This is why shops are required to have recovery equipment.
You need two wrenches to tighten this fitting. You have to hold back the one
on the condenser to avoid twisting it. The hose fitting or the seat in the
condenser fitting may be damaged or corroded preventing the o-ring from
sealing. The condenser may also have a small crack near the fitting. This is
a common failure for them.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
David Clarkson
Sent: Sunday, August 01, 2010 3:48 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Need help with leak at fitting on AC condenser

I have had great success in getting my ac running super cool (34 deg. F. at
 the center vent). All is well until the freon leaks out at the larger of
the two  connections where the hose connects to the condenser. I have put
dye
in the  system and checked for any other leaks all over with a hydrocarbon
sniffer-none. I have tried all different combinations of o-rings, different
 sizes and even 2 o-rings and finally went back with the factory o-ring
after all  sorts of o-ring swelling (stop leak) chemicals introduced when
recharging. I  inspected it again with UV light and found that it is
definitely
leaking at this  one point. Cleaned up the dye here and gently turned the
nut
on the fitting  about 1/8 of a turn. I have been scared to crank on this
too hard and have the  threaded portion break off and then have to replace
the
condenser. Has anyone  else on the list had a leak at this connection? I
feel really confident that it  is not leaking from a crack at the fitting
where it connects to the condenser or  from where the hose crimp is. How
much
force should I use when tightening this?  Am I likely to break off the
fitting
from over torqueing? R134A isn't expensive  but not exactly cheap either.
Dang, I am so close to having this fixed. Hoping  cooler heads will have
some
suggestions here. I'd really like to charge it one  more time and be done
with this project of epic proportions. Thanks list for all  your help.

David  Clarkson
1990 Westfalia