Air Con issues

[jeffreycrowder]

Having recently bought privately my 2005, 987 car with 59k on the clock, I noticed that the A/C system did not produce any cold air even though it was only serviced two months earlier.
My local service specialist advised that the system won't hold pressure and it probably needs new condensers!
Is it always the condenser/s that fail, what about the pipework?
Never had a car with a/c issues with such low mileage, is it a common issue?
Any advice please.

 

[tscaptain]

The condensers are prone to damage whatever the mileage and corrosion with age. If they can tell you it won't hold pressure they should be able to detect where as the fluid should contain a dye which shows under UV light.

 

[jeffreycrowder]

If I change the condensers and ensure there are no system leaks would it then be ready for a re gassing or are there other items that could need replacing?
Has anybody other than on the US chat sites done a rebuild themselves?

 

[Robin M]

Air con issues always come with age irrespective of mileage. Seals fail if it's not used much as well as the well known condenser issues TSCaptain refers to. Get it leak tested and replace what's failed which probably will be the condenser. Then either regas and see what happens or retest and go from there. My 11 year old VW started to hiss and groan a bit this year which is a sign of seals going to fail eventually.

 

[AndyW1973]

The Boxster is prone to 'collecting' leaves and debris via the front bumper intakes, which gets trapped in the corner between the condensers and radiators (on both sides of the car). I'm not sure how similar the 987 is to the 986, but would imagine it is much the same looking at the front bumper on the 987. The collected damp debris has a tendency to corrode both the rads and condensers if not removed. You really need to take the front bumper off (not too bad a job) to get the stuff out from between the two units. I have made a vacuum cleaner extension using a piece of garden hose that allows me to regularly suck out most of the leaves at the front by feeding it through the bumper intake to reduce the amount of rubbish build up.

Attached is a photo showing how much debris builds up and the resulting leak in my condenser (clearly visible bottom left and top right by the dark, oily areas). I sourced a new condenser and O-ring for under £50 from Eurocarparts and fitted it myself in less than 5 minutes. I had it refilled and pressure tested for 3 hours at a local garage for £70.

 

[jeffreycrowder]

Thanks for the comments, new to this sort of communication!
As Andy kindly points out that the condensers are prone to corrosion and probably made of aluminium for lightness. I guess they would not corrode if copper like many radiators.
I am intending to strip the front down when the inevitable colder weather arrives, at the moment its really warm and the aircon would not be used with the top down.
I picked up a condenser from Europarts for under £50 which is very different from the ones quoted from Porsche centres.
They are probably built in the same factory but with the 'badge' attached warrant a four fold price hike.
So as suggested, strip the system, replace faulty condenser/s and o rings, etc and re-gass at £35 from FastFit shops!
It will be a few week yet but armed with the ability to do it myself should save a packet!
I will come back and advise.

Whilst chatting, I had another problem that I hope to have now fixed.
The warning light came on the dash suggesting an engine problem.
Having already spent £120, after purchasing the car, having the car checked by a local specialist with no errors showing, and a suggested further £60 to advise on the latest warning, I bought a POR11 diagnostic tool.
It advised that both engine banks were running rich at idle, I had experienced a couple of instances of stalling when at low revs suggesting a mixture issue.
When starting it sounded rough and smoke was issuing from the exhaust.
Being both banks it seemed it might be an issue before the combustion chambers, not plugs, etc, so I researched and someone suggested the filler cap could be leaking and allowing the car to run rich.
Replaced the filler cap and bingo, started straight away and no smoke or irregular running.
The cost, £8, bit different to the £60 to investigate!
Are we being ripped off?
I know of the saying that if you can afford a luxury car then you need to be able to pay for its servicing but £65 per hour compared to £35-40 seems a bit of a rip off! IMHO.
My local Wheel & Tyre depot fitted discs, pads and hand brake shoes in 3 hours for £120, again the service centre wanted £250!
Thanks for the support from members and user groups.
I guess this is why 70% of Porsche cars are still running, being maintained by motoring enthusiasts.

Jeff C.

 

[Boxbrownie]

£65 per hour? [:-] Please tell me where this OPC is exactly?.............I'll pre book all my services for the next ten years there

More likely 120-150 an hour depending upon location I am afraid.

 

[PaulBG]

Remember to clear regularly the leaves from the front air inlets.
They create a damp problem to the bottom outside corner to each condenser, shortening their life.
Had my two condensers replaced by an air-con specialist recently, with a bill of just over £300.
Better to clear the leaves!

 

[jeffreycrowder]

Thanks PaulBG,
Does anybody have any thoughts/experiences with the aftermarket wire mesh grills seen on some cars?
I can't imagine they would affect the volume of air passing to the radiators, especially for road use in the UK compared to the Deep South.
Strange that such a simple mod has not been adopted, even some fine chicken mesh would stop the rubbish lodging in the obviously vulnerable condensers and could be pulled out and cleaned without recourse to a strip down!
Just a thought.

 

[kitchens]

https://www.google.co.uk/#q=zunsport+grill

Zunsport is one company that do them there is a few topics around re this product

 

[Motorhead]

Jeff,

There's a useful DIY on wire mesh grilles here:

https://www.porscheclubgb.com/forum/tm.aspx?m=613041

Jeff

 

[Boxbrownie]

Jeff,

There's a useful DIY on wire mesh grilles here:

https://www.porscheclubgb.com/forum/tm.aspx?m=613041

Jeff

Link just leads to general forum page for me I am afraid, do you have the specific subject thread?

 

[jeffreycrowder]

I am thinking of fabricating a pair of grills from copper wire so that the joints can be soldered and filed flush.
The finished job can then be spray painted according to body colour and fitted in the recess in front of the opening.
That way there is no need to remove the bodywork and risk of damage.
A couple of colour matched tie wraps could discreetly hold them in place.

Also, if the condensers are made of aluminium and subject to such early corrosion, why are they not coated with an inhibitor.
I read that you should not wash down a Boxster engine because it would remove the factory applied aluminium protective coating, strange!

 

[jeffreycrowder]

Thinking along these lines!
http://www.porscheshop.co.uk/acatalog/porsche_997_body_styling.html
Hope this link works, first attempt at such things.