Diavia Aircon info thread.

[Storm 0]

Chaps, having messed around with my A/C system I have spoken to a number of specialists and the following is the total of my knowledge. I have to thank Borderair who really knows his stuff and kindly sent me the wiring diagrams and I will be forwarding these to Dinkus for posting. Also Keith at Ace services who also did alot of the original installs.

 

The Diavia install was totally an aftermarket setup. Diavia made car specific kits with Diavai factory made hoses. I believe the kit used in the Corrado is also used in the Passat & Golf. If you haven’t got the instructions or taken it out, this is going to be very difficult / impossible to refit. I am going to try to obtain the instructions at some point and get them posted.

 

On the fitting the way forward is to remove the front bumper, slam panel & dash. This gives you the access that you need.

 

The Evaporator Housing sits behind the dash. In the Diavia Install there is not enough room so the parcel shelf has to be cut and Diavia supplied a piece of plastic to mask the hole. The ABS wiring is also in the way and has to be tucked up high under the dash to make room for the housing.

 

In the Diavia install two brackets attach to the top of the Rad and then sit in the radiator support panel. See the link at the bottom for more info.

 

Thepartsneeded:

The Evaporator Housing which sits behind the dash and also contains the unreliable fan. The Condenser, sometimes referred to as an A/C Radiator. Diavia made up custom condenser brackets, Diavia dryer bracket dryer (cylindrical) bolted to Condenser. Various hoses. Wiring, relays, pressure switch and switches. Plastic fillet for the parcel tray. Compressor and new belt. I may have missed stuff.

 

Hoses:

Compressor (marked S suction) to Evaporator Housing Longest pipe (with charge port).

Compressor (marked D discharge) to top of condenser

Evaporator Housing to drier

Drier to bottom of the condenser

 

Gotchas:

Undo the hoses at your peril. The condenser is made of alloy and they are done up tight, when you undo them they can screw up. The best way to remove it is by undoing it at the housing end an leaving it all intact underbonnet.

Its all old stuff so inspect and replace as necessary, you have to replace the drier about £35 + regas is £50-65

The hoses are a bit long and the routing is important when looking for a decent install.

 

 

AC Rads

[Supercharged 2]

Stickied...

[Scruffythefirst 0]

Sounds about right to me. I;ve just taken the dash out of dinkus' C and it looks like a pig to get it all out in one piece. I will manage it tho. Hoses can be replaced for a few quid from a hydraulic or aircon specialist. I havent looked into it yet but it looks as though the pipes may not go through the bulkhead intact.

[Andy Brookes 0]

Top job Storm. I'm buying both of the kits that are currently for sale, one for me and one for a mate. I will do a full write up while doing the two.

[Storm 0]

I'll try and get the instructions on Saturday. If I cant get the Corrado ones, the Passat ones will be close. Good luck.

[dinkus 10]

Scruffythefirst is taking pics of the extraction, so hopefully that'll help the installation and proper write-up on installing it.

[Scruffythefirst 0]

Yeah, can you upload them and post them for comments before i take it any further

 

Think i'm going to wait until the engines out as the wiring needs sorting and pipework etc and it'll be easier if i can get to the back of the engine bay.

[dinkus 10]

Yeah, you need to learn how to use my camera though, most of the close up stuff is just blurry crap... :)

[Scruffythefirst 0]

Yeah, you need to learn how to use my camera though, most of the close up stuff is just blurry crap... Smile

 

 

I'll use mine then, at least the auto focus works. :oops:

 

We can take new pics at lunchtime - I doubt i'll be doing anything more to the shell itself untill monday.

[Storm 0]

Scruffy, please note strip it at the evaporator end. This will be covered in black tarlike insulation, which has to be replaced. I think its there to prevent the condensation rusting the fittings.

 

The two hoses can then be drawn through the bulk head.

[Storm 0]

Wiring diags added courtesy of Borderair

[Andy Brookes 0]

Picked up my first aircon system from Bigpantsbaby last night. (Thanks Bigpants). Will take some pics tonight of all the bits.

 

Has anyone got any pics of the installed pipe runs?? I'm particually interested in how the pipes run from the compressor. But any pics would be very useful.

[Bruno 4]

I'm particually interested in how the pipes run from the compressor. But any pics would be very useful.

Andy I've got a diavia set up on my VR6. I'm too busy with other chores to take photos of the bay (it involves removing the slam panel and rad to get the shots right, but if you em me, I can walk you through the layout that I've got and also altert you to some of the problems you may have.

[Andy Brookes 0]

Thanks Bruno, going to pick the other aircon setup tomorrow eve. Which is mostly still fitted, so I think I should be ok. But will shout if needed. Thanks.

 

Andy

[Andy Brookes 0]

Evening All,

 

Made the trip to sunny Essex tonight to pickup the second aircon system (thanks for your help scruffy).

 

Took a few pics of the bits and the holes that need to be drilled in the bulkhead.

 

Still a little unsure of the pipe runs around the fans and the radiator as that was all disembled already. So any pipes of the pipes in situ would be great.

 

The other thing that I am unsure about is a wiring connection, at the botton lefthand corner of the main wiring diagram is a connector with Green, Gey/Yellow and brown wires that was disconnected on Dinkus's setup and bigpants cant remember if it was connected to anything. The wiring diagram calls it the 'connection for minimum idle, see diagram 4'. If you look at diagram 4 it shows these wires connected to a green and blue/red wire......but where are these wires in the car? The connecter was inside the car hanging over the top of the evaporater box. Does anyone know if this should be connected, if so to what?

 

The fans are different makes on the two systems I have, ones a Spal and the other is a Valeo. The boxes are also slightly different moldings.

 

Cheers Andy

[Storm 0]

Andy, the above pic with the Valeo Fan motor, can you please advise the how it comes out of the housing? I will get you pics by the end of the week on routing of hoses.

[Andy Brookes 0]

Will have a look tonight and take closer pics. From what I can remember from last night it looked like it twisted out like the standard fan. Will get back to you later on.

 

Andy

[Andy Brookes 0]

Here are the pics of both fan assemblies taken apart.... just undo the 4 or 5 screws that hold the bottom plastic part on and the fans pop out. Very easy. Also a pic of the part number on the Valeo fan.

[Storm 0]

Cheers Andy, IIRC the issue is that you cant get to all the screws if its installed.

 

The part number is defo Mk3 Golf.

[Andy Brookes 0]

you should be able to, the screws are fitted from the front and below on the ones I have. The screw positions do seem a little random when comparing the two. Guess its a drill on assembly thing and that one operator may have decided that screws round the back would be a good idea!!!

 

ps, if anyone has a spal fan and it goes bang, the housing could be easily modified to fit the Valeo fan.

[Andy Brookes 0]

Had a quick play with the bits tonight. Had to remove one of the hoses from the condensor as Dinkus cut it to get it out. Unfortunatly the tread has gone on the condensor, even socked it overnight in WD. So a new condensor is needed, along with a new pipe.

 

Any recommendations on where to get a new condensor (how much?) and a new pipe. Also need to source new dryers and seals for all the pipes.

 

Otherwise things are looking good. Compared the pipe work on the two systems, all the matching pipes are slightly different lengths. Seems that I have two systems where all the components are slightly different. Makes you wonder if each system is a one off and they just chucked whatever was hanging around in a box and put a corrado kit sticker on the outside!!!

[Storm 0]

Call auto air in Glos an its about £100 delivered and from stock. You need to speak to Chris, who knows all about the install, the parts used etc. He was a real help. You will need a new dryer as well, dont scrimp here its just a total waste of time. Dryer and Condenser were £144 delivered IIRC.

 

http://www.autoairglos.net

 

It took me months to find these guys. On the hose side its best that you fits all the assemblies condenser / evaporator housing and wiring. When its gassing time I'd drive up to see Keith get him to make the hose up that you need, fit with new O rings and gass it up.

 

I think Keith charges about £30 for the hose and about £60 for the gas. A/C is not cheap thats for sure.

[Andy Brookes 0]

Top tips, thanks Storm. Not cheap but so nice when it works!

[Storm 0]

Just remembered Mr Renshaw mentioned something being able to get hoses sorted, I think he's close to you.Also when doing hoses up there's knack to it; hand tight + a half turn or so.

[borderair 0]

Andy - dont forget to change the oil in the compressor as its hydroscopic so if no caps have been fitted it will need replacing. To quickly check it should be almost clear (unless a UV dye has been added)

Also it may be worth flushing evap / hoses etc to remove old oil and possible debris.

 

Storm - how are you getting on with your system?