a good set of gauges. I bought some from AutoZone after the gauges I got from Harbor Freight were useless. You want to pull vacuum on the system for awhile, close the gauges, shut off the pump, and have it hold vacuum indefinitely (overnight). There's YouTube videos that walk you through it.

Also, replace the drier while you're at it. It's in the rear of the front left fender well. I used the drier from a Civic. This only works on older 964s that have the 90-degree drier fitting.

This drier.


Read through this thread too, I left some more notes in there.
https://rennlist.com/forums/964-foru...vice-help.html

Vandit

Here are the o-rings I ordered for the whole system.

999-707-261-40-M325 $0.50 3 $1.50 A/C O-Ring (9 X 1.8 mm) Brand: Santech

999-707-251-40-M325 $0.75 5 $3.75 A/C O-Ring (14 X 2 mm) Brand: Santech

999-707-434-41-M325 $0.75 7 $5.25 A/C O-Ring (10.6 X 2 mm) Brand: Santech

999-707-247-40-M325 $0.25 6 $1.50 A/C O-Ring (7.5 X 2 mm) Brand: Santech

999-707-534-41-M325 $0.75 5 $3.75 A/C O-Ring (17 X 2 mm) Brand: Santech


I basically went through the PET diagrams and jotted down all o-rings mentioned and ordered extras just in case. I can't tell you which I used and how many, but I am pretty sure I used all sizes I ordered and was able to do the whole job.

Nylog Blue on all o-rings.

Earlydays

...did your specialist also inspect the evaporator, this is the most common leak area.
I agree with Vandit, replace all the O-rings and dryer at the same time.

Johannvb

Thanks for the advice gentlemen!!

My Specialist did notmention the evaporator, but I will ask to see if they tested/checked it. I saw the DIY thread on that and I really hope that my evaporator is good

Feudal Serf

Hey,
Once u start you are likely to dig out the whole front "suitcase".

Most AC guys dont really know these old systems.

Is there a hole in condenser where you hear the leak or a slow leak where the system loses charge over a few days.

If a slow leak you might consider some ac water remover and stopleak and a recharge :0. I know.

Basically this worked for me and i havnt needed a majot overhaul.

If there is a hole in condenser, then u have no choice.

Cheers

griffiths

The condensers are subject to external corrosion because the of the design/location gathers and retains debris, dirt and moisture = corrosion; at the bottom section of the condenser. I suggest a yearly inspection, looking at the bottom area and clean as needed.

The OEM evaporators, simply a poor design. When the system has a refrigerant charge you would sniff the evaporator box condensation drain tube under the tub and the vents with an electronic sniffer.

http://griffiths.com/porsche/air-conditioning/964-993/