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Old 10-19-2018, 01:02 PM   #1
Harlard
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Default Air Conditioning Retrofit

Hi all,

I have been wanting to run some form of air conditioning for a while now that the summers in the PNW are getting actually warm, and road trips to California can be slightly unbearable with all windows open at 90 MPH with the cabin still at 100 degrees...not ideal.

Recently I retrofitted my 242 with a later AC HVAC box (not sure whether it's 91, 92, or 93. I know that the fitting sizes on each one of those is different...) when fixing a leaky heater core.

What I do know for sure:

1. I'm swapping over a grandpa series accessory bracket setup and remote res power steering
2. I want it to work better than the crappy early 90s R134A setups with leaky hoses
3. Currently looking at the 940 series line routing. Looks way more useful than the diagonal hose on late 240s

ON TO THE [/a]QUESTIONS:

1. Should I get OEM hoses? Are there other options available? This begets:
2. Should I get an OEM condenser?
3. Is the stock compressor and dryer good enough?
4. What brands of components (compressor, receiver, hoses, condenser) should I seek out/stay away from?
5. What else am I missing??
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Old 10-19-2018, 09:18 PM   #2
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im doing the same as this but for a 164. from what ive learnt is the later Evap is a good start
use the stock setup accumulator variable orifice and get a rotary sanden compressor and paraflow condenser.

im in the process of getting some custom hoses made up since nothing factory will fit mine. I believe hardline are meant to be better not sure how much of a difference they make. custom lines are expensive

im using a replica of the sanden sd508 so will see how that pans out and universal 12x21 paraflow condenser(I think a bigger one will fit in a 240 front)

and use best pusher fan hooked up to the compressor.

I will be hopefully using HC refrigerant as I see the general consensus r134a is crap.

I would use genuine components if but budget has constricted me.
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Old 10-19-2018, 10:00 PM   #3
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Its getting warm in October? You guys got some weird weather out west
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Old 10-19-2018, 10:19 PM   #4
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Its getting warm in October? You guys got some weird weather out west
Ya we had some 80's out in the big valley but the weather girl is saying that'll be about it for indian summer by next week.
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how psi stock cna support?

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Old 10-19-2018, 10:32 PM   #5
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I recently replaced my entire AC system and fabricated all the hoses. It was easy, cheap, and no leaks so far.

eBay parallel flow condenser and stock drier work fine.

www.coldhose.com

Mastercool 71550 manual hose crimper

Lots of info here, even if you aren’t doing the CAA conversion.
http://www.240turbo.com/classicair.html
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Old 10-19-2018, 11:51 PM   #6
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Thanks Hutch. Looks like factory hose is in the cards for me unless I can have a local shop do the crimps for me. Would also need to figure out where to put the high and low pressure switches if custom hose ends up being used.
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Old 10-20-2018, 01:34 AM   #7
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Im running 90 v. 240. Evaporator is stock, rebuilt compressor, upgraded condenser. and built my hoses I used a pex hose crimper (dont laugh, Im in middle of nowhere). I did install condenser fan but isnt needed. My temps are cold in hot humid air. Im running duracool.
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Old 10-20-2018, 01:51 AM   #8
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How did you figure out what the fitting sizes are. Are they all standardized?
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Old 10-20-2018, 08:57 AM   #9
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Mine is an 87 setup (dryer and expansion valve) with a 93 134a compressor.

All the high side hoses and fittings in mine are 8. The connection from the evaporator low side however, is a 12 and the compressor is a 10. I ran a size 10 hose with a 12-10 reducer fitting at the evaporator. Now I’m thinking I should’ve used a 12 hose with the 12-10 at the compressor. I don’t know if it would’ve made any difference though.

I also put in high and low side inline charging points to make it easy.

Duracool.

Last edited by Hutch.; 10-20-2018 at 09:12 AM..
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Old 10-20-2018, 09:33 AM   #10
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Correction:

#8 from compressor to condenser. #6 from condenser to dryer and dryer to expansion valve. #12 fitting at evaporator to #10 fitting at compressor.

Hope that helps.

Last edited by Hutch.; 10-20-2018 at 10:56 AM..
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Old 10-20-2018, 04:25 PM   #11
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Getting a good radiator and fan will make or break the A/C, especially in hot weather during long drives.
-L
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Old 10-20-2018, 09:29 PM   #12
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Quote:
Originally Posted by Harlard View Post
Recently I retrofitted my 242 with a later AC HVAC box (not sure whether it's 91, 92, or 93. I know that the fitting sizes on each one of those is different...) when fixing a leaky heater core.
The HVAC box is the same from '91-93. The stuff under the hood is what is different.

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Originally Posted by Harlard View Post
Thanks Hutch. Looks like factory hose is in the cards for me unless I can have a local shop do the crimps for me.
You're not going to get factory hoses to work from a '91+ car (or the rest of the underhood stuff for that matter) to work with your '85- front sheet metal. Things just don't bolt up and there isn't a mix-'n-match formula for what you want to achieve.

First off, do yourself a favor and buy a Mastercool hose crimper and then you can make your own hoses and not have to rely on a hydraulic shop for everything (plus you'll be the envy of all of your friends). The crimper will pay for itself.

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Originally Posted by Harlard View Post
How did you figure out what the fitting sizes are. Are they all standardized?
Yes, they are all standard, although the '93 models use some metric threads for the accumulator fittings.

Swapping in a better system is possible, but it takes time to get everything sorted out.
You're using terms like "dryer" in an accumulator system. Slow your roll a bit and let's get this all sorted.

Do you have the rest of the system that donated the '91+ evaporator box?
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Old 10-20-2018, 11:25 PM   #13
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Quote:
Originally Posted by Lazarus View Post
Getting a good radiator and fan will make or break the A/C, especially in hot weather during long drives.
-L
He has neither.
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Old 10-21-2018, 12:22 AM   #14
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Yeah just a stock radiator and 940 fan
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Old 10-21-2018, 01:14 AM   #15
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Quote:
Originally Posted by Harlard View Post
Yeah just a stock radiator and 940 fan
And you threw away most of what you need when the gold car went away?

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Old 10-21-2018, 01:27 AM   #16
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No, I sold it
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Old 10-21-2018, 01:39 AM   #17
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No, I sold it
Ok I'll let you go this time but don't let it happen again.

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Old 10-21-2018, 02:11 AM   #18
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Quote:
Originally Posted by Wren View Post
The HVAC box is the same from '91-93. The stuff under the hood is what is different.
Excellent


Quote:
You're not going to get factory hoses to work from a '91+ car (or the rest of the underhood stuff for that matter) to work with your '85- front sheet metal. Things just don't bolt up and there isn't a mix-'n-match formula for what you want to achieve.
Not afraid to cut a hole or two and make brackets. That's child's play

Quote:

First off, do yourself a favor and buy a Mastercool hose crimper and then you can make your own hoses and not have to rely on a hydraulic shop for everything (plus you'll be the envy of all of your friends). The crimper will pay for itself.
Check. The vendor linked above listed the crimper at near $400 but I see that it's available on amazon for $150. Mu ccu more manageable.

Quote:

Yes, they are all standard, although the '93 models use some metric threads for the accumulator fittings.

Swapping in a better system is possible, but it takes time to get everything sorted out.
You're using terms like "dryer" in an accumulator system. Slow your roll a bit and let's get this all sorted.
So what do we call it? Big ugly aluminum bottle?

So far my takeaways are to use everything factory except hoses, compressor, and evaporator.

Would be nice to have a labeled diagram, but the internet doesn't have it. Shame.

Quote:

Do you have the rest of the system that donated the '91+ evaporator box?
Nope just bought the box.
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Old 10-21-2018, 10:50 AM   #19
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Dryer and accumulator are two separate systems. The accumulator came with the 90s models and works with an orifice tube. The older models have a dryer and expansion valve. They also have different evaporators.

You can use all factory with a couple caveats. You want a parallel flow condenser, factory 93 units are mad expensive. That’s why I recommended an eBay/generic model. I also recommend a 93 compressor because, it’s got 134a fill ports already. Then use duracool for best results.

Last edited by Hutch.; 10-21-2018 at 10:58 AM..
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Old 10-21-2018, 12:43 PM   #20
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Ok good to know. I knew the difference between old and new systems was only orifice tube vs expansion valve. Thought the drier and accumulator were different designs of the same thing.

The parallel flow condensers I see on AC vendors are reasonably priced and look like they have their ports in roughly the same location as the Volvo stuff.

Thanks for the input so far.
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Old 10-21-2018, 01:21 PM   #21
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Quote:
Originally Posted by Harlard View Post
Nope just bought the box.
You're going to need at least the accumulator and the high-side lines from the compressor to the condenser and from the condenser to the firewall/inlet for evaporator. Some of this can be fabricated.
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Old 10-21-2018, 01:39 PM   #22
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I do plan on using as many of the hard lines as possible.
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Old 10-21-2018, 11:14 PM   #23
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Quote:
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Thought the drier and accumulator were different designs of the same thing.
Not particularly. They both contain desiccant for removing moisture from the refrigerant charge, but have 2 different jobs and locations in "the loop". The similarities end there.

Speaking in automotive A/C terms; A "Receiver/Drier" (typically a Drier is separate on non-automotive applications) goes on the "High" side of the loop which manages liquid. Its primary job is to remove moisture from the charge and store refrigerant for demand, ensuring that the TXV (Thermal Expansion Valve) has a constant supply of liquid refrigerant. And that's pretty much it. It's important because on high demand days, the Receiver is often responsible for ensuring the evaporator gets its complete liquid refrigerant charge.

An accumulator's job on the other hand, is to prevent compressor slugging. That is, it's there to "accumulate" the liquid phase refrigerant that didn't boil off in the evaporator (as well as the oil charge) on the "low" (gas phase) side. Slugging is when excess liquid refrigerant gets pulled into the compressor. It damages it and causes all sorts of problems (like diluting the oil charge or even forcing the lubricant out of the compressor). The accumulator regulates how much liquid refrigerant and oil go back to the compressor through bleed orifice in the return tube for lubrication and cooling.

Disclaimer: I'm not an A/C professional, but this is what I know from my research into fixing my own vehicles. YMMV.
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Old 10-22-2018, 10:29 PM   #24
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Random question on this topic. Does the accumulator need be mounted vertically. If its mounted on an angle will be detrimental to its function
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Old 10-23-2018, 06:41 AM   #25
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OP, my son salvaged a 93 parallel flow condenser.... and at least 1 line. As Wren will tell you, the 93 only 2 series compressor will be tough to find..... my son also has that baby from a 75K vehicle. Last I discussed with him, he wasn't sure if he was going to keep for his 2's or flip. Shoot me a PM if interested and I will hook you two up. He harvested the entire system minus the low side hose (hacked) and I think the high side hardline from condenser to the entrance to the evap. I believe he even has the pusher fan which the 2 series needs, what with the factory weak a$$ mechanical fan et al.
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