2005 XC90 Condenser replacement

[Nowyousee4]

All,

Been combing through all the usual suspects in terms of this helpful forum, as well as many other for a simple breakdown repair procedure for a leaking condenser. Haven't actually found anything on this, so hopefully it's so easy it needs limited explanation. Can I just remove the bolts, slide out the old, slide in the new, reattach hoses, and recharge system?

There is a pin-hole leak in the front of the condenser unit next to the receiver drier portion (Volvo P/N CH 664303) of the OEM unit.

Vehicle is a 2005 XC90, 2.5T, FWD (VIN ends in X51203240). Honest indy repair shop says $850 repair, but they are using a Volvo part and aren't the cheapest labor. I've looked this thing over and over, and it seems like the easiest repair in the world. The only catch is the system evacuation and recharge.

The shaded area at the far left side of the radiation portion is the dye from the leak testing

The shaded area at the far left side of the radiation portion is the dye from the leak testing

The shaded area at the far left side of the radiation portion is the dye from the leak testing

Questions:
1) Should I take the vehicle to be evacuated before replacing the part, and then return to have the system properly recharged? Can I do this myself, or do I run serious risk of endangering the passengers/driver, or ruining the compressor unit if simply buying a canister of R-134a with a built-in pressure gauge for the recharging?

2) What exactly would be the procedure for evacuation, removal, and recharge of the system so as to not accidentally ruin expensive components (compressor and the like)?

3) My unit appears similar to the following unit: http://www.volvopartswebstore.com/produ ... 69510.html; however there are other units which I believe are for newer models that include a very differently styled receiver dryer (Google condenser and you'll see a little appendage off to the side which is canister shaped and quite larger and rounder than the older configuration which I believe mine is...). Do I need anything other than a replacement unit, or should I also have on hand replacement hardware, seals, lubricants, etc.?

4) Can I simply by a canister to recharge the system, or is this a dumb idea?

Any ideas or procedural breakdown would be appreciated. Will post repair video once I get the part, but can't decide if I should do this, or leave to AC shop...

[bguzz]

If you have a leak and no ac at all, the r134 has already leaked out of your system, so nothing to capture. If it is still running, but cycling on and of frequently and not very cold, then you still have r134 in your system and you can have it evacuated by a pro.

After you replace, it is critical that you have the system purged of air quickly so that the internals do not get damaged by the air/moisture. This is done by pulling a vacuum through your system for 30 minutes or so...it removes the air and moisture. Then the system can then be recharged. Recharging can be done via cans, but you should have a hi side and low side gauge to determine when you have the right amount in it. Your real challenge is how do you pull a vacuum? You need a vacuum pump, which you likely don't have, or you can use an air powered one that is driven by a compressor, but you need a REALLY big compressor for that to work. I do lots of DIY work, but AC stuff is the rare occasion that I have someone else do it.