What it takes to install HVAC system

[Brett Proctor]

This isn't going to be a step by step of how to install HVAC, I've done that in another post.

Instead Sector has asked some questions that this will address

Hope he doesn't mind me answering them here. Thought it would be easier for others to find

What type of tubing or hoses to use to connect condenser to the compressor and to heater core. I have subaru oem compressor, evaporator and all hvac cotrolls. The condenser will be located in front of the radiator, which is at the front of the car. This means that I need to run plumbing from the back of the car to the front? Not ideal but not sure how else to make it work. Any suggestions on parts to use is greatly appreciated.

I knew nothing about AC systems till I installed one in my car. Now I know a little about it.

Hose
I found there are 2 types of hoses used in AC systems
Reg Barrier and Reduce Barrier hose.
I thought Reduced Barrier hose would be the best way to go since it makes a tighter bend, but I found out later that Reduce Barrier hose was being phased because Reg Barrier hose has better insolation qualities and Reduced barrier hose was getting harder to find.

Tools Needed
Crimper

Swaging Tool
This had some bad reviews but if you take it real slow and do a little at a time it does work

Filler rod used

To Be continued

 

[Brett Proctor]

Fittings

Never having done this before I wasn't sure what I needed or how much to order so I had some extra left over.

Ferrule/Sleeves
These come in aluminum or steel construction. I went with steel. Thinking when crimped it would be a stronger connection.
When getting a crimping tool make sure it crimps the size of hose your using (reg barrier or Reduced barrier)
I used barbed fittings in my build

Fittings at the compressor and condenser were OEM
I went to the pick a part yard and pulled the fittings that were at these spots. Then cut the ferrule and removed the oem hose. This gave me something to tie into.
These fittings also contained the High and Low pressure ports for charging the system.

On one of the fittings for the condenser I heated the fitting up to remove the oem tubing and installed a new section that I made. On another section of tubing I kept it as is from the oem section/manifold and swaged the end of the oem tubing to attach a section of aluminum tubing that was bent to fit.

Straight sections (or any sections that I could use aluminum tubing) on the AC and Heater systems I used aluminum tubing. All sections that used aluminum tubing on the AC system got insulation covered around it.

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Fittings

Oring, flare, quick disconnect and metric are four of the main a/c connections. Coldhose uses pictures to identify these fittings. Please match your fitting to the picture as a quick reference when choosing what part you need. The fittings listed on the site have the hose and thread size also...

coldhose.com

For the size of tubing used I stayed with what size the oem stuff was.

When wiring the system in I stuck with the oem wiring diagrams so there would be no issues with the ECM getting any bad info, this included the wiring for the fans also.
This included the drier, pressure switch, expansion valve and any thermal switches. all items were oem. (fans weren't oem but wired in the same as oem)

 

[sector]

Thank you for taking the time and summarizing in such great detail. This is extremely helpful.
I am assuming, in your case, the condenser is located at the back of the car with the radiator. So you had significantly shorter runs than what I will have in my setup?

 

[Brett Proctor]

Radiator and condenser are in the front.
I wanted the best location for the air to reach the radiator and condenser and that was in the front.
I also had to make an air intake duct because of the extreme angle the radiator and condenser sit at. Without it air had a hard time reaching the radiator, air would pass by without going through the radiator.
I had overheating issues without it. Now even with the hot temperatures we have here, driving down the road the fan doesn't need to come on. That air duct funnels air directly into the radiator and condenser.

I did change out the water pump for a high volume one since the distance to pump water is considerably farther.

Front view

Drivers side

Passenger side