Date: Fri, 3 Sep 1999 12:07:48 EDT
Reply-To: FrankGRUN@AOL.COM
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Frank Grunthaner <FrankGRUN@AOL.COM>
Subject: Re: Subaru was: 2.1l engine / Digifant / AC Detail
Content-Type: text/plain; charset="us-ascii"
Described it here before, some time ago but I'll give a quick recap.
I used the 508 compressor and brackets from the original donor car ('90 8V
GTI - RV engine code). I bought (from a junkyard - Russ Recycling, City of
Industry, CA) the Vanagon AC components (evaporator, condenser, blower
housing, etc.). The hoses were cut but I took them and the wiring harness.
This was the unit for the regular Vanagon, pre '86, I think, which has a
distribution manifold just above the windshield and a connecting duct to the
main cooler/blower assembly which mounts behind the front seats.
The original assembly would have placed the blower/cooler system nearly in
the middle of the pop-top opening. Not good! I mounted the blower as far
forward as possible, while clearing the driver and passenger brain cases. The
duct was shortened appropriately. This still gave a substantial overhang into
the pop-top area, but the configuration is such that with the upper bunk down
for sleeping, there is sufficient clearance such that my svelte frame (230 +
pounds with a Gaussian middle profile) readily passes through the opening.
The wife and daughter don't notice the restriction. I believe the overhang is
about 10 inches but I haven't measured it for more than a year. This left the
unattractive top of the blower showing, so I fabricated a wooden contoured
(to the shape of the roof) shelf from a set of oak strips. The shelf cleanly
drops into the original sunroof sealing grooves and goes over the end of the
blower assembly. The blower assembly is bolted to the shelf, body, etc. The
whole thing was finished with a marine varnish. It has proved to be very
handy to place clothing, books, keys, drinks on while in the penthouse suite.
A complication was access to the pop-top release latch when closed. I
fabricated a latch and handle extension which is readily accessible. Works
fine. Looks stock.
For the plumbing, I went to Hoseman (Duarte, CA) and had a set of hoses
fabricated to run under the van to points similar to a stock location. I
mounted the AC condenser in front of the diesel radiator (no problem). I then
wired the system up in a hybrid fashion using part of the early Vanagon
wiring, included the Digifant control of idle system, and the various safety
interlocks. Used a $30 dryer from Pep Boys. Biggest hassle was designing the
plumbing exiting the compressor, and getting the fill and test points,
switches, etc., in place between the cooling hoses, cooling tank, battery, in
the engine compartment.
Had to seal the water collection pan in the blower assembly. Ran water hoses
down the inside of the pillars behind the front doors. Brought the AC hoses
up inside the sink cabinet, and used my router to bevel the stove cover to
clear the hoses.
All in all, less trouble than I expected. When finished, I leak-tested the
system at home, then went to a local AC shop and had it filled with R-12
(purposely not R-134). Works like a charm. Sends plenty of air to the rear
seat, bathes the front seats in cold air. Engine doesn't notice the load. Oh
yeah, I wired in a compressor cutout at full throttle just in case. Also have
set of lights wired into dash console to monitor status of high and low speed
fan switches (radiator), high and low pressure AC switches and compressor
activity. No noticeable effect on oil temperature.
Hope this helps.
Frank Grunthaner
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