Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos

[ALIKA T3]

Aloha all!

I`ve always been admirative of rare options, elusive parts etc, undocumented parts ....

One comes to mind is the AC unit fitted in tin top vans before 1986 German factory AC, known as the AC tunnel.

I have a van with such unit that I just took apart to save it for a future project. I also have another van with some parts of it left.

From my research, I came across a few interesting threads on the Bay Window buses forum where I first learnt about the names DPD and CCCcool.
https://www.thesamba.com/vw/forum/viewtopic.php?p=6892573
https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=40

DPD manufacturing company incorporated was in San Antonio, Texas.
https://trademark.trademarkia.com/dpd-73239940.html

CCCcool is actually VPC, I was chasing 2 different companies when in fact it is the same one : Volkswagen Products Corp, out of Fort Worth, Texas

I couldn`t find any parts diagram online with parts numbers, so , searching for one of the control knobs 113819661F I came across one diagram but not much more info on the other part numbers, it is not available anywhere else....but... funnily, typing in other part numbers from parts I found dismantling the unit, I came across a much more complete list, posted at the bottom of this thread.

So, after documenting the teardown with lots of pictures and finding little details, these units were definitey made in the USA judging by the type of connectors and electric wires.
They used American made electric fans, American Plasti-Plate Corp, from Tyler Texas ( patent US 3464622A) https://patents.google.com/patent/US3464622A/en

and some VW German parts.

The zip ties used were made by an american company : Panduit.

The hardware used was metric, the little self tapping screws on the chassis have a 7mm hex head.
Hoses were Uniroyal 1/2" (13mm) and 13/32" (10mm)

The AC units were likely assembled in Texas, like DPD and VPC units for older VW`s but these Vanagon units came out of Garland, Texas from the tags I found, pictures further down below.
Some research turns up that Carrier Enterprise is also in Garland, I`m wondering if there was some kind of partnership to make these with Carrier.

Pictures!

First, I found this pic that was lost above the sun visor

Most of the wiring harness had paper tags around them, I could only save one, they turned into dust as soon as I was touching them. Notice Garland, TX

255272289, probably position 19 on the diagram

255272967, probably the part number for the warning tag since the capillary tube is attached to another part number, the font looks similar as the commonly found warning stickers part numbers

Here is the routing of the hoses under the chassis, brackets,clamps, edge trims:
The rubber grommets were generic rubber parts, not VW grommets, and of inferior rubber quality that hardened a lot compared to VW parts.

Below radiator, left side , inner side chassis beam. Hose 255272740A front drier to condenser.

The hoses were sealed very crudely with grommets and putty, notice the knot on the wiring harness to lock it in place from pulling. The carpet piece that was cut was folded and used as a spacer to dampen vibration on the evaporator housing sitting above the sliding door.

I don`t have the compressor ends, they were cut off and probably had the part numbers on them
255272740A, hose from drier to condenser, position 6 on the condenser diagram at the end of this post.

Electrical harness ran in one piece for the battery box to under the van where the drier was, branching off wires going to the back where the compressor was, and main power to the fuse panel following factory main wiring harness behind the instrument cluster.

VW fuse holder with american wires

Blue wire to position 10

Somebody added this fuse holder I believe.
The relays were mounted next to the radiator relay up in the dash on the pilar. Bosch relays but not VW part numbers.

Similar connector as VW-Amp but these are american. Not sure of the maker.

This is the hole in the inside upper sliding door track, just a simple screw hitting a metal plate inside the evaporator housing. A piece of the carpet mentioned previously was used to put in between.

[img][/img]

Grilles, no markings but "4" and "100.2", which is not the size, one could have thought it was 4 inches, 100mm....

Hose 255272738, position 31A on the diagram

This is the tag I found that fell off the face of the expansion valve at some point, 175272679 position 27 on the diagram
I read that on older VW`s it`s the same as some Ford but I cannot find the picture I ran across on TheSamba. The VW part number is still available.

These are the condenser brackets, I didn`t have the condenser.

Hose cover for driver`s side, in 2 pieces

Center tunnel piece where the thermostat probe runs from the switch, as well as the electrical sub-harness.The upper white shield is glued with double sided tape, it`s brittle but easily replaceable.

Left Thermostat switch 255272295 position 20 on the diagram, A10-6353-00 I wouldn`t be surprised if it was made by RobertShaw. They supplied a lot of stuff like that in the industry.

Right Fan switch 255272323 position 24 on the diagram, made by Indak, Patent number 3.159.722, it was widely used apparently on International trucks

Fan speed resistor mounted above the rear view mirror

Front part

Condenser diagram, not model specific
Condenser 255272413A

Evaporator housing parts list:

Alright, many hours later, I`m done here.

I hope I demystified this AC unit a little bit for ya, keeping you entertained during the lockdown

Edit:

_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[erste]

Interesting info!

I was surprised to find A/C or heater components with Fort Worth, TX markings on my '85 Golf, but not that surprised since it was assembled in Pennsylvania. A bit of info if you search "texas" here:
https://en.wikipedia.org/wiki/Volkswagen_Westmoreland_Assembly

If you have more corona time on your hands, it'd be cool to track down the PO and send the family that photo if possible.

[rmcd]

Wow great work Documenting all that. I pulled one of these from a donor with the intent of installing it in mine but decided to go a different direction. It’s still sitting in my rafters. I would’ve given you a hug for putting all this together. Thanks again.
_________________
VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[ALIKA T3]

[rmcd]

Yes. The smallcar unit. I will not suggest it is easier than R and R on oem unit!!
_________________
VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[ALIKA T3]

[dhaavers]

D@mn, you had a busy afternoon...

Very nice work and documentation!

- Dave
_________________
86 White Wolfsburg Westy Weekender
"The WonderVan"
<EDITED TO PROTECT INNOCENT PIXELS>

[Steve M.]

I had this AC installed in my '84. It was such a PITA because I kept hitting the back of my head on it! It was also a PITA because going from front to back I had to duck under it.
I removed it and life in the Vanagon was much more comfortable!

It's great to see the documentstion on it, good job.
_________________
This free advice is worth exactly what you paid for it.

There are seven days in a week. Someday is not one of them.

[jimf909]

This is a candidate for best post of the month. Photos, interesting history, odd parts and kids in a basket.

Winner!

Thanks for all of that.
_________________
- Jim

[Zeitgeist 13]

This would be a nifty way to add dual A/C in my van.
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[rmcd]

[jlrftype7]

I feel like I’m back to last year when I dropped the same unit in my ‘84 with some intent of starting to rehab it. I took a few pictures and posted them ,but nothing as detailed as this thread....
I’ve gotten better about not hitting my head on it , moving to the back to access something there..... Just takes practice.
Electrically, everything still works on my system, amazing that all 6 speeds via the range switch still function and the resistor elements haven’t burned up.
Blower needed the same bearing oiling that we’re used to with the front blower motor...
I swear that those L shaped expansion valves are almost lifetime worthy on any vehicle you find them in, as long as they’re clean with no debris on the internals.
One well made part.
_________________
'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto

[ALIKA T3]

I edited the message to add a drawing of the 2 part condenser I found.

[dobryan]

I was thinking about how to install one of these in a westy but could not see how to do it well because of the reduction in opening to the pop top, the hacking of the spice rack to fit the a/c width, and the access to the pop top latch. In total I thought it would be more pain than worth it.

Does anyone know one a westy that installed this unit?
_________________
Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

MD>Canada>AK>WA>OR>CA>AZ>UT>WY>SD
https://www.thesamba.com/vw/forum/viewtopic.php?t=620646

Building a bus for travel in Europe (euroBus)
https://www.thesamba.com/vw/forum/viewtopic.php?t=695371

The Western Syncro build
https://www.thesamba.com/vw/forum/viewtopic.php?t=746794

[borninabus]

nice work!

you are indeed correct in that the CCCOOL units are good and of robust construction. i've seen the brand installed in ACVWs back as far as early 70s. they can usually be made to work without "major" overhaul.

the only thing i would add is that i do not believe that the 86+ "tunnel", or as i call it "airplane" unit was installed @ the factory. either @ the dealers individually, or at some waypoint in the shipping process. if memory serves, the "airplane" units carry a ZVW part number, which means VWoA approved accessory part supplied by a third party.
_________________
88 Van WBX, A/T - 13 JSW TDI 6M/T - 2012 Touareg TDI Sport

[jlrftype7]

https://www.thesamba.com/vw/forum/viewtopic.php?t=722871&highlight=

Here it is...
_________________
'68 Westy- my first VW and vehicle/Bus- long gone.- sold it to a traveling Swiss couple....
'67 Type 3 Fastback, my 2nd car- gone
'69 Semi-Auto Stick Shift Beetle-gone
2017 MINI Coopers, our current DDs
‘84 Tin Top - Hilga....Auto

[r39o]

[ALIKA T3]

[Zeitgeist 13]

My interest in a front cooler is less about max cooling effect, than a more even distribution of the cooling, especially on startup after the van is sitting in the sun. That long tunnel tends to absorb a lot of heat which needs to be displaced. I will never give SC any of my money. Ever
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[r39o]