AC Installation Advise - D90 with 2.5TD Engine

[johnsondml]

I did one couple years back to to 2.5 n/a , I bought an after market kit online from one of those ac companies for a classic mustang and made the compressor bracket and an a/c company locally made up the hoses for me...also upgraded the alternator to 110 amp..I fabricated all the mounting brackets, pretty decent for my first time...here in miami you need a/c

[Maryland 110]

Gents for all those interested. I have now found everything needed to install the AC kit thanks to everyone at Rovers North. The 300TDI kits work but it requires you to not use the compressor that comes in the kit. You need to source a new Sanden Compressor which I have done. When my pulleys come in I will start a new thread with Photos and the step by step instructions on installation, including Parts needed and where to get them.

Essentially the Kits you get for the 300 TDI will work for the older engine and the modifications are very minor. Shopping list besides compressor also includes new alternator, AC Tensioner Pulley (may not be needed) and the Mounting Bracket for the compressor. More information to follow after a few weeks.

Of course they work. The only part of the kit that is sensitive to what engine you have is the compressor. The rest of the system is universal with the exception of some plumbing bends to mate with different compressor locations.

[RoverDover]

Has DHS let your truck out of Jail yet?

[bsjbrown]

Gents for all those interested. I have now found everything needed to install the AC kit thanks to everyone at Rovers North. The 300TDI kits work but it requires you to not use the compressor that comes in the kit. You need to source a new Sanden Compressor which I have done. When my pulleys come in I will start a new thread with Photos and the step by step instructions on installation, including Parts needed and where to get them.

Essentially the Kits you get for the 300 TDI will work for the older engine and the modifications are very minor. Shopping list besides compressor also includes new alternator, AC Tensioner Pulley (may not be needed) and the Mounting Bracket for the compressor. More information to follow after a few weeks.

[bsjbrown]

Les thanks for the assistance today on the pulleys. Let me know what you find out on the Compressor mounting parts. Also does anyone know if I will have to change Alternators from the current 45AMP to 65AMP? Obviously will want to do all of this at one time.

Have found some Universal mounting kits for Sanden Compressors for special engine applications. May be SOL on the parts but will let everyone know how this turns out.

[bsjbrown]

Personally I have no clue why the sent me the two pieces of equipment they sent to me. They sent me an AC Belt idler pulley for a 300 TDI which is a serpentine belt. That will not work. I have ordered an AC Belt idler pulley for the 200TDI from an outfit in Houston. They will have it to me on Tuesday. They also sent me a Pulley for the water pump - 300TDI - again not going to do a thing because we are dealing with a V-belt versus a Serpentine belt configuration. Essentially I do not believe the guys in the UK that sold me this vehicle have a clue about the installation of the AC Kit they provided with the car.

I am not going to do anything as far as ordering parts until I get the car and have a look at what is in in the AC Kit and what is currently under the hood. I know that I will have to fabricate a bracket for the AC Compressor to mount it to the engine. I may or may not have to change out the water pump pulley - depends on what is there already. V-Belts do allow for a bit more versatility in how you can get the system to work. I also know that if I do need an AC Idler Pulley the one for the 200tdi that I ordered will work with some slight modification to the mounting bracket.

This is just going to be a wait and see situation - once the vehicle is released to me from customs (fingers crossed this week) then I will tackle this AC issue and figure this one out. Right now I am blind not knowing what is in the AC kit and not knowing what is under the hood as far as current equipment.

For your amusement the parts I received from the folks in the UK were the following:

Drive Belt Tensioner ERR4708
Pulley Water Pump ERR3734

I already know just from schematics and my repair manuals - neither of those parts will do a thing for the purpose of installing an AC kit into my 2.5 Diesel Turbo.

[Maryland 110]

I think you over estimate your engine as far as the load the compressor will put on it.

Your engine is a v belt engine. It sounds as though they have supplied a homemade compressor bracket as the td front timing cover isn't set up for a/c. You will have to drill and tap the timing cover in order to mount the compressor bracket. You will need a disco 200tdi front crank pully if your crank pully doesn't have an empty belt slot. The access plate on the front cover that gives access to the injection timing adjustments is replaced with a 200 tdi cover that has a tnesioner built in. this is how its been done on the older trucks I have seen a/c on. If you have a serpentine belt setup I don't see how they intended that to work.

[bsjbrown]

I think it will be fine with respect to the HP. The AC Compressor is powered by bests to the water pump and will continue when idling. I don't think the HP or lack of will cause too much of an issue. Once I get it installed I will let you know how it works. Have to pick up the car first - waiting on CBP to release after they do their obligatory checking of VIN etc.

[dreamin88s]

thank you for posting this as I too would like a/c for the 2.5na,just wondering if the low hp of the 2.5 could/would keep up the a/c with it's lack of power when driving

[bsjbrown]

Make sure that wax has a high melting point. . But that shouldn't be a issue with a/c.

That is if the AC Kit installs. We shall see when it gets here. I am starting to relax a bit more over the whole issue and realize it will get done. Have friends in low places with machine shops that can help me fabricate what I need to. May take a bit longer than a weekend but the job will get done one way or another.

[bsjbrown]

I had only 1 diesel and no problem with parts from RN and others when they did not have it. The diesel should not require much attention other than filters (RN has all these). Maybe glow plugs eventually but should not be an issue, even if order from UK. With my last 84 110 2.25 petrol, I even ordered some from the UK. Usually had the part within 7 days and the price with shipping was ok. Most expensive part I have found is the front doors for 1984 and later - crazy expensive and too big to ship from UK where they are reasonably priced. Just keep your door bottom dry inside - I have heard a UK trick is to fill with wax.

Wax? Not worried about keeping them dry here. We are in drought conditions in North Texas and do not see any relief for some time. If I was back in Houston I would be somewhat concerned with the humidity. What type of wax would I use? I have seen some sealants used and found some documents for waterproofing the Defender. May use that.

[ArlowCT]

Make sure that wax has a high melting point. . But that shouldn't be a issue with a/c.

[nate6472]

Well I am good there. Documents are in order and VIN is good - 25th Birthday was Feb 14th, 2013. Which is exciting. Nate - have you had difficulty sourcing parts for your imports? I know the Rover North guys have good selection and have seen others. Lots for 300TDI which is not even supposed to be over here yet as they are not even 21 years old yet to my knowledge - which is funny. But not lots for the 2.5 TD.

I had only 1 diesel and no problem with parts from RN and others when they did not have it. The diesel should not require much attention other than filters (RN has all these). Maybe glow plugs eventually but should not be an issue, even if order from UK. With my last 84 110 2.25 petrol, I even ordered some from the UK. Usually had the part within 7 days and the price with shipping was ok. Most expensive part I have found is the front doors for 1984 and later - crazy expensive and too big to ship from UK where they are reasonably priced. Just keep your door bottom dry inside - I have heard a UK trick is to fill with wax.

[bsjbrown]

Well I am good there. Documents are in order and VIN is good - 25th Birthday was Feb 14th, 2013. Which is exciting. Nate - have you had difficulty sourcing parts for your imports? I know the Rover North guys have good selection and have seen others. Lots for 300TDI which is not even supposed to be over here yet as they are not even 21 years old yet to my knowledge - which is funny. But not lots for the 2.5 TD.

[nate6472]

Ok living where I do - oppressive Texas Heat. The defender I have purchased from the UK which is to about to arrive is coming with an AC Kit that is being sent in the box from the company I purchased the rover from. It is the kit from Bearmach. My landy is an 88 LHD 2.5 TD and she looks great. Mechanically restored, but not remanufactured. The AC is not being installed in the UK for that reason - I don't want to chance it getting held up in customs. I know the kit is probably for a 300TDI so what additional parts will I need to get to install it. Assuming a new pulley for the compressor to fit the belt and probably an AC Tension Pulley. Need some guidance and advice please.

Google classic auto AC Kits. There are a lot of AC kits for unique, older cars. Many under the dash units in the $900 to $1500 range. Since no one has anything for me, this is the route I will check into further when she arrives.