64 51 ... Leak-Testing Condenser
Special tools Required
- 00 9 030 (Wedge)
- 64 5 121 (Connection hose with clamp)
- 64 5 122 (Climate condenser test adapter)
- 64 5 123 (Climate condenser seal plug)
Risk of injury!
Refrigerant circuit is under high pressure!
Follow safety instructions for handling refrigerant
Comply with the standard national safety instructions and precautions on handling nitrogen.
Ensure that employees are advised of how to handle pressurized vessels and nitrogen correctly (danger of asphyxiation). For this purpose, follow the notes and instructions in the technical safety specifications available from the gas supplier.
Necessary preliminary tasks:
- Drain off air conditioner
- Detach refrigerant lines from condenser
Risk of damage!
Special tool 64 5 122 and special tool 64 5 123 have different diameters (A, B) at the seal plugs!
Ensure correct connection assignment on condenser.
Fit and secure sealing adapter 64 5 123 to connection of low-pressure line.
Fit and secure test adapter 64 5 122 to connection of low-pressure line.
Tightening torque, see 64 53 6AZ in 53 CONDENSER AND DRYER .
Connect special tool 64 5 122 to special tool 64 5 121 .
Risk of damage: Use only nitrogen pressure bottles with pressure reducers for leak-testing.
Pressurize condenser to 10 bar slowly only. Excessively fast pressurization and pressures in excess of 20 bar may cause damage to the condenser.
Connect nitrogen pressure bottle with pressure reducer to pressure gauge and then connect to special tool 64 5 121 (connecting hose).
- Testing apparatus must be leakproof.
- Ambient temperature and temperature of vehicle must not change during the test procedure.
- Do not move the vehicle during this period
Apply test pressure of 10 bar slowly and close nitrogen pressure bottle.
Check leak-tightness of testing apparatus and of connection to refrigerant line.
Set test pressure of 10 bar is only permitted to drop by 2 bar to 8.5 bar over a test period of 1.5 hours.
If the pressure loss is greater than 1.5 bar, this indicates that there is a leak in the condenser unit.
After leak-testing:
- Replace all sealing rings. Use special tool 00 9 030 to mount sealing rings without damaging them.
- Assemble A/C system
- Evacuate and fill A/C system