A/C leak on my 2004 C2 cab

Just taken off the undertrays as part of the annual look see and there is a large patch of something which can only be A/C fluid on one of the rear trays just towards the rear on the drivers side where the A/C pipes are approaching the engine. Pipes all look fine and it's likely to be from the joint in the larger diameter pipe which is just there! I presume these joints have an O ring seal so is it a DIY job to change the seal and have it regassed? Any tips, issues to be aware of etc? Thanks for any responses.

I replaced my condensers as the air con hadn't worked for years (previous owner had it 9 years and never used the air con). On the pressure test prior to re-gas mine had gone in the same place. I bought two boxster pipes off ebay and managed to swap them out but if the bolts on those joints are seized it's a pig of a job under axle stands to grind off the pipes and drill out the bolts, as I found out. If/when you get the joints free you might find that the ally has corroded and new o rings won't help it. Aircon guy was super helpful and said it's common fault on these. I nipped an o ring doing it up as I'm not sure Porsche list the right size (bought an assorted pack off ebay for a few quid), he replaced it in ten minutes, pressure tested to 200psi (usually runs much lower) and it's been brilliant for the last few weeks. Awesome today taking the kids for an ice cream in a nice cool car. If you do DIY it and mess up the "good" side of the pipes, air con guy said he could fit a "joiner" rather than having to drop the engine to replace the pipe.

Just done this job on my car for the same "wet patch" around the joints. The large diameter pipe joint came apart easy (low pressure side) but the small diameter pipe (high pressure) was a nightmare, the bolt had completed corroded inside the fitting so I ended up having to drill the bolt out which wrecked the fitting. Luckily the small diameter pipe is the cheaper of the two and I paid just over £50 from Porsche Exeter for a replacement (from front to back). It also looked like the large diameter pipe was leaking on mine but I'm guessing it was the small diameter, high pressure pipe and the leak must have contributed to the bolt corroding in the fitting. The o-rings are a standard size and I replaced them with some universal ones from an air conditioning o-ring set from amazon with a lubing of ester oil. Not sure why Porsche didn't protect this joint better as the front joint has a steel cover plate covering it...

Thanks for the replies. I had a first attempt at undoing the joints and as predicted nothing moved! Retired unhurt to consider the next move. Am I correct in assuming that these joints are there only for Porsches convenience during assembly and that a piece of suitable pipe plumbed in would be just as good? Has anyone done this and if so what did you use?

Finally got round to attacking the leaking A/C pipe! Got a mobile A/C man to degas the system and I have been dousing the joint regularly with penetrating spray. Its the low pressure pipe, drivers side, the usual culprit. Initial attempts did not look promising, absolutely no movement and a real risk of rounding the hex recess in the bolt or damaging the aluminium pipe. Eventually got a good grip on the fitting with a Stilson wrench and with extra leverage the bolt actually moved and came out intact. Result! No obvious corrosion and joint looks good so I have cleaned up all surfaces and will replace the O ring and use a new bolt and washer, then have it leak tested. I will also replace the receiver dryer before having the system refilled. If there is still a leak it will be a new front section pipe or a good used if I can find one. For info the bolt is threaded into the forward, thicker piece of the joint only but it will appear to be locked in to the thinner rear section due to corrosion of the aluminium,so if you have to cut the bolt head the joint should separate, if not, its only corrosion thats holding it together. Hope this helps if you are about to tackle this problem, seems to be very common!

...same issue on my 996...gently but with commitment ,having soaked the offending Allen headed boot in penetrating , I undid it and like you cleaned the pipe and aluminium union which fortunately showed no corrosion...New £9 (!) O ring from my opc...put other I together...when I did mine I also changed the condenser and drier...regass and lovely cold air conditioning

No way am I paying £9 for one O ring ! A box of 270 is available on EBay for £5.95 incl postage, supposed to be suitable for A/C but who knows? I will get one from the mobile guy.

...indeed but didn't want to risk it leaking once regassed so splashed the cash!

On more careful inspection the low pressure pipe looks a bit dodgy in several places so I will replace it. Removed the old one today, what a pain, don't quite know how I will get the new one in but it must be possible if I got the old one out. Typical Porsche type job!!

Just to give you the heads up, after the same problem I've just ordered a brand new suction pipe as mine was damaged and it was £112.42+VAT from Porsche Centre Bolton (part number 996 573 091 01); I rung round several breakers and Douglas Valley wanted £128 for a used part. The O rings were a couple of quid each...

Thanks for the info, paying just under £125 from Porsche Silverstone and they may well throw the O rings in for that. Parts dept very good to deal with and well organised.

Breakers yard taking the piss...bloody typical of the greedy bastards ! I am sure they make the prices up on the spot :nooo:

Agree, some of the advertised prices on ebay for used parts are just ludricrous. What planet are these people on? You really have to do your homework first!

Some of the independent OEM suppliers are as bad, always worth checking with OPC first and buying from them will encourage them to continue to supply parts for older cars, Porsche are especially good in this respect.

I'll second this - Silverstone OPC have a great parts department in my experience. Think it was just over £125 for the pipe and o-rings, and they threw in some PAG oil to lubricate the o-rings when I realised I didn't have any.