[Garvin]

Just replaced the condenser - that's the third condenser that has failed in the vehicle's 18 year life time for exactly the same fault! The top left corner (as viewed from the front) had sprung a leak - is this a known weakness and, if so, is there an easy solution?

 

[Richard_G]

There's a foam block that sits against the condenser at that point which traps moisture and causes it to rot. Leave the foam out.....

 

[tanis8472]

Mine has gone there too. Due to replace it soon

 

[Garvin]

Thanks for the responses.

Examining the foam block I noticed two things. Firstly, it is becoming detached from the slam panel and, secondly, it has become crusty and abrasive on its exposed faces. I have concluded that it not only holds water but then, probably through vibration, applies an abrasive action to the corroding part of the condenser.

i have shaved the offending abrasive faces back to 'proper' foam and re-glued the foam blocks (both sides) back onto the slam panel. On inspection the foam block does not now touch the condenser. We shall see if this puts a stop to the condenser corroding!

 

[xrav22]

Do you have any pics of this, and how hard is it to access the foam things?
Thanks

 

[Richard_G]

Dead easy, they are under the slam panel.

 

[xrav22]

Will be checking that soon, easy task.

 

[scimitargtc]

Yup this is correct my 4.0 went through 2 in 2 years for this exact issue take out the foam after removing the grill 6 screws and slam panel 4 bolts

 

[xrav22]

Ok I think mine was on the way, after all the work I would hate for this to happen. I removed the offending part of rubber. On the other side nothing to break
so I left alone.