A few years ago, I’ve bought a new passat. At first I thought the AC wasn’t working to well. The temperature didn’t get low, but the mechanic had tested it just on temperature and compared it with a A4, and concluded it was oké.
A few months later after a holiday to France, I still thought the AV wasn’t working the way it should so I visited a local Mazda dealer in my hometown. They did a thorough check and found just 275 gr. of R134a in the system instead of the required 650 gr..
They filed it and added a yellow dye to it. A week later a small leak in the condensor was visible.
The front of my passat
Here you can see in the middle of the picture a small dark spot where the R234a is leaking with a little bit of oil.
The two white spots up and down are two markers for the spot in the middle. As you can see I carefully cleaned the spot of dirt, paint and oil.
Then I use JB weld, an advise of a forum member at the time, and paddled it exactly on the spot.
In a amount so that the spot was widely covered with the stuff.
I even spay painted it black, and as you can see, it looked rather nice.
This is the stuff I used.
Just see: Don't scrap it, J-B weld it!!