Keeping cool for 31 years
Acouple of months ago the air- conditioning system in the 1988 XJ40 Sovereign was gassed up after replacement of the receiver- drier unit. Therefore, I was rather surprised when the system failed yet again. Even though the air- con system is used mostly in the summer, the system also needs to be working properly if you want to keep the screen from steaming up on damp winter nights.
A quick examination by airconditioning guru Denis Bourne confirmed that the condenser was now leaking and had finally given up the ghost. Since it had been in place for the last 31 years, I suppose it hadn’t done too badly. Fortunately, SNG Barratt had a replacement in stock for a very reasonable price, and it was delivered within a couple of days.
When Denis came over to fit it, he first checked that it was the correct part before setting to work. After removing the two hydraulic rams that usually support the bonnet, a prop was wedged in place so that the bonnet was held open vertically. The two refrigeration line pipes to the condenser were then undone, followed by the four bolts that retained the radiator cowl panel, which in turn holds the condenser in position. The metal clips that hold the fan cowl to the horizontal radiator cowl were then removed and then cowl could be lifted free.
With the bonnet still propped open vertically as described, we were then able to lift the condenser out of position. Once out of the car, it became clear how badly it had deteriorated. In fact we were amazed that it had not begun to leak earlier because the unit pretty much fell to pieces before we could lay it on the ground, and upon further examination was so blocked with years of crud that it was a minor miracle it had been working at all.
Lowering the new condenser into position was fairly easy, but it was a fiddly job jiggling it around until the two lower fitting lugs finally slid down into their seats. It was at this point that we realised the two refrigerant lines would not marry up to the pipes on the new condenser. It was extremely frustrating, but no matter how much we pushed and shoved, we simply could not get the pipes aligned so that the lock nuts would locate onto the threads of the pipes.
Of course, this is not an untypical situation when purchasing an aftermarket product. The only answer in this instance was to remove the new condenser from the car so
“After about ten minutes, it was time to test the results”
that Denis could then bend the two pipes very gently until they would mate correctly with the refrigeration lines in the car. The condenser was then lowered back into place – they do say practice makes perfect, and Denis’ eye was spot on this time because following some more jiggling, the lower mounting lugs dropped into place leaving the pipes from the condenser lined up perfectly with the refrigeration lines. These were duly bolted into position.
The radiator cowl panel was then refitted with its two securing bolts at each end. The clips that secure the radiator fan cowl to the radiator cowl were then refitted, after which Denis finally tightened the nuts securing the refrigerant lines to the new condenser. It is essential of course that this joint is perfectly gas-tight.
After moving the car within reach of an electricity supply, Denis then set about gassing up the system. After about ten minutes, it was time to test the results and to my great relief, all was well – the air conditioning was fully revitalised and blasting out chilled air once more.
Before leaving, Denis checked everything very thoroughly for leaks one final time, but thankfully none were found. Hopefully the system should not require any further attention for some time to come.