I created a thread last year ( 2010 ) asking if anyone had retro fitted aircon to a phase 1 and failed to get any yes answers!
So, I looked into it, got together a parts list and started investigating the electrical side. I also had a vague notion of later upgrading the basic airconditioning to Phase 2 climate control.
With a fair amount of the research done, other things took preference and it got put on the back burner until a post in my thread by Rich Wookey asking about upgrading to climate control made me look into the phase 2 climate control in more detail. Which was just as well as there is no upgrade path from phase 1 aircon to phase 2 climate control. They are completely different not only in operation but every component ( except two ) are different. To upgrade aircon to CC means stripping everything out and starting again. That even includes the ‘L’ shaped gasket on the bulkhead through which pokes the heater and aircon pipes.
After thinking about it some more, I decided to go with climate control. This thread is about the upgrade.
In my original thread, a number of objections were made to airconditioning with people stripping it out of their cars – mainly for weight saving. I’ve seen a figure of 60Kg mentioned as the weight of the aircon system in a GTV/Spider. That figure, as far as climate control is concerned, is pure fantasy.
The components weigh as follows :
1. Compressor bracket ( cast aluminium ) : 1.6Kg
2. Compressor : 7Kg
3. Condenser : 2.85Kg
4. Evaporator : 2.7Kg
5. Pipework : 2.07Kg
6. Receiver/Drier & Bracket : 0.82Kg
7. Additional pulley : 0.38Kg
8. Longer auxiliary belt : 0.12Kg
9. Wiring/fasteners/gas ( estimated – most likely over ) : 5Kg
10. Pressurevalve : 0.085g
Total = 22.6Kg. So nowhere near 60Kg. I can live with the additional weight of 22.6Kg ( max ).
Someone also criticised aircon as sapping power but again this does not add up as the engine ecu disengages the compressor when it detects high power demand.
I’ve also lived with a GTV without aircon. It’s stupidly hot in summer and prone to misting up in winter. To me, adding aircon/climate control is a no-brainer.
Finally, I set myself a standard. No bodging and all electrical work had to look as if it came out of the factory. That meant using proper factory type connectors and new terminals in those connectors.
Some thanks are in order :
Alfaowner member Romek for many of the parts I used sourced from his accident damaged car.
The support staff at Tyco electronics for their help ( see text )
Chris Hellewell at FCI for help with a difficult to find terminal ( see text )
Staff at Raffenday for help with some terminals ( see text )
Alfaowner member fantom alfa for some photographs of a 916 with the dashboard removed
Alfaowner member .:ian:. For looking at his G133a connector and photographing them
Alfaowner member Mitch166 for help with the speedometer.
I really hope I’ve not forgotten anyone. Please come forward if I’ve missed you off the list.
I shall be posting a parts list for the project later once I’ve got my master list in order.
A final point before going into detail. This process only applies to late Phase 1 Twinspark cars. That is Twinsparks built from May 1997 ( from VIN ZAR91600006023907 ). Phase 1 Twinsparks built before then have a different engine ECU and the cooling fan(s) are not controlled by the ECU but by a timer and temperature sensor on the radiator. This would require a lot more investigation as to whether climate control can work with radiator fans controlled by this method. I’ve not looked at the V6 in any great detail, but I believe the same situation applies there. UPDATE : see more info on this with a possible solution for early Twinsparks and all V6s at the end of post 16 - http://www.alfaowner.com/Forum/4488488-post16.html (Retro fitting Climate Control to a Phase 1.)
The following is a bit verbose. If you don’t want to read it, just look at the photo galleries where you’ll find a more concise description of the process.
On to the fitting ……