RHD 200di Custom Air Conditioning Install - Defender Source
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  #1  
Old July 31st, 2012, 08:56 AM
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RHD 200di Custom Air Conditioning Install

Thought I'd document my RHD 200tdi AC install. While the Elite AC kits are great and a "factory fit", AC can be retro fitted to these trucks quite easily at a fraction of the cost. After doing some research, I found Pierre Jourda's (piekas) thread on his Nostalgic Air kit install: http://www.defendersource.com/forum/showthread.php?t=31409&highlight=300+tdi+ac&page=2

Based upon his parts list, I ordered a similar setup. Nostalgic air (http://www.nostalgicairparts.com/) can build the evaporator for R or LHD. You can even get one with a heat option.

Here's my parts list:

15-5001 New Sanden Style 709 V- Belt Double Groove $184.99
119-9902 Male Trinary Safety Switch For Electric Fans $19.99
2400 York Compressor Adapter Plate / Universal Mount $39.99
44-1420DR 14 X 20 Superflow Condenser With Drier Mounted $124.99
CS1000 Condenser Mount Kit $4.99
790-2005 11 Inch Low profile High Performance Electric Fan 1110 CFM $81.99
A601-4 Inline Switch Port Female 5/16 Barrier Hose $9.99
77-2008 Relay And Mount $14.98
77-2003 Adjustable Fan Thermostat 180 - 240 Degrees $24.99
77-2009 Adjustable Thermostat Control Unit $49.99
BH6 # 6 (5/16") Barrier A/C Hose Per Foot (4ft) $3.49
BH10 # 10 (1/2") Barrier A/C Hose Per Foot (4ft) $3.99
BH8 # 8 (13/32") Barrier A/C Hose Per Foot (4ft) $3.75
UD170 UD-170 Slimline Under-Dash Evaporator $259.99
HK920 Universal R-134a Hose Kit $79.99

Total from Nostalgic Air: $941.79


Land Rover Parts (as needed):
Cover plate for timing chest (ETC8853) 26.29
Pulley on ancillary drive (614718) 57.20
3 groove crank pulley (ERR3093) 59.98

Total from John Craddock: ~$300

Mastercool AC hose crimper:
http://www.amazon.com/Mastercool-71550-Conditioner-Hose-Crimper/dp/B000WBQ4U2

Hose crimper: $160

Total for all parts so far: $1401.79

Next Step, starting the install!
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  #2  
Old July 31st, 2012, 09:13 AM
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Thanks for the list. I have seen this type installed before and it is pretty nice! I still think OEM looks better but, for the money, this set up rocks.

The tensioner parts are all made by Britpart as well as Rover. You can save a few $$$ in there for the same stuff in different boxes.
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  #3  
Old August 15th, 2012, 06:58 PM
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Pretty much finished up the install today and will post pictures shortly.

Of note in the parts list above, you need need either:

1. 77-2008 Relay And Mount $14.98
2. 77-2003 Adjustable Fan Thermostat 180 - 240 Degrees $24.99

OR
1. 77-2009 Adjustable Thermostat Control Unit $49.99 (Relay and switch combined).

NOT both. They both perform the same function.

Surprisingly, I only needed my stock 2-groove pulley, and I already had a tensioner mount on my motor. So they only LR specific parts I needed was the tensioner.
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  #4  
Old August 15th, 2012, 08:14 PM
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Looking forward to your take on it once it is charged up.
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  #5  
Old August 15th, 2012, 08:21 PM
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Quote:
Originally Posted by grnrvrs
Looking forward to your take on it once it is charged up.
I'm getting it charged tomorrow - can't wait! The blower blows pretty fast, so I am already impressed.
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  #6  
Old August 15th, 2012, 08:29 PM
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My timing chest already had provisions for AC, so it was must a matter of moving my ARB compressor from this spot to the sweatbox. The tensioner and mount are straight bolt on.

The first thing you'll notice is that evaporator is not full length. That was a surprise to me, but it won't really affect AC flow.

The instructions are pretty straight forward. First I had to install the expansion valve on the evaporator and use the supplied asphalt tape to seal it up.
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  #7  
Old August 15th, 2012, 08:31 PM
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Then, mocking up the evaporator, I drilled two holes in the firewall for the hoses.

I bought their "universal" compressor mount, which required some extra length welded to it to fit the 200tdi mounts.
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  #8  
Old August 15th, 2012, 08:36 PM
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Next up was crimping all the hoses. Using the MasterCool tool made it super easy to crimp all the fittings. The tool was $160 on Amazon, and I will sell it to recover some of the cost. Making the hoses was a simple as mocking up the lengths and orienting the fittings correcty.
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  #9  
Old August 15th, 2012, 08:44 PM
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Mounting the condenser and drier was pretty easy, although with a winch mounted inside the grill it made the area pretty tight. I won't be able to use the 12" fan due to space, so I plan on getting 7" fan instead.

Bolting up the compressor tightening up all the fittings was pretty straightforward.

More tomorrow...
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  #10  
Old August 15th, 2012, 09:58 PM
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This is awesome! Can't wait to see the full install and hear how well it works.
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  #11  
Old August 15th, 2012, 11:37 PM
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Sweet thanks for posting!

If one was to go with the unit with heat, would you keep the factory heat for the demisters or can you plumb it up with the nostalgic unit (or similar)?
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  #12  
Old August 17th, 2012, 03:09 PM
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More pics to come, but here's the evaporator installed. It pretty much can only go in one spot and it's just a matter of how far you want it "under" the dash.

After the install I realized you can't unroll the window now without opening the door! I don't know what the solution is, but hey, I have AC.

Yesterday when I was having the system charged it passed the leak test, but when they went to charge the system the schrader valve on the high side failed.

The 11" fan I ordered was too big for my application, so I am waiting on a 7" fan.
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  #13  
Old August 17th, 2012, 04:09 PM
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Woohoo, got the system charged up and it blows cold!

So the base AC system was $900, the LR specific parts were $60, the crimper was $160, and the AC charge was $60. If you need the pulley and Tensioner mount you'll pay about $200 more.

All told, the system installed was $1180. Once I sell off the crimper for $130 or so, the complete system was $1050. Not bad considering an Elite kit is $2k. Is that extra $1k worth a "stock" look? Not for me.

I used to think AC systems were scary complicated, but building one from scratch proved they are actually quite simple.
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  #14  
Old August 17th, 2012, 05:24 PM
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Have you had experience with the Elite kits in the past? How would your Nostalgic Air compare?

Can't wait to add some AC to mine....
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  #15  
Old August 17th, 2012, 06:10 PM
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Quote:
Originally Posted by texrover View Post
Have you had experience with the Elite kits in the past? How would your Nostalgic Air compare?

Can't wait to add some AC to mine....
The only difference in the two systems is the size of the evaporator - the Elite/stock one is longer - meaning it has more vents (but isn't pushing our "more" air). I think it all ends up about the same amount of cooling effect.
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  #16  
Old August 17th, 2012, 06:24 PM
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Quote:
Originally Posted by Wolf Fabrication View Post
Woohoo, got the system charged up and it blows cold!
That's great news. How well does it cool the 2nd row and way back? Any probs accessing the fuse box?
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  #17  
Old August 17th, 2012, 06:34 PM
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Quote:
Originally Posted by grnrvrs

That's great news. How well does it cool the 2nd row and way back? Any probs accessing the fuse box?
Haven't quite made it that far in the testing stage yet. I have plenty of room with the fuse box, more than I thought I would.
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  #18  
Old August 21st, 2012, 05:28 PM
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So far so good with the AC system. I have driven the 110 the past few days and it cranks out some good cold air. It takes a few minutes to "warm up", but just like most cars. The AC does make it to the second row seats too.

I do need to look in to tinting and a headliner to help control the climate.
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  #19  
Old August 22nd, 2012, 07:06 AM
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nice job, looks good
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  #20  
Old August 28th, 2012, 08:58 AM
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Finally got the smaller fan in. Since my winch is literally inside my grill I have very little space for a fan, so this 7" fan was the best I could do.
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