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Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos
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ALIKA T3
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PostPosted: Tue Mar 24, 2020 4:57 pm    Post subject: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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.
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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
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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.
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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

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and some VW German parts.

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

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


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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.
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VW fuse holder with american wires
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Blue wire to position 10
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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.
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Similar connector as VW-Amp but these are american. Not sure of the maker.
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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.
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[img][/img]

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Grilles, no markings but "4" and "100.2", which is not the size, one could have thought it was 4 inches, 100mm....
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Hose 255272738, position 31A on the diagram
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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.
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These are the condenser brackets, I didn`t have the condenser.
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Hose cover for driver`s side, in 2 pieces

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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.
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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.
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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
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Fan speed resistor mounted above the rear view mirror
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Front part
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Condenser diagram, not model specific
Condenser 255272413A
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Evaporator housing parts list:

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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 Cool

Edit:

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Last edited by ALIKA T3 on Fri Mar 27, 2020 5:25 pm; edited 2 times in total
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erste
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PostPosted: Tue Mar 24, 2020 5:45 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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. Very Happy
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PostPosted: Tue Mar 24, 2020 6:05 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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. Itís still sitting in my rafters. I wouldíve given you a hug for putting all this together. Thanks again.
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PostPosted: Tue Mar 24, 2020 6:17 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

erste wrote:
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. Very Happy


Ok, gonna read that!

Yeah I gotta find the owner of that pic Smile
No date on the back but seems like 90's photo paper.

Aloha !

rmcd wrote:
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. Itís still sitting in my rafters. I wouldíve given you a hug for putting all this together. Thanks again.


You're welcome! You went with an in dash unit , right?
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PostPosted: Tue Mar 24, 2020 6:32 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

Yes. The smallcar unit. I will not suggest it is easier than R and R on oem unit!!
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PostPosted: Tue Mar 24, 2020 6:40 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

rmcd wrote:
Yes. The smallcar unit. I will not suggest it is easier than R and R on oem unit!!


Yes, I was on the SC AC thread too. I havenít filled mine yet. Almost done....
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PostPosted: Tue Mar 24, 2020 7:40 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

[email protected], you had a busy afternoon... Wink

Very nice work and documentation! Very Happy Cool Cool Cool

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PostPosted: Tue Mar 24, 2020 8:00 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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.
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PostPosted: Tue Mar 24, 2020 8:08 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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.
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PostPosted: Tue Mar 24, 2020 8:17 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

This would be a nifty way to add dual A/C in my van.
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PostPosted: Tue Mar 24, 2020 8:29 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

Zeitgeist 13 wrote:
This would be a nifty way to add dual A/C in my van.


Ka Boom.
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PostPosted: Tue Mar 24, 2020 8:34 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

I feel like Iím back to last year when I dropped the same unit in my Ď84 with some intent of starting to rehab it. I took a few pictures and posted them ,but nothing as detailed as this thread.... Shocked Shocked
Iíve gotten better about not hitting my head on it , moving to the back to access something there..... Razz 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 havenít burned up.
Blower needed the same bearing oiling that weíre used to with the front blower motor... Rolling Eyes
I swear that those L shaped expansion valves are almost lifetime worthy on any vehicle you find them in, as long as theyíre clean with no debris on the internals.
One well made part.
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PostPosted: Tue Mar 24, 2020 10:08 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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

dhaavers wrote:
[email protected], you had a busy afternoon... Wink

Very nice work and documentation! Very Happy Cool Cool Cool

- Dave


Thank you!
I spent all morning typing it, arranging pics etc... It`s rare I have the time to do such posts, the list on the back burner is so long!

Steve M. wrote:
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.


Thank you!
lol, I never ever felt it was in my way when moving around, but I stealth-lived in a Westy for over 2 years, rarely popped up the roof, I guess it`s a habit Razz

jimf909 wrote:
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.


Wow, thank you for the kind words Razz I will try to find the owner for the picture, it`s a small island, I`m sure somebody on Facebook will recognize the kids when I post it.

Zeitgeist 13 wrote:
This would be a nifty way to add dual A/C in my van.

Do it ! How hot is it that you need dual AC?? I don`t even need it here in Hawai`i, but I never grew up with AC, and worked for 10 years on roofs installing solar in the blazing sun, I`m resistant to heat Laughing
The hottest I have ever experienced was driving with my dad through Andalucia in Spain back in the 80`s. I remember we couldn`t roll the windows down bc the air was burning us. It was evil hot. Olive trees as far as you can see, nothing else for hours. Better not overheat there.....

jlrftype7 wrote:
I feel like Iím back to last year when I dropped the same unit in my Ď84 with some intent of starting to rehab it. I took a few pictures and posted them ,but nothing as detailed as this thread.... Shocked Shocked
Iíve gotten better about not hitting my head on it , moving to the back to access something there..... Razz 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 havenít burned up.
Blower needed the same bearing oiling that weíre used to with the front blower motor... Rolling Eyes
I swear that those L shaped expansion valves are almost lifetime worthy on any vehicle you find them in, as long as theyíre clean with no debris on the internals.
One well made part.


I just restored an AC tunnel for a customer, making brackets and reinforcing all parts etc... I have to post pics with part numbers so results come up when searching Google.
I can tell you this older unit is much simpler and more solid built. The resistor looks bomb proof!! Nice industrial grade parts in there, not model specific.
Do you have the link of your posting?

Aloha all!
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Syncro transmission upgrade parts in the Classifieds.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
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PostPosted: Wed Mar 25, 2020 5:48 am    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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?
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PostPosted: Wed Mar 25, 2020 9:10 am    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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.
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PostPosted: Wed Mar 25, 2020 10:17 am    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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

Here it is...
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PostPosted: Wed Mar 25, 2020 11:06 am    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

Zeitgeist 13 wrote:
This would be a nifty way to add dual A/C in my van.


It was on my list too......butt, butting my head on it, listening to the noisy fan next to my head and especially knowing cold air blowing on my head promotes headaches, I decided not to plague myself with one. (I too had one from a parts van.)

Ditto a front Behr unit. Big, old and loud, not good too. (Two in personal stock.)

They are a practical addition to double cabs, though.....seen that done twice now.

For now, my SmallCar system works just fine, thank you and we may hook up the rear system again if Summer proves the need.

Unless you fit a bigger compressor, you will likely be diverting between front and rear, meaning only one at a time is actually cooling.......plus the issue of making sure the compressor lube does not pool. Plus a second condenser. Lots of additions and compromises...
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ALIKA T3
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PostPosted: Wed Mar 25, 2020 11:33 am    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

borninabus wrote:
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.


I am torn about this, I know in Europe they also had the same AC tunnel, but for having taken one apart recently to completely restore it ( I will do a post about this model too) I found some weird details.
No part numbers with ZVW or anything weird other than the classic 255xxxxxx part numbers. BUT most of the plastic parts are labelled USA and have a TX2 writting on the bottom of the part number sticker. TX2, really close to TX-Texas. A coincidence? I don`t know what could be different in the plastic parts to have them labelled specifically for the USA market.
I once found a bare plastic electrical connector housing brand new, unused in the ceiling above the AC. I don`t know what to think, I highly doubt the AC tunnel was assembled after leaving Germany, it`s way too much work, the wiring harness is well integrated with the chassis stuff, hose routing etc, but why marking the parts for USA market? Mystery.

dobryan wrote:
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?



Yes it has been done once, I have seen it shared a few times during my research here. Not pretty but it worked with the mods you mentionned, extending the roof latch etc...
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PostPosted: Wed Mar 25, 2020 1:41 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

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
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PostPosted: Wed Mar 25, 2020 2:56 pm    Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos Reply with quote

Zeitgeist 13 wrote:
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


I can not have the AC blow on my head. Therefore the subject system is not good for me and has several install challenges for a camper. I do not like it blowing on my back either (I have camper AC.). Blowing out the dash suits me. Shoot yourself and not get the SC front AC bits, they just make life a lot easier installing the Vintage Air box. I have yet to know of any real complaints about a working dash mounted system. In the mean time the front of my van blows cool, you can keep blowing hot.
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1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)
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