Well, I changed the cabin fileter and started using the air-recirc button and it seems to have made a difference. I drive the X for 2 days and it only acted up once (seemes like it was acting up more often before). When I get a chance, I am going to get the levels tested.

agree with Weasel ,I always use auto recirculation with air con , that is the left side of switch with the " A" within the circle .
full recirculation in tunnels . switch between auto and full if more than 1 mile tunnel .

well i think there's really no harm keeping the re-circulation on all the time. i have done that for the past 20+ years of driving. bad air outside does not give me much option. only time i need to use it is when i get bad air inside after my little one farted. :rofl:

happy to know that it is better. if you are game enough to experiment further, you can try blasting the heater with the doors open before driving off, it should help clear any h2o within the sys. opening the doors at the same time should let the hot moist air escape from the cabin. then go on your long drive and see if it acts up.

anyway, if it does act up again, you can also try to pinpoint the cause to evaporator freezing up by taking the X quickly to any ac shop to have the measurement taken. see attached. if you see low inlet pressure & high outlet pressure, it could be evaporator freezing up and the culprit may be the evaporator sensor or some obstruction.

cheers

how does an undercharged system cause the evaporator to freeze up? i thought it will cause the sys to lose its cooling ability?

He may have meant overcharged... but you are right. When the charge starts getting lower it doesn't cool as much on the right side compared to the left.

Well, I may have spoke too soon. Drive around again today in 90+ degree weather and it acted up a couple times. I did notice that with the air recirc button on the air stayed a similar temp on both sides, but the fan was definitely acting up. It just quit and when I turned up the fan speed, the air did not increase, but I did notice the blower sound increasing.

Two more questions;

How much is excessive condensation under the car? It a medium sized pizza puddle too much?

Also, for Weasel, what is the best method to clean the FSR connection?

Thanks for this info.

If the blower speed sound is increasing, just not the actual air speed out of the vents it isn't going to be the FSR... It is going to be either the evaporator freezing up or possibly some flaps acting up somehow. When it stops blowing out of the vents will it blow out of the floor or defrosters? If yes than it is a flaps/control problem. If no airflow out of any vents it is most likely freezing up.

Trying to remember... have you had any other AC work at all done recently? (other than the FSR)

New high side service port and IHKA control unit.

I will test to see if the air blows out of the top and bottom vents when it acts up next time.