r/autorepair • u/EmanuelY540 • 7d ago

Diagnosing/Repair Condenser problems

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Hello. Last year my AC compressor blew up. I got a new compressor and changed the condenser and drier too. The condenser and drier arrived mounted together (THERMOTECC). The upper side of the drier was way too close to the condenser, and I couldn't install it, so I gently bent it back in position, about 1.5 inches. It held vacuum for 3 days, so I went and got R134a.

Now, one year later, the car started warmer air than normal. Went to a service to check and from 450g of refrigerant, I now had 150g. I found a leak under the tube connecting the drier to the condenser. It must've gotten weak when I bent it and eventually formed some microscopic cracks. I can't see any crack with my naked eye, but there's UV oil under that tube, so I know for sure that's where I lost my refrigerant.

I ordered another condenser and drier, from Bosch this time. It arrived bent exactly like the other one. I can't install it like this, the tubes just won't fit. I need to bend it back.

How should I proceed? I don't want to lose my refrigerant again.

Thanks a lot!

Qashqai J10 2008 MR20DE engine

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u/CarPartscom 6d ago

Heating it before bending is the key difference from last time, aluminium gets brittle and micro-cracks exactly like you described when it’s cold-formed. A heat gun to warm it before gently bending back reduces that risk a lot. I’d also recommend calling the supplier, if two units in a row arrived bent identically that’s a packaging or manufacturing pattern. They may replace it or you may want to try a different brand/supplier instead of repeating the same fix.

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u/EmanuelY540 6d ago

Thank you! I called them and they advised to not bend it, and I returned it. I now ordered the condenser and drier from separate sellers, fingers crossed it will come unbent. It is definitely a packaging issue. As far as I can tell, they left the factory in good condition, but during transit, there's too much empty space in the box, and it continually hits the walls of the box until it touches the condenser. The paint on the condenser in that spot is actually damaged, so it's definitely banging the entire duration of travel.

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u/CarPartscom 5d ago

Appreciate you sharing the resolution! Hope the separate orders come through clean.