Air Conditioning Restoration Project

[zoti]

1988 Westfalia.

Previous owner decided to pull out the rear AC, headbanger cabinet and rear closet to make the bed wider which I actually kind of like but I am now going to restore the AC system.

I have managed to collect most of the parts needed.

The plan is the replace the condenser with a modern one. Restore a 709 compressor, re make the hoses with modern hoses. New Dryer, refurbish the blower motors and clean the original evaporator.

He left all the wiring so it seems but i have another set.

Step one is refurbishing the compressor. I bought a set of back and a set of front seals on eBay. Going to clean it up real good and put all new seals while making sure all the components are good.

I’d take any tips while doing that if you have any. Here’s some pictures.

[zoti]

I kind of cleaned everything but will continue to disassemble the whole compressor to bits, clean, inspect and put back together.

[Deberius]

Just wow!
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1990 Caravelle GL 2.1 MV syncro -> 1990 Multivan Syncro 2.3 MV

[zoti]

I went on to disassemble the compressor and I’m not sure it is worth restoring.

Can anyone with experience give their opinion in the condition of the internals?

[MarkWard]

I rebuilt the entire system on my 90 camper. It worked awesome for a few days. Turned out the compressor was weeping freon. Ended up with a replacement compressor from Rock Auto. Kicked myself for not replacing the compressor after all that effort. Your call. I was impressed you were willing to reseal yours.
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[dhaavers]

Yeah, I feel like djkeev has experience here. I'm pretty sure he'd drop all the bits to soak in the
ultrasonic overnight, brighten all gasket surfaces with 320 grit in circular motions on a glass table,
reassemble with Hylomar, week long documented bench test running from 60 to 3600 rpm in 1.5x
increments @ 12 hours per step, then tear it all down again for post-test inspection.

Important final steps: buy new 709 unit from Nostalgic air, install as is, be cool & happy.



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

[zoti]

[MarkWard]

I like a challenge too. Lost one charge of freon to the atmosphere over a week, had to recharge a second time to find the microscopic leak that ended up being the compressor. That included checking all my new fittings for leaks. Some not so easy to access. Then recover the freon, replace the compressor that I could have installed originally, adjust the belt and evacuate and recharge again. Wasn't worth the fire drill.
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[zoti]

[MarkWard]

Technically you are resealing the compressor not rebuilding. I don't see anything glaring. As long as the reed plate sits flat and you can reverse it. The piston cylinders look ok. So, I'd say it sounds like you want to reseal it and install it.

As I outlined above, if it doesn't work, you are only out the seal kit and your time. Maybe some freon. I vote to go for it. Best of luck.
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[joyfulpursuit]

It looks like you're already planning on doing so, but if you can have a detailed write up with pictures documenting your process, it would be of incredible benefit to the community. There's not much information about retrofitting the factory AC properly, and I plan to do it at some point.

Thanks much! Looks like you're doing awesome work and have a high standard of detail - both great things.
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📖 For God so loved the world that he gave his one and only Son, Jesus,
that whoever believes in him shall not perish but have eternal life - John 3:16
🚐 1987 Westy, EJ22 small car conversion
🚗 1991 e30 325i Sport MTech II coupe
📸 instagram.com/joyfilledpursuit

[djkeev]

Honestly I prefer using new genuine Sanden compressors.
When you factor in the rebuild kit prices, getting a new compressor isn't much more of a step.

Vintage Air has great prices but their shipping kills you!
Sanden 709 side exit, if you are rebuilding the system you are making new hoses anyway.

JEGS sells vintage air products with free shipping!
Vintage Air even drop ships them......

https://www.jegs.com/i/Vintage-Air/960/04709-VUA/10002/-1

I'm on the same journey with my 90 but got side tracked!

https://www.thesamba.com/vw/forum/viewtopic.php?t=...mp;start=0

Dave
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Stop Dead Photo Links how to post photos

Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[SyncroHead]

[khughes]

Although more cost up front, you might also take a look at a variable displacement type:

https://www.acparts.com/product/new-original-sanden-compressor-1222/

This is the compressor I've been running on mine and it is smoother, pulls less HP unless the system is calling for maximum (160cc) displacement. Given the BTU requirement of the Vanagon Big Box, a variable won't save as much as it does on a "normal" vehicle, but it's definitely a savings. R-134a as well. About the only thing that ever fails on them is the PRV, but it's $50 and a freon charge if it does.

Just another option.
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'86 Westy FAS GenV Turbo (Marvin)

[zoti]

[Zeitgeist 13]

There appears to be two wires, but they're not routed together.
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Casey--

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

[Howesight]

Up here in the Great White North, we often can't get the auto parts deals you Yanks can get or else we have to pay ridiculous prices. I have problems with the compressors on the S4 and the S6 in the fleet. They both have no difficulty keeping up with the heat, but they leak refrigerant. I completely rebuilt both systems with new hoses, condensers (both stone-strike damaged) o-rings, accumulators, etc, etc. The only potential leak point I did not address were the compressor shaft seals.

These Zexel compressors are mandatory since the climate control unit is looking for the speed signal, otherwise I would consider a less expensive unit for replacement. So, I am going to replace the shaft seal on one of these compressors and see whether a weekend hack like me can do this without screwing up. Obviously, if there is any shrapnel at all (including bits of teflon) in your system, this approach will not work as the piston rings will be the culprit in that scenario. But if the opened system is clean and the compressor was not noisy previously, then a seal replacement is a viable fix.

I found a couple helpful resources online:

1. https://www.youtube.com/watch?v=uIeqahYPrCQ

2. https://www.shopcenturyautoair.com/store/c5/Compressor_Tools.html (these are inexpensive seal-installation tools that you MUST have)

As much as I have played with, built and rebuilt AC systems, I have never replaced a compressor shaft seal before, so this will be interesting. If it works, then I save $900 on compressors and eliminate my Ebay delivery wait time.

On that Sanden 709 in the OP's pictures above, the only thing jumping out at me was the shims/races that bear against the radial needle bearings. You can clean up that brinelling by rubbing those items on, say, 1000 grit paper on a glass surface. Be sure to touch up the surface on the compressor shaft that contacts the shaft seal using a very fine Scotch-brite pad.
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'86 Syncro Westy SVX

[Steve M.]

[Abscate]

I’ve sourcedinternal compressor AC partsfromTaiwan but had to aggregate orders to make the import costs work. Luckily, my customers are in areas where they can live withoutAC for 9 months and save one time costs.

The parts inside are amazingly cheap. I rebuilt a Sanden variable compressor for under $30 in parts. Seals must be replaced.

Leak test first with vacuum, then with propane, not Freon.
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.ssS!