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Topic: MK3 Aircon into MK2 anyone got a guide? (Read 1439 times) previous topic - next topic

Re: MK3 Aircon into MK2 anyone got a guide?

Reply #45
Thanks Monkey.

I was hoping that I would only be removing the metal on the back face of the slam panel hence could leave it in situ. I'll have a look what is involved tomorrow.
I have some carry over leave from last year so I really do want to make some progress this next week.

Interestingly the front offside floor is now dry as a bone even after all this recent mad weather/rain. I suspect there was a leak, now fixed but I was also suffering from lots of condensation. The rear carpet is still drying out tho. Here's hoping.

Re: MK3 Aircon into MK2 anyone got a guide?

Reply #46
So today I removed the slam panel to make a cut-out for the AC condensor....Unfortunately the slam panel is a bit crusty with rust so I may need a new one. I used a hole saw and it faired quite well but wasn't man enough to cut through the double skinned metal, more shopping!
I also fitted the what turns out to be not a "PAC", but an C & A mount...It replaces the MK2 PAS swivel mount and secures both the AC compressor and the MK3 alternator.. It is now obvious why the mount has cut-outs for the compressor bolts because you need to fit the compressor bottom bolt first - good access from below the car, but the top bolt is too long to fit (Chassis rail in the way when the compressor is in. So you have to put the top bolt in about an inch and twist it into the "cut-out"...I'll take a retrospective piccy. That took a few mins of thinking !
Finally put the slam panel back and fitted the rad...hmm The MK2 8v radiator bottom outlet lines-up nicely with the side of the compressor....looks like I need to change the rad..I think 16v ones are smaller aren't they ??
Time-out to think on the next plan of attack and shop for parts.

Album updated

Aircon Album

Re: MK3 Aircon into MK2 anyone got a guide?

Reply #47
After responses to a couple of posts on CLUBGTI from Rubjonny and Davidut5 who has actually done the aircon retrofit I ordered a MK2 aircon rad from Latvia (circa £47 all in) that was the only one I could find on ebay RADAD.....I must have been half asleep since there are some local UK suppliers I've subsequently found. The rad is about 675mm wide but the bottom hose outlet is angled down hence the hose will route under the compressor. Because the rad will sit snug in the first cross member hole next to the battery the existing top hose should be fine but I've ordered a new bottom hose. I've tempoarily rigged the existing rad up so I can flush the system of crap.
I tried to fit an 1148mm ribbed aux belt which is apparently a standard aircon fit but no joy. I had to fit a 1155mm and remove the alternator bolt so I could get it over. That's now sorted.
I now need to get a new v belt for the waterpump and PAS because none of mine are the right size - hmm.
Whist the PAS fluid is drained I've treated the resevoir to a dishwasher tablet soak. Might do that with the expansion tank too.
I have made another cut in the slam panel using a hacksaw since it looks like the original hole is in the wrong position. Luckily that cut is mainly through a single skin of metal. Not too bothered because the slam panel needs replacing due to it being rusty.
Driver's side floor still appears to be dry. I must have had some leak in the bulkhead since the indicators aren't working (hazzards are) and all leccy windows except for the drivers have stopped working too... Arrrgh.




Re: MK3 Aircon into MK2 anyone got a guide?

Reply #48
The new rad arrived from Latvia on Thursday, well packed and undamaged.
On Bank Holiday Friday I connected the PAS up and fitted a new V belt. After the "minor" issue with the clutch I took the car for a run round - all good.
Have made-up some strips of metal so I can attach the fan cowling and condensor to the bigger rad.
Today its snowing!!!!

 

Re: MK3 Aircon into MK2 anyone got a guide?

Reply #49
A little more progress...and I mean a little!

The new rad is in along with the the correct upper and lower hoses...With hindsight I should have used the aftermarket product codes (eg Gates) for the hoses and I could have got both hoses quicker from UK suppliers along with the aircon rad...lesson learned.
I made some metal strips so that both the condenser and fan shroud attach using the mounts on the sides of the rad. I didn't want to put holes through the perfectly straight fins. They could do with painting the strips properly which I'll do at a later stage, really wanted to stop them rusting.

I've trial fitted the Aircon hoses but don't have a clue how they route, particularly the evaporator (heater box) to compressor hose which is really long so must take a convoluted route . I think it goes in front of the radiator but now I've fitted the radiator I don't really want to remove it again. I may remove the grille, loosen the rad so I can move it across and see if I can work it out, otherwise cut it and route it along the cross member forward of the PAS pipes.....pondering. We have a few local companies that should be able to splice in the correct length of hose.

The pipe which goes from the evaporator to the drier routes across the top of the firewall and guess what ...that too seems to have a kink in the wrong place making it the wrong shape and a bit long. I'll do a bit of pipe bending to see if i can lose a bit of length since it is currently against the suspension mount, if not I'll modify that too. Fortunately the hose from the compressor to the condenser appears to fit fine but they are only about 600mm apart!

If I do use the original aircon hoses I'll have to move the expansion tank because the hose ends won't fit with it in its original location. I've temporarily undone both mounting nuts and moved the expansion tank forward as a temporary solution (attached only by the front mount), That seems to have done the trick. I wonder if the MK3 expansion tank mounting bracket is different ?

The indicators are still dodgy, sometimes the light stays on. I thought it was damp in the fuse box but a chance wriggle of the indicator stalk makes them flash...assume the switch is worn. Luckily I have a replacement.

More pics in the album:

Aircon Album