987 Aircon condenser replacement - Page 2 - Boxster/Cayman - PistonHeads UK

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.

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

Yes it does look like PAG46 from what I can tell, thanks for that

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

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.

Change the receiver dryer as well

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 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.

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!).

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.

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 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!

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.

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.

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.

Thanks Paul

Resurrecting this thread as today's warm weather confirmed that my Cayman's condensors need replacing — I had the system re-gassed about six weeks ago, and today nothing came out of the A/C apart from a loud hissing noise. I got an estimate from a well known independent a few weeks back and it's just a wee bit more than I was expecting . Labour Replace front A/C condensors, inc. removal and refitting of front bumper cover. 248.75 Replace A/C reciever drier. 49.75 Vacuum and regas Air conditioning system including carry out operating pressure and leak test 119.40 Sub Total 417.90 Parts ACR134A Air Conditioning Refrigerant R134a 1.00 45.00 45.00 99657391102 condensor (OEM Quality) 2.00 256.98 -50% 256.98 99970743441 o ring 4.00 5.19 20.76 94457314301 receiver/drier (OEM Quality) 1.00 63.26 -30% 44.28 99970726240 o-ring 2.00 3.59 7.18 Sub Total 374.20 That's nearly a grand after VAT, so I'm looking for ways to get that down a bit. Unfortunately DIY is a non-starter as I don't have off-street parking. Is this is the kind of job a non Porsche specialist could be trusted with? It would be good to shave a few quid off the labour bill. Also it looks like I could cut the parts bill in half by just buying that Design911 kit ... does anyone know if the parts are directly equivalent to OE? I'm wondering if I could just rock up somewhere with that kit and have them fit it and re-gas, although in the past I've found some places won't fit parts they haven't supplied. Any advice appreciated!

I've not had to do it but I saw this on boxa.net the other day which may help: https://www.boxa.net/topic/70576-what-have-you-don...

I did it last month .Plenty of u tube vids on bumper removal. You need a 6 mm hex socket and penetrating oil to move the pipe bolts to the condensers . Find a relatives or mates drive . Costs were condensers £50 each , O rings a tenner , new dryer £30 .Then £60 @ Quick fit for the pressure test , re gas .The machine takes 40 mins to vac out the system , pressure check and refill . Also check the pipes by the drivers door front .They get damaged by lift pads as they are in very close proximity to the cars pad .That’s another £225 from a OPC for the parts , but easy to replace . While the fronts off waxoil the rad behind the condensers, it’s bracket and the notorious front coolant pipe connectors . If the cars a long term prospect owners really need imho to be able to remove the front bumper to waxoil stuff and clean between the condensers and water rads . It’s well engineered and Porsche have thought this one through.

Thanks for the detailed advice, unfortunately I don't have anywhere I can work on the car. If I did it would save me a packet as the car is in need of new discs all round soon. Downsides of city dwelling. On the plus side I've already shelled out for the coolant crossover pipes recently, so at least that's one unpleasant surprise avoided! Shopping round a bit I've got an estimate of ~£670 now which is a bit easier to swallow.

You should easily be able to get parts for under £200 and I changed the condensers on mine in a couple of hours. So £200 + a couple of hours garage labour and the cost of a recharge should be all you need to pay. My trusted local garage is £62+vat/hour and was about £75 for the aircon regas so around £400 all in should be doable even if you don't do any yourself. It's not the sort of job I think you need a Porsche specialist for, just any mechanic you trust. Brakes on these are a doddle to work on so again, any half compotenet garage can do them, although worth noting that caliper bolts are meant to be single use so should be replaced when pads/discs are done.

globular said: Thanks for the detailed advice, unfortunately I don't have anywhere I can work on the car. If I did it would save me a packet as the car is in need of new discs all round soon. Downsides of city dwelling. On the plus side I've already shelled out for the coolant crossover pipes recently, so at least that's one unpleasant surprise avoided! Shopping round a bit I've got an estimate of ~£670 now which is a bit easier to swallow. I think my car also has this issue. Globular- you you PM me details of the garage you found who can fix it for this price? If you used them was the work of a reasonable standard & the price as quoted? Thx

Just had mine done on my 986 2X aircon rads, desicator, 6 x seals £188 from Design 911 I trusted my Local garage to fit rather than my Porsche Indie. £160 plus vat inc regas Under £400 all in.

Looking to do mine in the near future and was wondering if anyone had updated prices? With their current discount until midnight, Autodoc have the condensers and dryer for £178 delivered. That would just leave the O-rings at approx. £6 each from Porsche. Out of interest, Porsche dealer quoted £450 each for the condensers. By the way, the Autodoc quote is for Mahle parts. Edited by Jellyfishfields on Wednesday 1st February 16:46

Jaykay495 said: 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 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! Picking up on this thread and about to replace condensor and drier this weekend.. I got the A/C evacuated yesterday and got 151ml of oil out at the time. The garage was confused to get that much out. Typically they get 30ml or less, the balance remaining in the compressor reservoir. My question is is this typical and should I put the same amount back? The OPC also thought it was strange. Was thinking I would put 100ml to be safe