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  • #46
    Europian countries still seem to need A/C during summer...

    My A80Q B4 Limo with 2.8 AAH engine V6 has suffered non working manually driven A/C (NO A/C automatics exist) for a long time.
    The car had original R12 compressor system and luckily all stickers on top of compressor existed.
    Compressor has enable A/C plug and the 2 pole RPM sender plug and driven with long V6 2260mm nicely routed (check etka when refitting...) multi groove belt
    Audi: 4A0260805D ( and another code 506031-02447)
    Zexel type: DCW-17B
    Zexel part: 506231-0252
    Serial: like Japanese quality products do have... 261J807825
    Oil (original for R12) D-90PX 300cc
    R12 Leak test high side 30kg/cm2, low side 15kg/cm2, high pressure exp valve 37kg/cm2

    Zexel part number is important (and also the coding .... 805D) when searching for new replacement compressor
    My old .... 805D AC compressor has INCH threaded connectors at the back of the compressor
    - those threads look close to metric but below the car when fitting compressor pipes you get crazy with the non matching threads.

    http://www.alanko1.de//dateien/Kompr...log_Online.pdf
    - with audi codes, zexel codes and compatibility
    - that has 4A0260805D (550 130 vs. later 550 030); see also compatibility chart
    ( what was the factory reasoning to change from inch based threads to metric threads ?)

    https://www.ebay.de/sch/i.html?_from...0805D&_sacat=0
    Learning point is that ask before the deal about RPM sensor and pipe connection thread type.
    The compressor what I ordered had the RPM sensor but metric threads at the back of the compressor.

    Some butchering was done and rear plate from old compressor was moved to new compressor
    ( warranty expires) but pipe threads are then matching.
    Back end bolts were tightened to equal torque and bolts were oiled.
    The new compressor had "installation oil" only
    => the new compressor was "cleaned" with with Hella BEHR PAO68
    (use color version or regular oil) that is recommended in Hella pdf for R12 retrofits.

    Interesting A/C product finding was an errecom small leaks fix fluid that is promised to
    fix smaller than 0,3mm "problems". I don have experience if that fix is good or not.
    https://www.ebay.de/sch/i.html?_from...treme&_sacat=0
    See the tube videos of errecom
    https://www.youtube.com/watch?v=0m-v4OpC4X0
    https://www.youtube.com/channel/UCZ-...b0RN8Uv3mAra1Q
    http://www.eurorefrigerant.com/r134a...-cylinder.html

    Next step will be the system vacum test and nitrogen presure test before filling with r134a.
    All O-rings have been changed, new drier changed in the whole system for pipes and sensors.
    O-ring sizes from ETKA and rigs from local O-ring shop. Old system may still have many points of leak failure, but lets see.
    If pressure test is successful the drier is changed and system vacuumed again and then r134a filled.
    Remember that total oil quantity in system must be 300cc.

    System has still deposits of old R12 oil residues unless all parts washed with AC wash system.
    Old compressor did not have any metal flakes inside.
    Possibilities for bad A/C experience exist, but lets see if lucky or not or do I need another new compressor.
    better clean results with pro machine - that takes several hours at proshop.
    https://www.hella.com/techworld/uk/T...C-system-1891/
    Attached Files
    Last edited by Tommy200rs; 30 August 2019, 10:01.

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    • #47
      Kind of went well with the new compressor. Nitrogen test was ok. Suction was 50 minutes and 650g r134a was filled in and additional oil to reach the 300cc total. R134a fill in adapter was attached to drier. Other fill in positions are limited and the other one is at the compressor. New systems have way more points for filling in. Vacum process would be faster when one at high side and other at low pressure side and vacuum process with 2 hoses connected. System has now worked few weeks but cold delivery is not any more as good as in the beginning. -> small leakage.

      Problem (so far) identified is the condenser, that started to get slightly "wet look" at left behind the grill at the point where left middle attachment steel bolts are visible. Steel bolts and aluminum condenser have corroded together and the condenser needs to be replaced. See picture of bolts. Condenser picture is not from my car. ( Klima Kondensator Kältemittel R12 8A0260403D )

      Because the car has been with the old R12 system the hose/pipe connections are not metric and finding the spare unit with ETKA part number was challenging. However there is a place to buy condenser https://shop.kuehler-rath.de/ (find parts with etka part number) , which states with details what kind of condenser is offered. UPS Delivery time 6 days from order.

      Edit:
      After opening the package today the condenser does not have the safety switch connection position below the big connector pipe/hose at top left when watching in front of the car. I do not recommend that supplier unless you agree 100% first what they send and deliver. It might fit, if I put the sensor to but not known yet.

      ETKA number matches in Rath catalog , but
      - "red" safety sensor (o-ring fitting) position (#24) on top is missing. There is vacuum /fill - in hose plug
      - "green" high pressure (o-ring fitting) switch #23 below is missing, There is vacuum /fill - in hose plug
      - it is a fact that in old system there are few points where to connect suction/fill in service hoses. Drier had R12 connection to which the R134a adapter was connected
      - Condenser thread sizes for pipe connection/hoses also need to be checked - metric or inches
      - System needs safety switch and high pressure switch
      - Condenser ordered with etka R12 version spare part number https://shop.kuehler-rath.de/Audi-Co...121::4341.html
      - also the new water radiator arrived today and was cheap 70 eur including DHL delivery. That looks ok and made in 2019
      - for illustration purposes the red and green switches in attached pictures (not my condenser, but same switches)

      To be continued....
      Attached Files
      Last edited by Tommy200rs; 31 August 2019, 11:42.

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      • #48
        I buy refrigerants from Top-refrigerants.com. Never had problems with them.

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