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The Final Frontier

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PNZWGN
Posts: 1007

The Final Frontier

Post#1 » Wed Jan 22, 2020 9:13 am

So..... I usually post my work once I've finished the project and validate that it works (for vanity's sake as much as anything.) This time I'm attempting something that is a different animal for me. I will need all of the collective clubg knowledge to complete it :D

Parallel to another 617a winter project I'm already underway with (and a basement that I'm building out :shock: ) I am attempting to install "factory" air conditioning into my W460/617a. I know, I know... but the summers here are sub-tropical and it's just something I've got to get behind me to maximize our enjoyment of this truck. It is miserable to be in this truck without AC and windows down/top up is great sometimes and sometimes its not.

The way I see it, restoring a W460 (regardless of the engine) is your undergrad work that earns you your BA in W460 ownership. Swapping in a 617a is your postgrad work that earns you your master's degree in W460 ownership. Ultimately one earns their doctorate by later swapping in a 606 which is honestly not going to happen for me, so an air conditioning install will be my terminal degree, thus The Final Frontier.

Anyway, I've acquired a W463 heater box with AC evaporator installed from a fellow clubg member. I went this route as I wanted a "factory" AC set-up that utilizes my existing W460 lever controls and would allow for a "clean" install without butchering anything from the firewall back. Not knocking anyone who's successfully completed a Vintage Air set-up as that is an equal and probably superior accomplishment.
I just like factory. After discussing this box with a number of G gurus and after digging into the box myself it does appear to me that the upper half of my W460 non-AC heater box will marry-up to the W463 lower half that houses the evaporator and I think a hamster wheel style blower motor (more on that later.) I'm reassured of this theory by the part numbers stamped on the housings.

I have secured the "special" 617a AC thermostat housing which should be here in the next few weeks. I also have a line on the 617a compressor bracket and two rotary style compressors for test fitting (although I've not ruled out an electric compressor... I'm that desperate.) I think I know what dryer I need and the condenser/fans seem pretty straightforward. Once I have all of that installed I plan to backfilll with the hoses, switches and all of the other stuff I'm sure I'm not thinking of.

So let's get to it. Picking up the box from a G friend...

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Long day but home safely

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Disassembly on the Light side work bench (I would of course usually start this process on the Dark side work bench but it's at capacity with the 617a project...)

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"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

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PNZWGN
Posts: 1007

Re: The Final Frontier

Post#2 » Wed Jan 22, 2020 9:15 am

Reassurance that all of this might actually work...

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Getting after it...

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"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

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PNZWGN
Posts: 1007

Re: The Final Frontier

Post#3 » Wed Jan 22, 2020 9:18 am

Factory evaporator out...

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Looks like R134a is the final answer...

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"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

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PNZWGN
Posts: 1007

Re: The Final Frontier

Post#4 » Wed Jan 22, 2020 9:28 am

I will of course PNZWGN'n the evaporator and erry thang else before I install. Clean up the fins that were probably deformed during shipping over the pond. I also have a hot rod Radiator guy in Richmond lined up to "check it out" for me and give it a good bill of health. Seemed like a good idea and he said that he could.

And then... my first set back. I think there is supposed to be something here :lol:

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Like a blower motor/fan. :?

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W463241BlowerMotor.jpg (22.2 KiB) Viewed 343 times

So here I am with my first question... am I correct that the blower motor in the upper half of my heater box will not be used in a factory AC scenario? And that I need to source the blower motor/fan for this lower portion? That is what I am thinking but I'd love someone to confirm that. (And send me the part number for it LOL.) If I can get by with the upper blower motor/fan assembly that I already have so much the better as I just did all that a few years ago.

I'm hoping I haven't already dropped a hefty sum to be derailed this soon so please let me know.

Anyway, I will apologize in advance for the rookie questions as I've never attempted anything like this. Just a 40 year old small town white boy that doesn't know when to quit. And I'm counting on all the tribal knowledge and positive energy from the clubg community to help me see this through. As a well known clubg guru put it... "you need to become an air conditioning expert". I am definitely trying.

I have a house rented on the OBX middle of July and beach driving permits in the mail. That is my deadline for this factory AC install... this is my final frontier.

I'm off to go clean everything in the wife's kitchen sink.
"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

dcurbet
Posts: 3430

Re: The Final Frontier

Post#5 » Wed Jan 22, 2020 9:48 am

Oh no what happened to the blower motor! Did someone swipe it? Or is it in a different place in this box? Glad you got started on it.
That evap core is available new I believe for not crazy money. Just in case.

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PNZWGN
Posts: 1007

Re: The Final Frontier

Post#6 » Wed Jan 22, 2020 11:22 am

dcurbet wrote:Oh no what happened to the blower motor! Did someone swipe it? Or is it in a different place in this box? Glad you got started on it.
That evap core is available new I believe for not crazy money. Just in case.


There was never a blower motor in it... at least since I've had it. Split it open and nothing was there. This is what makes me wonder if the W460 blower motor is to be used in lieu of the hamster wheel style :?:

I can tell that it had been opened before in the past for a small patch repair. Whoever did a nice job but forgot to put the blower motor back in maybe :?
"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

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PNZWGN
Posts: 1007

Re: The Final Frontier

Post#7 » Wed Jan 22, 2020 11:27 am

Blower motor/evaporator box has been PNZWGN'd. Had to knock that out before the wife gets home. The mesh filter disintegrated by just looking at it.

Patch..

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Working on the evaporator now. It's clean and looks solid just need to straighten out the fins.
"wherever I may roam..."

PNZWGN Mk II build thread: https://clubgwagen.com/forum/viewtopic.php?f=18&t=5605

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vadimivanovich
Posts: 8033

Re: The Final Frontier

Post#8 » Wed Jan 22, 2020 12:15 pm

You need the hamster-wheel blower motor. I have a gut feeling that it was shared among other sedans of the era, but I don't have a part number to offer.
"The way you think is the way you live"

blueg
Posts: 2013

Re: The Final Frontier

Post#9 » Wed Jan 22, 2020 4:35 pm

Parker.
You might get in touch with mickeyg.
I think he's on this forum but I know for sure he's on the Aussie G wagon forum.
He fitted A/C to a 617A in a 460 a year or so ago.
He may be able to help with some first hand experience but he may also have RHD G.
I know he made a pretty impressive bracket to hang his compressor at bottom of engine.
Best luck and don't over clean things too much. Oil and sludge keep an old Merc happy.

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kafkaonwheels
Posts: 316
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Re: The Final Frontier

Post#10 » Wed Jan 22, 2020 5:12 pm

It is great to see finally someone has guts. Many people just seem complain, wanting and if no-one rushes to do all the work for them, they drop the idea.

You have a correct picture of needed blower fan. Mercedes part code is A0008306208. I think original is Behr-Hella, same as case, their code is 8EW 009 159-171. Motor without fans is BOSCH 0 130 111 006. Bad news is that this blower is G specific part. And all aftermarket replacements, including Hella, seems currently out of stock. Mercedes shows it available for what is pretty ridiculous price for such part. I kind of remember from somewhere somebody combining fans and motor from different vehicle but I didn’t chase that deeper because I have good part for myself.

Also needed is small bracket what holds the motor in case, if it is missing, A4638350014.


If you think it helps I can try to do a quick write-up on my A/C setup for OM617A, parts, modifications, research and workarounds this far. But it is not yet functional system as I am still ‘greatly enjoying’ last bit of primer sanding. For A/C I have still to figure out lines under hood and modifications to wiring harness.

But anyways: good luck!
1985 300 GD Turbo (Project)

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