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Air Con

Boris the spyder

New member
Hi All, first issue encountered with the car, both air con rads weeping. So first time DIY fix for me, as its an expensive job at the OPC. Parts arriving today including the desiccator. Looks like it should be straight forward enough [:-]. We do domestic air con so have the gauges and vac pump. So going to tackle it, vac it out, drive it into my local Mitsubishi dealer who has the kit to do the work. Would have done this too but their machine automatically measures in the correct gas and oil and I dont have that gas in stock anyway. Got a great step by step PDF for the bumper removal and dont need to get into the engine bay. Anyone who can add any tips would be good. I read something about purple o-rings from the OPC, should i get these and discard the kit ones ?

Best Graham
 
I have just done this job on my 981.

When I bought the car the intention was to pay people to fix anything that should go wrong having worked on cars for 40 years I thought I would pay someone else to do it.

Then I got some prices and after some youtube videos I thought this jobs looks easy, and it is.

I bought two OE quality condensers from Euro Car Parts that came with green O-rings. I soaked the O-rings in PAG oil for a few hours before fitting (PAG oil I also bought from Car Parts 4 Less for about £5)

I also bought the drier from ECP but the supplied green O-rings were too small so I was very careful in removing the old purple ones then soaked these in PAG oil before refitting.

I was also concerned about the front bumper duct openings being the culprit to early condenser failure. Every time I wash the car I clear the ducts of debris & stones but thought they should have more protection. So I bought some plastic mesh from Car Builder Solutions and from paper templates I cut this to fix to the rear of the duct opening cross bars with small cable ties. The mesh cell size is 25mm x 10mm.

https://www.carbuildersolutions.com/de/moulded-abs-hex-mesh-large-sheet-1500mm-x-300mm

I know the aftermarket steel mesh ones have a smaller mesh size and they told me when I was enquiring about their grilles that they have never had any feedback that the small mesh restricts the air flow.

However my son works in F1 (not in aerodynamics but he uses aerodynamic theory in what he designs) and he recommended the larger mesh size for adequate air flow.

The cable ties cannot be seen as I put them under the cross bar covers.

I then took it to a local garage to refill with gas.

I was quoted that for a system up to 650 grams of gas costs £45, above 650 grams the cost goes up dependent on gas used.

I understand that all Boxster's take 850 grams.

Cost me £88 for a recharge.

And the used o-rings obviously held up as their automatic filling machine apparently prevents a refill if there is any leakage on the system under vacuum conditions.

 
Hi LL, thanks for the reply, parts arrived today from Design 911. Hella rads, dryer, and o-rings. Did notice how small the dryer ones look, might scavenge original ones too. Yes the costs do get out of hand quickly these days at dealerships and not only at Porsche. I was quoted almost £1200 to do the job and just could not justify that in my mind. I have all the tools and info and even with the help of the dealer in town to re-gas when I am done the job will come in below £500. There is a lot of things I can spend £700.00 on. I love the car and i want to keep a full Porsche service history, but if I can safely do intermediate faults with the car then I shall. I am an enthusiast not a millionaire 🤓

 
Boris the spyder said:
Hi LL, thanks for the reply, parts arrived today from Design 911. Hella rads, dryer, and o-rings. Did notice how small the dryer ones look, might scavenge original ones too. Yes the costs do get out of hand quickly these days at dealerships and not only at Porsche. I was quoted almost £1200 to do the job and just could not justify that in my mind. I have all the tools and info and even with the help of the dealer in town to re-gas when I am done the job will come in below £500. There is a lot of things I can spend £700.00 on. I love the car and i want to keep a full Porsche service history, but if I can safely do intermediate faults with the car then I shall. I am an enthusiast not a millionaire 🤓
Did mine too, parts from the same supplier. Yes it was easy, no issues. I saw one video of somebody removing the clips that hold the bumper the wings near the headlights by puling fairly brutally. They slide to one side, use a pair of long nose pliers and slide them out. I used Design911 supplied o rings. Also thought about changing bolts but used old ones. I printed some grills on a 3d printer and fitted them before the bumper went back on

 

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