987 Aircon condenser replacement

987 Aircon condenser replacement

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dunc_sx

Original Poster:

1,295 posts

161 months

Wednesday 3rd March
quotequote all
Car is 987.2 Cayman S.

I've had a suspected a/c leak confirmed as being a drivers side condenser leak (now evacuated), I'll be doing the work myself then taking it back to get refilled. Anything in particular I should be looking out for? Planning to order and fit:

  • 2x Condensers (any recommendations on brand/where to buy them?)
  • 4x O-rings (will use OEM)
  • Zunsport grills (other alternatives?)
  • Garage suggested replacing the x-over connecting pipe between the two condensers
Any other bits I should be purchasing (fasteners etc) or other jobs I should be doing at the same time?

It's the first time I've done this job, plan is to use any guides/vids online.

Thanks in advance,

Dunc.

colin_p

3,214 posts

176 months

Wednesday 3rd March
quotequote all
Only thing I can think of is using the correct PAG oil to wet the 'o' rings on assembly. Probably PAG46, but double check.

dunc_sx

Original Poster:

1,295 posts

161 months

Wednesday 3rd March
quotequote all
Yes it does look like PAG46 from what I can tell, thanks for that thumbup

tozerman

1,071 posts

191 months

Wednesday 3rd March
quotequote all
Very straightforward job to do.
Hardest part is removing the bumper, but even that is not too bad.
Can't really see the point of replacing the connecting pipe if there's nothing wrong with it, they can be expensive.
I got a kit from Design 911 with Hella/Behr condensers and drier. Cost about £250 from memory.
Good luck

Edited by tozerman on Wednesday 3rd March 19:05

churchie2856

292 posts

154 months

Wednesday 3rd March
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If doing yourself you could fit black mesh inside the bumper rather than fork out on Zunsport grills. The mesh costs about a £15.00.

I made my own grill for my 997 and 718 - there’s a thread on PH about my 718 ones.

kilarney

436 posts

187 months

Wednesday 3rd March
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Change the receiver dryer as well

dunc_sx

Original Poster:

1,295 posts

161 months

Wednesday 3rd March
quotequote all
tozerman said:
Very straightforward job to do.
Hardest part is removing the bumper, but even that is not too bad.
Can't really see the point of replacing the connecting pipe if there's nothing wrong with it, they can be expensive.
I got a kit from Design 911 with Hella/Behr condensers and drier. Cost about £250 from memory.
Good luck
Hi tozeman, I'll take a look on design 911 for the kit. He seemed to think the link can be weak having done multiple others, I'll just see how it looks when I've got the bumper off, ta smile

churchie2856 said:
If doing yourself you could fit black mesh inside the bumper rather than fork out on Zunsport grills. The mesh costs about a £15.00.

I made my own grill for my 997 and 718 - there’s a thread on PH about my 718 ones.
Churchie, having now seen the price of the Zunsport ones that was my first thought, I'll take a look for your thread - thanks.

kilarney said:
Change the receiver dryer as well
Kilarney, what's the theory behind changing these? I hadn't planned to but have since seen it's fairly common to do so.

Thanks all.

Dunc.

PaulD86

1,214 posts

90 months

Thursday 4th March
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I did this job a few weeks back. Easy enough. I also changed the dryer, but not the cross hoses. The hoses looked absolutely fine. The dryer removes moisture from the system and if it has been leaking badly, as mine had, who knows how much condensation or whatever could have worked in.

Don't go for the design 911 kit as you can buy identical parts to what's in it for considerably less. Some of the generic car part places sell them. I got the seals from my OPC and also changed the dryer seals. My OPC were cheaper than design 911 (which I have found to be the case on all but one genuine item I've bought so far - there have been a fair few recently and sometimes OPC have been a third less than design 911!).

kilarney

436 posts

187 months

Thursday 4th March
quotequote all
dunc_sx said:
Kilarney, what's the theory behind changing these? I hadn't planned to but have since seen it's fairly common to do so.

Thanks all.

Dunc.
It has dessicant in there which absorbs moisture but becomes depleted in a holed system. Water in the system is corrosive and also freezes affecting the system functionality. Deffo change it.

Jaykay495

26 posts

42 months

Thursday 4th March
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Just done the same on my 987.1

Both condensors replaced, as well as the drier/dessicator. There are seven seals, two per condensor and three on the drier. Get new ones. About a fiver each, but well worth not skimping on.

I got the condensors from wherever (cant remember, about £100 delivered), and the drier and seals from Porsche. If you ask the parts peeps nicely, they will chop 10% off, and if you are capable of charming the birds from the trees, they’ll post the parts to you. I had to settle for 10% off wink

There are a few guides as to how the bumper and arch liners come off, so take a look at them. Liners have to come off due to a torx screw each side on the bumper up near the repeaters, and also an electrical connector that has to be undone on drivers side.

I used a medium sized cardboard box to put the torx screws in as i went around the car, and pushed them through the cardboard forming their placements on the front bumper and inner wings. This kept things simpler for me.

I also jacked up the car on the front drivers side jacking point and removed the front wheel to be able to get at the arch-liner screws. The front passenger side was ok without removing the wheel. Drivers side needs to come out to undo the large electrical connector that powers all the stuff in the front bumper.

Once the front bootlid is raised, the black trim is velcroed on between the wings and the front boot. The trim around the bootlid lever is a bit of a faff to remove, but you’ll work it out.

There should be two clips that sit on a diagonal line between the headlamps and the front number plate. These need to be undone by sliding them in towards the bootlid lever. They are metal and have a small hole that Porsche may have a tool for. I eased them out using a thin screwdriver, and protecting the paint with a microfibre.

Once bumper is off, everything is easy to access. You’ll need an allen socket for the condensor connections, but mine came off easy on a 2005 car.

It all buttons back up nicely, as long as its all in the right place.

Was about 4 hrs for me, but I was taking it very steady. Check all the lights work once you’ve reconnected the plug and before you refit the drivers side arch liner.

I was a bit nervous as there are seven seals and seven points it can leak at, but it all gassed up well and works fine again. I scavenged oil from the outgoing condensors for my seals, and there wasnt much to go around.

Boxsters need quite a bit of gas, 850g of R134, and 195ml of oil. Be sure to tell them its had new condensors and drier at the regas, so they know the oil will also need refilling. Some machines wont be able to add as much as 195ml.

Quite a nice job, and just take your time.

Good luck!


gsewell

619 posts

247 months

Thursday 4th March
quotequote all
dunc_sx said:
Kilarney, what's the theory behind changing these? I hadn't planned to but have since seen it's fairly common to do so.

Thanks all.

Dunc.
When I had the condensers replaced on my Scooby, the invoice said the guarantee was null and void if the driver was not replaced and the system was flushed before filling.

dunc_sx

Original Poster:

1,295 posts

161 months

Saturday 6th March
quotequote all
Thanks for the detailed resposes folks, great effort.

Understood on the drier but can't beat the design911 price on the Behr/Hella condensers.

OPC price for the parts (2x Condensers, drier, 6x o-rings) is £736, Design911 is £264, other online parts places are cheaper for cheaper brands but higher prices for the more highly regarded brands.

Think I'll be going with the Design911.

Thanks,

Duncan.

PaulD86

1,214 posts

90 months

Monday 8th March
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I found the condensers design 911 sell for £80 each. Wish I could remember which seller that was. The O rings I got from Porsche and the dryer was from one of the generic parts places but a decent brand. Worked out cheaper than the kit.

Hope it goes well. thumbup

dunc_sx

Original Poster:

1,295 posts

161 months

Monday 8th March
quotequote all
Thanks Paul smile