Small Car Performance, DIY Front A/C Installation

[ALIKA T3]

Hey guys, I finally tackled the bigger electric fan conversion from 86-91 into an early van.
That was fun tracing the wires of different colors sometimes and different relay contacts from what I have, minor stuff though....

A couple questions remain please. Trinary switch not wired yet.

1-Where do I connect the Vanagon BK/Y wire to? It comes from the 3rd speed relay, contact #86. To Blue wire from SmallCar compressor relay?

2-Where do I connect the blue wire from the SmallCar compressor relay? Should I have the 2nd speed of the fan running anytime the compressor is running like Jeff settings?

3-From 2nd speed relay 53, I have a thin Red/Blue wire coming off contact #86 (see H6 on the diagram), would it be the one connecting to the trinary switch blue wire?

4-I have an extra R/BK wire coming off the fan stage resistor, it is tee'd at the connector with one end going to the radiator thermoswitch and the other end I cannot find where it goes on the diagram....

For info, this is the mount for a 1985 Westy no AC, with coolant sensor level relay and fan relay mounted on the pilar.

I removed the connectors off the mount for the coolant relay to mount it on its own plastic mount.
See it here, separated and remounted on a single bracket.

You can see it is predrilled for the later style bracket, so it will be easy to mount the 86 Syncro w/AC wiring I have stripped off my donor.

1985 wiring harness for the fan, the big R/W wire goes to fuse #7

1986 Syncro w/AC wiring harness for the fan. Relay 53 for 2nd speed on relay panel location #5, brown connector "H", big Red wire from 50amp fuse blade goes to B+, the R/W wire goes to C7 , on my 85 it will go to fuse #7. Relay 53 will be mounted on an additional snap on mount next to the 3rd stage relay/ 50amp fuse blade on the pilar.You can spot the extra relay holder I'm adding

Cheers!
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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

[Farf]

[ALIKA T3]

Thank you Farf!

I pulled out the 1990 Bentley book I got at home (I keep this one clean) to have it all square, so page numbers would match yours and I did find the number 12 track, thank you for pointing it out

From what I understand, it should go to one side of the blue wire off the trinary switch , the other side of the switch wire to the little red/blue wire (H6, track 14?) The gauge sizes are way different, that seems wrong.
The blue wire from the SmallCar AC relay would go to the Black on the trinary switch, then to the compressor, but I'm left with a Vanagon black/yellow wire on track 17 that I have no idea if I have to keep it or tap onto that same relay, on #85.

I don't think I'm gonna figure these ones by myself
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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

[rmcd]

Fair warning. My high speed fan runs most of the time so this may not be correct. I’m still trouble shooting. To quote Bluto after he totally Flounder’s brother’s Lincoln. YOU f’d up. You trusted us.

I spliced the black/yellow based upon someone post early in this thread.
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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]

[Pcforno]

Low speed should always run when the compressor is on. I used a relay off the compressor wire to run low speed fan.
It should also run from the radiator thermostatic controller when it reaches 203

Medium speed should run when the trinary switch flips. I ran this off the normally off switch on the trinary switch from ignition power to a separate relay

High speed should run direct from the large relay on the a pillar from the radiator thermostatic control when it reaches 215

[ALIKA T3]

[Pcforno]

Alika - I agree. I set my low speed to operate off the compressor wire and a speed sensitive relay which interrupts the ground of the relay at speeds greater than 15 mph so the fan only runs when there is insufficient air flow

[ALIKA T3]

[Pcforno]

Yes - I used this
https://www.lingenfelter.com/product/L460340004.html
I also use it to turn on my transmission pump to lubricate 4th.
You can get the signal off any VSS so long as it uses pulses per mile. You can select any PPM configuration and it will learn it

[ALIKA T3]

[Pcforno]

Yes but it takes quite a bit of trickery depending on what you want. Check the PDF instructions and you can see if you can get it to work for the two different things and speeds you need

[ALIKA T3]

[Pcforno]

Cool! Yes Thanks Alika - that means a lot coming from you 🤓

[GreggK]

I'm just about ready to start up my engine for the first time. As it stands my SC in-dash A/C unit is installed with the heater hoses and power sources connected. I do NOT have the trinary switch connected nor the A/C hoses or the compressor. The control knobs do function as well.
Back in the engine bay my compressor has both hoses connected to the compressor only a few inches long and then they terminate right after the service ports. Do I need to do anything with the open hose ends if I am going to attempt to start my engine? I have a serpentine belt that runs the compressor so I don't think I can bypass that. I'll go out and shoot a picture of what I'm dealing with.
So basically I want to engine running and just run the heater and then as time and money allow , I will complete the A/C function .

[GreggK]

Here is a picture of what I have. Am I able to run the engine with these hoses as they are. They are going into the compressor on the other end.

[JudoJeff]

Go ahead and start your engine. Open lines might get dirt inside, plug off the openings. System won’t turn on without a charge.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[Westaru]

After reading this thread 4 times I've decided to tackle the Smallcar AC for my '84. System is ordered as well as a condenser and crimper! I'm curious if the Vintageair or OEM Vanagon Drier/receiver is preferred? Neither is listed as a needed part on the smallcar site but their 'included' parts list doesn't include it.

The only parts I'm having a tough time sourcing is a compressor bracket and compressor (1991 EJ22). My engine doesn't have either and I can't seem to find a junkyard that has one of these locally. I'm curious if anyone knows of an internet source for these? Would like the compressor for the 'plug' and for a core.

Thanks in advance,
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1984 'Westaru' Vanagon Westfalia EJ22
@UtahWestfalia on IG

[JudoJeff]

Does anyone have recommendations for 12v solenoid valve? This would be used if I add a second a/c evaporator under bench seat.

I looked on eBay, 1/4” or 1/2” for $15-$20, but not sure if they can handle the pressure. Expensive $115 valve rated to 300 psi found. I suspect this actually refers to valve gate pressures, not the pressures the valve can withstand.

My concern is the valve grenading at high system pressures, not leakage by the gate.
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1989 Vanagon GL Westfalia Camper, Burned up on 7/31/16.
1987 Vanagon GL Westfalia Camper, Bostig & Rebuilt, sold
1986 Vanagon GL Westfalia Camper, Bostig Sold May 10, 2021
1999 Ford GTRV Westfalia camper (30% bigger Westy layout)

[Farf]

Here's one that's not too expensive, ready to go with #6 o-ring connections.

http://www.partdeal.com/hvac/hvac-valves/red-dot-l...T8QAvD_BwE