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Old 07-17-2013   #1
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Air Conditioning Refrigerant Hose Leak

I finally charged my A/C for the first time on the Touareg only to discover an audible leak near the driver front wheel. Put her in Xtra high jack mode and took off the wheel well cover to see where the refrigerant was leaking from. Found the part on jim ellis vw parts schematic and ordered it from vwparts2go for just under two hundred clams. Looks easy enough to do (2 torx bolts?) once the plastic is removed since the system is already evacuated (vag com reads 0.0 bar refrigerant pressure and no more hissing) thanks to corrosion and/or rubbing on the refrigerant line. Hope it is as easy as it looks!

Part number:
7L0820722F

Anyone perform this already and have any wisdom or know what size torx bolts are used for the A/C system components?

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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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Old 07-26-2013   #2
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Just got this message from vwparts2go:

Justin, I put in the order to Germany to get your part and I got a report back
and it looks like there are none left in the German warehouses. So
unfortunately, I will not be able to get it for you. I will go ahead and cancel
and refund your order. Thanks!


We appreciate your business!

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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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Old 07-26-2013   #3
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Have you tried going to an aircon specialist and getting them to make up a pipe for you?
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Old 07-26-2013   #4
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Anyone know of a competent A/C specialist in upstate NY?
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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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Old 08-09-2013   #5
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DIY Refrigerant Line Fix

My DIY for fixing the AC leak:

Cut out the damaged portion







Build the replacement line using:
Dorman 800-632 3/8" X 12" Straight Rigid Aluminum Tubing
JEGS Performance Products 100392 -6AN Tube Sleeves
JEGS Performance Products 100382 -6AN Tube Nuts
JEGS Performance Products 100202 Flare Union
Tubing bender
37degree flaring tool









File and sand down the Touareg aluminum tubing because it is too large for the AN6 fittings (OOOOPS!)



Fit it together and tighten the fittings







Replace the drier using Spectra Premium 0210098 A/C Accumulator. Oil those O-rings!!!





Vacuum the system



Fill her up and tighten the fittings until leaking stops but don't over torque.

Enjoy cool air from the vents =).
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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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Old 08-09-2013   #6
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Outstanding work

Yea a bit of a trap the 3/8 tube to the 10mm at the end but lucky not much difference.

Well done

Regards
Drag
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Old 08-10-2013   #7
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Tretx - Nice DYI! do you have some specs on the filling tool?
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Old 08-10-2013   #8
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Quote:
Originally Posted by TheSkinnyViking View Post
Tretx - Nice DYI! do you have some specs on the filling tool?
I used an Interdynamics filling hose with the attached gauge and trigger from my local advance auto store.

I purged the line by pulling the trigger while attaching it to the low pressure fill port to avoid introducing air into the system. I added three 12 oz. canisters of refrigerant which is close to the 39 oz. specification for rear A/C. I didn't have a scale to weigh it on so I just stopped after the third can. I added one 8 oz. can of the PAG oil which I hope results in close to the 10 oz. specification. I do not know how much oil was left in the system before adding, but I do know the area around the leak was pretty oily so I think it had lost a bit.

Pretty rudimentary setup, but the A/C is blowing nice and cold... I even had to turn my wipers on in full sun to clear the condensation from the outside of the windshield.
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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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Old 08-10-2013   #9
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Quote:
Originally Posted by Treetz View Post
I even had to turn my wipers on in full sun to clear the condensation from the outside of the windshield.
I like doing that bit!
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Old 08-21-2013   #10
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Still blowing nice and cold.

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2004 V8. Air Suspension. 255/65R17 Cooper Discoverer AT3. Replaced Tiptronic Shifter Assembly. Replaced Alternator/Battery B+ Cable. Replaced Headlight Washer Pressure Cylinder. Intake Flap Pivot Cleaning. Gruven Intake Manifold Linkage Arms. Air Suspension Compressor Rebuild. VAGCOM.
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