Pierced aircon pipe

[bongojoe]

I put my Bongo into the garage this morning to get the aircon looked at. I didn't think to check it when I bought it from the dealer in March, so only discovered it wasn't working at all when the sun decided to come out.

Turns out the problem is a self-tapping screw used to secure the plywood floor (by the dealer, who did the conversion) has pierced one of the alloy pipes which runs from the compressor to the back heater box, just in next to the sliding door.

Garage says the pipe is on back order, and could take 6-8 weeks to arrive, which is well past the date of my 10 day summer Bongo jaunt!

So, three questions:

1. Anywhere I could buy a replacement pipe more quickly? (I guess it's the thicker, right-hand most one on this diagram - http://www.igmaynard.co.uk/bongo/Graphi ... _6135A.gif)

2. Any way to repair? (The garage is looking into this tomorrow)

3. How much of a hard time should I give the dealer to cover the cost? (I had a six month warranty which didn't cover aircon, but it's clearly been there since purchase and of their making).

[scanner]

Surely it's up to the converter to put it right?

[corrour]

A good mobile aircon guy will be able to cut the pipe and crimp in an inline joiner
Pressure test ,regas and away you go.
Trouble is he is going to be bloody busy now.

Hope you get it sorted.

[bongojoe]

The dealer is a 100 mile round trip away, so trying to avoid if possible. I'll see what the garage says about price tomorrow and decide whether it's worth my while making the trip.

Encouraging that it should be a quick fix though.

[Simon Jones]

I blocked off my rear aircon and first DIY attempt to braze the ends of the pipe didn't withstand 180PSI used to test the system. Took them to a local welding company who welded them properly and they are now fine. Cost me a fiver contribution to their tea fund. Any decent welder who can do aluminium should be able to patch it up. If you go down the route of replacing the pipe, be aware the fittings changed somewhere around year 2000 and you can't mix and match different types.

[bongojoe]

I blocked off my rear aircon

That's a very good point - it looks like these pipes only serve the rear heater, which is now boxed in behind the side conversion, permanently switched off and therefore completely useless. Would a simpler fix not be to take that our of the equation altogether by sealing off the pipe as you have done?

[Simon Jones]

Well, if you don't need it, then blanking both pipes off would be an option. I blanked mine off under the passenger seat. This was take before I had the ends re-done:



I deliberately left the 'tails' quite long so they would be held in place by the clip (shown above):

[bongojoe]

"I think this might be the cause of your malfunctioning aircon, sir."



As you can see, the screw has gone right through and out the other side. They've repaired the pipe by adding a valve in place of this removed section (they were keen to do this rather than cap it off) and it's like the North Pole inside now.

While they were under the van, they spotted a number of other overly-long self-tapping screws which fortunately seem to have missed the petrol tank, wires and other vital components. I'll be having a wee word with the dealer about this.

On the plus side, the garage said the van was in surprisingly good nick.

[mikeonb4c]

"I think this might be the cause of your malfunctioning aircon, sir."



As you can see, the screw has gone right through and out the other side. They've repaired the pipe by adding a valve in place of this removed section (they were keen to do this rather than cap it off) and it's like the North Pole inside now.

While they were under the van, they spotted a number of other overly-long self-tapping screws which fortunately seem to have missed the petrol tank, wires and other vital components. I'll be having a wee word with the dealer about this.

On the plus side, the garage said the van was in surprisingly good nick.

I've been running my aircon nonstop in this weather, and the coldest air seems to come from the rear vents, so I'm glad you've not had your rear system blanked off just in case. Mind you, mine provides cooler air, but North Pole like, and I wonder if it would benefit from a little attention (its not been attended to in nearly 7 years of my ownership). Another job on the list - anyone able to recommend a reasonably priced aircon specialist round my way?

[bongojoe]

Update number 2... The dealer said he'd cover the cost of the repair. My faith in humanity is restored.