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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6347 Location: Honolulu,Hawaii and France
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Posted: Tue Mar 24, 2020 4:57 pm Post subject: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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
Last edited by ALIKA T3 on Fri Mar 27, 2020 5:25 pm; edited 2 times in total |
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erste Samba Member
Joined: March 29, 2013 Posts: 1110 Location: San Francisco
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Posted: Tue Mar 24, 2020 5:45 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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. |
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rmcd Samba Member
Joined: October 29, 2010 Posts: 1348 Location: PNW - its a dry rain.
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Posted: Tue Mar 24, 2020 6:05 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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= |
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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6347 Location: Honolulu,Hawaii and France
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Posted: Tue Mar 24, 2020 6:17 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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. |
Ok, gonna read that!
Yeah I gotta find the owner of that pic
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. It’s still sitting in my rafters. I would’ve given you a hug for putting all this together. Thanks again. |
You're welcome! You went with an in dash unit , right? _________________ 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 |
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rmcd Samba Member
Joined: October 29, 2010 Posts: 1348 Location: PNW - its a dry rain.
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Posted: Tue Mar 24, 2020 6:32 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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= |
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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6347 Location: Honolulu,Hawaii and France
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dhaavers Samba Member
Joined: March 19, 2010 Posts: 7754 Location: NE MN (tinyurl.com/dhaaverslocation)
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Posted: Tue Mar 24, 2020 7:40 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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> |
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Steve M. Samba Member
Joined: July 30, 2013 Posts: 6829 Location: Fort Lauderdale, Fl.
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Posted: Tue Mar 24, 2020 8:00 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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. |
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jimf909 Samba Member
Joined: April 03, 2014 Posts: 7465 Location: WA/ID
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Posted: Tue Mar 24, 2020 8:08 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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
Abscate wrote: |
Do not get killed, do not kill others.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12115 Location: Port Manteau
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Posted: Tue Mar 24, 2020 8:17 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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? |
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rmcd Samba Member
Joined: October 29, 2010 Posts: 1348 Location: PNW - its a dry rain.
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Posted: Tue Mar 24, 2020 8:29 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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Zeitgeist 13 wrote: |
This would be a nifty way to add dual A/C in my van. |
Ka Boom. _________________ 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= |
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jlrftype7 Samba Member
Joined: July 24, 2018 Posts: 3576 Location: Chicago
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Posted: Tue Mar 24, 2020 8:34 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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 |
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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6347 Location: Honolulu,Hawaii and France
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Posted: Tue Mar 24, 2020 10:08 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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I edited the message to add a drawing of the 2 part condenser I found.
dhaavers wrote: |
D@mn, you had a busy afternoon...
Very nice work and documentation!
- 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
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 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
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 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. |
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! _________________ 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 |
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dobryan Samba Member
Joined: March 24, 2006 Posts: 16501 Location: Brookeville, MD
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Posted: Wed Mar 25, 2020 5:48 am Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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 |
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borninabus Samba R&D Dept.
Joined: May 18, 2006 Posts: 4536 Location: Arizona Highways
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Posted: Wed Mar 25, 2020 9:10 am Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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 |
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jlrftype7 Samba Member
Joined: July 24, 2018 Posts: 3576 Location: Chicago
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Posted: Wed Mar 25, 2020 10:17 am Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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 |
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r39o Samba Polizei
Joined: May 18, 2005 Posts: 9800 Location: San Diego
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Posted: Wed Mar 25, 2020 11:06 am Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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... _________________ "Use the SEARCH, Luke" But first visit the Vanagon FAQ!
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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ALIKA T3 Samba Member
Joined: July 30, 2009 Posts: 6347 Location: Honolulu,Hawaii and France
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Posted: Wed Mar 25, 2020 11:33 am Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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... _________________ 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 |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12115 Location: Port Manteau
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Posted: Wed Mar 25, 2020 1:41 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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? |
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r39o Samba Polizei
Joined: May 18, 2005 Posts: 9800 Location: San Diego
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Posted: Wed Mar 25, 2020 2:56 pm Post subject: Re: Dealer installed AC, headbanger, DPD, VPC, CCCCool : infos |
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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. _________________ "Use the SEARCH, Luke" But first visit the Vanagon FAQ!
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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