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Abscate
Samba Member
Joined: October 05, 2014
Posts: 22641
Location: NYC/Upstate/ROW
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 Posted: Tue Aug 03, 2021 5:02 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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Big no for stop leak. It won’t work and no one here will ever talk to you again.
You need to pump on a system for a few hours to get the moisture out. Vacuum should hold overnight.
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djkeev
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Joined: September 30, 2007
Posts: 32584
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32584
Location: Reading Pennsylvania
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djkeev
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Location: Reading Pennsylvania
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mrshrimp
Samba Member
Joined: March 24, 2013
Posts: 373
Location: Portland
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| Posted: Mon Aug 09, 2021 4:49 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| Just got the AC working in our 89 westy. Only thing im mad about is that I did not get it on sooner. Its so nice. I did just have to order the Vanistan cabin air control unit. The cold air to the front is spotty and I think this mod will help. |
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djkeev
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Joined: September 30, 2007
Posts: 32584
Location: Reading Pennsylvania
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Prototype4342
Samba Member
Joined: May 28, 2021
Posts: 10
Location: Rio Rancho, NM
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| Posted: Wed Aug 11, 2021 12:36 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| Looking forward to the parts list and line lengths etc. Gonna have to rebuild the A/C in my 86, it's a necessity here in New Mexico. |
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djkeev
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Location: Reading Pennsylvania
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mrshrimp
Samba Member
Joined: March 24, 2013
Posts: 373
Location: Portland
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| Posted: Wed Aug 11, 2021 1:12 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| djkeev wrote: |
| mrshrimp wrote: |
| Just got the AC working in our 89 westy. Only thing im mad about is that I did not get it on sooner. Its so nice. I did just have to order the Vanistan cabin air control unit. The cold air to the front is spotty and I think this mod will help. |
That's great!
How far did you rebuild it?
That reminds me, I need to get a material list together!
Dave |
Did not have to rebuild, besides a few parts. was always there but didnt get it running for first six years we had van. Then came kids and EJ2.5 conversion, so had it working again then clutch failed, just had friend and mechanic help with getting running again and its great. But need to set up that vanistan front air system. |
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Prototype4342
Samba Member
Joined: May 28, 2021
Posts: 10
Location: Rio Rancho, NM
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| Posted: Wed Aug 11, 2021 7:55 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| djkeev wrote: |
| Prototype4342 wrote: |
| Looking forward to the parts list and line lengths etc. Gonna have to rebuild the A/C in my 86, it's a necessity here in New Mexico. |
If you have an 86, that is very much a bastard/transition year!
My 86 had an 85/86 hybrid with components of both.
I understand that Some 86’s had the 86 system completely.
Anyway, if you do NOT have A/C relays and fuses in the LR "D" pillar and your receiver/drier is in the LF wheel well, you need the already completed rebuild thread.
https://www.thesamba.com/vw/forum/viewtopic.php?t=583818
Dave |
I haven't opened the D-pillar yet, but I do have the drier in front of the rear driver side wheel. I gotta get an exhaust welded up for my subaru swap and finish rebuilding my steering rack then A/C is probably the next step. I'll take a look at your other thread. Cheers. |
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djkeev
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Joined: September 30, 2007
Posts: 32584
Location: Reading Pennsylvania
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t3 kopf
Samba Member
Joined: October 22, 2012
Posts: 1115
Location: over by 'der
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| Posted: Fri Apr 01, 2022 8:37 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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Dave, do you have the part numbers for the fittings you used for the ez clip hoses you made? I need them for the 2 at the expansion valve, the straight fitting for the universal pressure switch and the fitting from the pressure line to the receiver/dryer. Those are the only hoses still original on my van and I'd like to make new ones.
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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion |
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djkeev
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t3 kopf
Samba Member
Joined: October 22, 2012
Posts: 1115
Location: over by 'der
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| Posted: Wed Apr 06, 2022 2:34 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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I ended up having a hose shop build my last 2 but the info would still help others using ez clips. In order to keep the oddly threaded trinary switch port, they brazed fittings on the ends. The system has held vacuum at 30 hg for 2 days.
Here is where the hosed are tied into the subaru system and the compressor cut relay. I havent put the belt on yet. I'm waiting for a new pulley.
And here's where I redid the wiring in the D pillar
For my ducting, I fiberglassed the broken parts for a little more security, then I used thin sheet aluminum pieces that fit between the screws for the ducting brackets to help hold it up. It fits very securely.
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'90 Carat w/ '95 phase 1 EJ22 OBD2 conversion |
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floodwood
Samba Member
Joined: October 22, 2017
Posts: 164
Location: Cambridge, MA
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| Posted: Thu May 12, 2022 4:27 am Post subject: Re: Rebuild...... 1990 Air Conditioning |
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I am not quite certain where this belongs - in its own thread or in an existing one. This thread has been a welcome treasure trove of information, even for someone completely new to a/c
I am doing some investigating into my own a/c - it blew slightly cold when I first got the van 3 years ago, and now is marginal at best. Yesterday evening I had two observations - note that per old shop records from the PO I have an original tin top system that is running r134a.
1. The a/c compressor clutch is not engaging- ambient air temp was about 60. Is there a fuse directly for the compressor, if so is this the 50 amp fuse behind the D pillar, or should I be looking elsewhere to solve this problem.
2a. On can speed 4, my front radiator fan comes on and stays on. Is this a feature, or a bug?
2b. Additionally, I noticed that when I turned on fan speed 4, I could hear the relay in the rear continually opening and closing repeatedly. I have heard of fires back there so to avoid the relay from overheating and catching fire, I turned it off. Any suggestions on where to look to remedy this? |
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Abscate
Samba Member
Joined: October 05, 2014
Posts: 22641
Location: NYC/Upstate/ROW
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| Posted: Thu May 12, 2022 4:44 am Post subject: Re: Rebuild...... 1990 Air Conditioning |
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The compressor won’t come on if the system pressure falls too low, so that’s the first thing to check. I’m starting travel to MIT agai soon, so maybe I can br8ng my sniffer and give you a hand ?
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floodwood
Samba Member
Joined: October 22, 2017
Posts: 164
Location: Cambridge, MA
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| Posted: Thu May 12, 2022 4:54 am Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| Abscate wrote: |
| The compressor won’t come on if the system pressure falls too low, so that’s the first thing to check. I’m starting travel to MIT agai soon, so maybe I can br8ng my sniffer and give you a hand ? |
Amazing. Name your beer and time, would love to look at the system with a guru and get an idea of what needs attention. I will send you a PM. |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 9603
Location: Western WA
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| Posted: Thu May 12, 2022 8:12 am Post subject: Re: Rebuild...... 1990 Air Conditioning |
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| floodwood wrote: |
| 1. The a/c compressor clutch is not engaging- ambient air temp was about 60. Is there a fuse directly for the compressor, if so is this the 50 amp fuse behind the D pillar, or should I be looking elsewhere to solve this problem. |
try jumpering the compressor from the 12v hot on your alternator. After it runs awhile it might start to take refrigerant,, the pressure rises. Try disconnecting the jumper and see if the compressor engages on it's own.
| floodwood wrote: |
| 2a. On can speed 4, my front radiator fan comes on and stays on. Is this a feature, or a bug? |
(I don't know)
| floodwood wrote: |
2b. Additionally, I noticed that when I turned on fan speed 4, I could hear the relay in the rear continually opening and closing repeatedly. I have heard of fires back there so to avoid the relay from overheating and catching fire, I turned it off. Any suggestions on where to look to remedy this? |
Some folks disconnect speed #4 to avoid rear AC fire. Only on "old" vans though. 
If you have a Westy with the "rear plenum delete" you prob don't need speed #4. We use speed 1&2 only with "rear plenum delete". We don't even use #3 anymore but it's there.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32584
Location: Reading Pennsylvania
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| Posted: Wed Jul 06, 2022 4:07 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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I made a material list.
Some items are personal choice for how many you use or what sizes.
Ie ..... How you mount the Condenser has several varying methods.
I was generous on hose length, there are different paths you can follow and I am one who prefers having an extra foot or two than being 6" short!
I also use the EZ Clip A/C hose system for which all the fittings, hoses, cages, clips and Orings are found herein.
Anyway..... here it is, feel free to comment or suggest changes......
1990 Vanagon A/C rebuild Parts list July 2022
Condensor 16x22 parallel flow
Nostalgic Air
PN # 54-1622
https://nostalgicac.com/catalog/product/view/id/255/s/16-x-22-superflow-r-134a-condenser/category/6/
Rec/Drier
Nostalgic Air
PN # 4-1000
A/C Compressor
Sanden 709 with V-belt Pulley
Sanden # 04709-VUA
VintageAir (Vintage Air charges for shipping, they have distributers who will ship their products free)
https://www.vintageair.com/accessories/?subcat1=Co...20V-Groove
Relays/sensors/switches if you need them
#171 959 141A the tall A/C relay on the right, from VanCafe
#100 937 0001 40amp Meyle Blower Fan Relay from FCP
#431 951 253F 20amp Compressor Relay from Pelican Parts
ambient temperature switch VAG# 8a0 959 625
Thermostat VAG#253965581
Hose sizes used
Size 6 feed hose from Condenser to rec/drier to Evaporator
Size 8 feed from Compressor to Condensor
Size 10 return hose from Evaporator to Compressor
Fittings
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I use hosewarehouse.com for my hoses, fittings, cages, clips and Orings.
https://hosewarehouse.com/collections/ez-clip-ac-systems
Note: Areoquip seems to have updated their part numbers during the past year.
Some of the part numbers are new numbers. These are the short part numbers.
The long part numbers are the old numbers.
They now also offer a fitting kit with the cage and clips.
You may need to use the description I included to get the proper fitting.
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"H" style Expansion Valve
FJ3052-0606S
#06 hose 5/8-18 MALE thread Straight O ring style (from Condenser)
FJ3113-02-1010S
#10 hose 7/8-18 MALE thread 45° O ring style (to Compressor)
A/C Compressor
FJ5985-0808S ( # FBE4333)
#08 hose 3/4-16 Female thread 90° O ring style (To Condenser)
FJ5985-1010S (new # FBE4334)
#10 hose 7/8-14 Female thread 90° O ring style (From "H" expansion)
Condenser
FJ5945-0808S (new # FBE4333)
#08 hose 3/4-16 Female thread 90° O ring style
FJ5985-0606S (new # FBE4332)
#06 hose 5/8-18 Female thread 90° O ring style
Rec/Drier
FJ5984-0606S (new # FBE4312)
#06 hose 5/8-18 Female thread Straight O ring style
FJ5984-0606S (new # FBE4312)
#06 hose 5/8-18 Female thread Straight O ring style
Pressure Switch Port
FJ3171-0606S
#06 hose 7/16-20 pressure port
Hi Pressure gauge port
FJ5995-0606S (new # FBE4512)
#06 hose
Low Pressure Port
FJ5986-1010S (new # FBE4514)
#10 hose
Hose
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GH001-6
#06 hose
9 feet "H" Valve to Rec/Drier (the High Pressure Gauge Port and the Binary switch port are in this line in the "D" Pillar)
13 feet Rec/Drier to Condenser
21' total
GH001-8
#08 hose
15 feet Compressor to Condenser
GH001-10
#10 hose
6 feet "H" Valve to Compressor (low pressure gauge port is in this line in the "D" Pillar)
Orings
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22546-11
#06 quantity 10
22546-13
#08 quantity 4
22546-15
#10 quantity 14
EZ Clip Crimping Pliers
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Very similar to fuel hose clamp crimping pliers
Get the EZ clip ones or use what you already have
EZ Clips
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IF40104-06C
#06 quantity 20
IF40104-08C
#08 quantity 4
IF40104-10C
#10 quantity 20
EZ Cages
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IF40105-06C
#06 quantity 10
IF40105-08C
#08 quantity 2
IF40105-10C
#10 quantity 10
Pressure Switch
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You cannot use the VW switch unless you salvage and reuse the VW switch port pipe. With EZ Clip, this isn't easily possible.
Get a 7/16-20 trinary switch
Vintage Air
#11076-VUS female 7/16-20
https://www.vintageair.com/search-results/?sqry=Trinary
Note:
I used UAC 4002C binary pressure switch, but I was in a bind.
I'd prefer wiring in a trinary switch but..... that ship sailed.
Do as you see best.
Insulated "P" wire clamps
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single mount hole
These are for mounting the hoses to the body.
Quantity needed is subjective. Buy too many, take some back. Size 06 & 08 have the longest runs, but the 1/2" clamps are used for mounting the new condenser.
You will also need self drilling hex head sheet metal screws to fit the clamps, stainless if you can find them.
Size 7/8" fits hose #10
Size 3/4" fits hose #08
Size 1/2" fits hose #06
An example....
https://www.homedepot.com/p/0-75-in-Rubber-Insulated-Cable-Clamp-2-Pack-PPR-1575/202875639
Double thread rubber vibration dampeners
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These are used for mounting the Condensor.
They come in different lengths. They space the condensor from the mounting bars.
I got a selection of lengths, of male ends and female ends.
I also got stainless washers, bolts and nuts.
It is a use what you need deal.
An example .....
https://www.mcmaster.com/catalog/128/1595
ZIP ties
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Helpful for mounting hoses.
Quantity is subjective
PAG Oil
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Used in the system and to lubricate fitting Orings and EZ Clip fittings on assembly get more than just 8 oz.
In system........
PAG Oil 240cc / 8 oz.
Oil distribution
0cc - Condensor (yes..... you read correct, zero oil preloaded in here)
60cc / 2.0 oz - Evaporator
10 cc / 0.3 oz - Rec/Drier
10 cc / 0.3 oz - High Pressure Hose
10 cc / 0.3 oz - Low Pressure Hose
Balance in Sanden 709 Compressor
Air Conditioner Cleaning Fluid / Flush
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This is to clean the Evaporator and the "H" expansion Valve
Various brands at any good auto parts store.
I suggest 2 qts, use it until it runs out clear.
Refrigerant
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I used RedTek r12a
3 cans
Dave
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Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
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http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
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https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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Howesight
Samba Member
Joined: July 02, 2008
Posts: 3274
Location: Vancouver, B.C.
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| Posted: Wed Jul 06, 2022 5:39 pm Post subject: Re: Rebuild...... 1990 Air Conditioning |
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Hey Dave:
What a great post!! It's so helpful to have all the part numbers, links to vendors, etc. Thanks for your hard work.
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