964 a/c repair underway (pics)

[bigchillcar]

hooked up to a vacuum pump, was planning a leak test but heard hissing immediately from the engine compartment. at least put immediate fears to rest of a bad evaporator. traced the high pressure line from the compressor to a leak that was only visible using a mirror, as it was on the back side of the aluminum line near where it enters the side wall of the car. the perforation appeared to be about a cm long and 1-2 mm in width..removal shows that the hole may not be as big as that, but enough to keep it from pressurizing. new pelican r/d is on the way since i don't know how long this car's system has been evacuated and exposed to possible moisture. at any rate, this was a 3-hour job for myself. jacked up the driver's side rear, removed wheel and removed wheel well liner, took some pics there. in the engine bay, wound up having to remove the blower in order to gain access (and retrieve my socket wrench..grrr. made the job easier anyway. once the line was disconnected at the compressor and inside the wheel well where it connects to another line running to the front of the car, i just duct-taped up the line ends and open compressor fitting to protect from debris, etc. the plan is to have a friend tig weld the perforation, put it back into the car, replace r/d and charge...then hold breath. anyway, here's a few pics from today's work. also changed out the front hood shocks - much easier on a 964 than an early car! tomorrow will probably see a change to my summer oil, castrol 20w50 and new filter..just replaced the fuel filter last week.

removed the bolt from the high pressure line at compressor:

the firewall holds both lines in place..bolt is hard to reach. fortunately didn't have to remove it, just loosen and twist the clamp sideways to remove the high pressure line at that point.
you can see the two aluminum lines. the thin is the damaged high pressure line..would need a mirror to see hole, as it's on the other side.
in the wheel well with fender liner removed exposes the junction. 20-mm wrench easily loosened the connection. surrounding plate must be removed then the line may be pulled through a rubber boot with holes for each line.
just a pic of the fender liner bent down out of the way..didn't bother to remove the very bottom one.

[bigchillcar]

another view in the wheel well of the high pressure line junction disconnected:

had to remove the blower to gain better access:
view of the engine compartment without blower:

[bigchillcar]

pic of the high pressure line removed:

finally, a close-up of the culprit 'hole' that's gonna get the tig welder this coming week. wish the focus had been better..think my hand was shaking from finally getting the b!tch outa there:


that's all for now..will try to post pics of the tig repair, etc. later.