HOW-TO: Removing A/C system

[KZL_99ES]

Alright, i've been meaning to make this thread for the longest time, ...and well now i actually have time to do it! yay!

IF YOU HAVE ANY QUESTIONS OR NEED TO ADD SOMETHING THAT I MISSED, PLEASE READ THIS WHOLE POST FIRST! ...thanks! (spin)

ALSO: remember to read this whole how-to before you start doing anything so you make sure you have all the parts, tools and knowledge to successfully complete this task!

Remember, ALL the 3rd Gen protege's including the msp's have the same a/c setup, so everything should be the same for later model 3rd gen.

Also, this is not a COMPLETE removal, for that you need to remove all the filters and whatnot inside the car...which i didn't do...i think all of that stuff is behind the glove compartment, that part is up to you!


______________________

So first off, make sure your engine is off (duh!) and has cooled down;

tools needed: 8, 10, 12, and maybe 14mm sockets, phillips screwdriver, two adjustable wrenches, rubber mallet, wire clippers and/or fencing sheers (both are optional if you want to save your aluminium tubing), last is a new p/s belt, i'll show you that at the end!

http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0247.jpg


next, purge all of the fridgerant out by pushing down in on the pin using the screwdriver, it's under the blue cap near the oil dipstick here:

http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0225.jpg

also do this one too, near your passenger side headlight, just to make sure all of it is out...plus i think one is for sending and returning, but don't worry about that stuff, just purge them both!

http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0224.jpg


next, use the tensioner and loosen the bolt there so you can take off the old belt, once you've got the bolt loosened up all the way, use the rubber mallet and SOFTLY tap on the power steering to bump it down so the belt can be easily taken off.
(you'll want to loosen the bolt A LOT more than that)
(you'll also want to tap on this big bolt...
...................................\/ here)
http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0230.jpg


Take the belt off and do what you'd like with it,

next i'd take off your front grill, this makes everything a lot easier, at least it did for me, it made taking out the condenser easier.

http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0223.jpg

i'd also undo the bolts here too, both of the radiator bracing brackets so you can lean the radiator towards the engine for easier access to pull out the condenser:
http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0226.jpg

next start unbolting all the feed and return aluminium lines you can, use the adjustable wrenches here if you want to save the lines...
if you don't care and just want to scrap them, you can take my route and either use a hack saw, or one of the clippers to clip everything off, and IMO, it's not like you can sell this stuff you anyone anyway, so you might as well go the easy way!

(this one's right by the battery)
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0228.jpg

(there's two by the passengers side firewall, near the cruse control(if you have it))
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0229.jpg

(this is what i did, just clip them right off because i didn't want to deal with trying to unscrew it)
plus clipping them will essentially seal the opening shut which is good...i guess...
there's more inside the car, like the filter and stuff, but i didn't want to take that out, so sadly i can't show you how to do it...
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0236.jpg

i just cut this one: and as you can see here, there's just one bolt and the other is a push fitting, which can prove difficult to pull out, just don't hurt yourself...
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0233.jpg

this is from the bottom of the condenser, another bolt and push fitting:
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0232.jpg


this is the refridgerant fluid catch can and because my bolts were really rusted, so i just clipped those to get it out of there, the electric plug i just electric taped it closed and tucked it away in with some other wires...
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0227.jpg


next you should be able to pull out your condenser:
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0234.jpg


So that should be everything for your a/c system lines and condenser, now for the compressor:
(i didn't take pics of it there...sorry, but there are i believe 8 bolts in total, either 12 or 14mm that should come off relatively easy,
four very long bolts that hold the compressor on and four short ones that hold on the mounting plate)
after the compressor is off, there is a mounting plate there, you can take that guy off too!
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0248.jpg


next, you're going to want to pick up a new power steering belt that's 18mm X 985mm or 11/16" X 38 & 3/4"
NOTE! this belt size is only for the UNDERDRIVE Pulley, not for stock; if you have a stock crank pulley, simply go to the dealer for an A/C delete power steering belt.
here's proof of the size! lol
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0245.jpg

when you put the belt on make sure it's on correctly and tighten down the the power steering using the tensioner i showed earlier, not too tight, look in your manual for specific specs on the tension.
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0237.jpg


and last, this is what your new engine bay should look like! ...well sort of, i took out my a/c fan, ...BUT, if you wanted to, you could leave that fan in and splice the wiring so when your radiator fan turned on, instead of just one fan, it would run both fans, so in theory the engine would cool faster. i'd prob want slim fans for more space, but that's up to you!
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0238.jpg

here's how small our stock radiators are... :(
we could have one twice as thick and still on the same frame!
http://www.mazdas247.com/members/KZL_99ES/ac/IMG_0250.jpg

and i took off my bumper just to get a better angle at getting things off and on, also wanted to look where i'd put my fmic now with all that room!!! :p
my car looks kinda weird like this, lol
http://www.msprotege.com/members/KZL_99ES/ac/IMG_0235.jpg


*ahem* anywho... let me know if i missed anything or if you have any questions about the process!

Kevin

[xJAZx]

did you notice any difference with it out?

[protege321]

great stuff! thanks. (2thumbs)

[KZL_99ES]

did you notice any difference with it out?

not a whole lot, but i'm sure it does help, your engine isn't working as hard to power another accessory... and the fact that you loose about 25lbs from removing everything, the compressor is the heaviest by far. so i guess there's that difference too...


great stuff! thanks. (2thumbs)

thanks! hope it helps!

[protege321]

you have some serious corrosion going on there, my car has never been in those conditions! i have never seen one bit of rust or corrosion anywhere on my car.

[Wagonbacker9]

FYI, purging your refrigerant strait to atmosphere is A) illegal B) very bad for the environment... i'm no environmentalist (going catless soon) and would still never do that.

If your system has lost its charge due to a leak, by all means go for it, but i just feel this is a very irresponsible thing to choose to do. you can get the system professionally evacuated for a reasonable fee, and your grandchildren won't pay the price for it.

[KZL_99ES]

lol, bad for the environment?! i just inhaled everything that came out!!! now i have 6x the lung capacity and can freeze things with my breath!


but... no, my system did lose all charge, when i did this, the amount that came out was less then 5 seconds...which is prob why my a/c didn't work! lol

i'll think about this and edit my first post later...gotta to to work... :(

i'll do some research on what it cost exactly too.

[Wagonbacker9]

new driver mod: Superpowers!!! LOL

[KZL_99ES]

but in all seriousness,

all of this is up to the one who is doing this, if they don't feel comfortable if it's illegal, or bad for the environment, then DON'T do it!

this is a how-to for your car, ...not your morals.

[Protege03ak46]

will this work for 2.0? I kind of want to do this. Ive never used my AC, even when it got to 110 last summer. Might as well remove it and gain some work space

[Wagonbacker9]

the entire process is to gut anything AC related... thats about it. so yes.

Again, I must reiterate, PLEASE have your system properly evacuated at a shop.

[protege321]

i did it on my 2.0l (thumb)

[Protege03ak46]

the entire process is to gut anything AC related... thats about it. so yes.

Again, I must reiterate, PLEASE have your system properly evacuated at a shop.


Yea, my auto-tech teacher is gana use my car as a demo to teach us how to do it properly. All for free (2thumbs)

[KZL_99ES]

sounds like a good deal to me!

[JCell]

why did u cut the lines rather than taking out the interior piece?

it gives the fan a lil more speed and removes a nice chunk of weight...

[KZL_99ES]

i wanted to remove that stuff too, but i honestly do not know how to get at all that stuff... haven't checked the manual first, need to do that.

[protege321]

i need to do the same..

[Proteggy]

i just got my license for handling refrigerant its a 7 hour course and you can be fined up to 100,000 dollars and maximum 6 months in prison for improper use of refrigerant lmao but u might want to mention that in the how too.

[slavrenz]

i just got my license for handling refrigerant its a 7 hour course and you can be fined up to 100,000 dollars and maximum 6 months in prison for improper use of refrigerant lmao but u might want to mention that in the how too.

What's a reasonable fee to have your A/C system evacuated? I need to replace my compressor, but I would like to just take it to a shop, evacuate it, and then go back and refill it once I'm done.

[Tarmac Terrorist]

Nice How to!
I'm gonna try doing this soon, mainly since i'm only home for half of the summer anyway...

[msp03.5]

Hmm my AC has not worked since last summer and I want to take it out so I might be heading to get it purged and remove it. thanks for the write up.

[iJay]

Sorry for the thread jack but for those of you removing ur AC systems I am looking for a condensor and a ac line as well. if n eof you can help would be great!
Thanks!

Great how-to

[Tarmac Terrorist]

why did u cut the lines rather than taking out the interior piece?

it gives the fan a lil more speed and removes a nice chunk of weight...
Do you happen to know what needs to be removed under the Dash?

*ahem* anywho... let me know if i missed anything or if you have any questions about the process!

Kevin
Is there a relay that should be removed or any fuses that would get rid of the power going to the Compressor or the Dryer?

[KZL_99ES]

Do you happen to know what needs to be removed under the Dash?

Is there a relay that should be removed or any fuses that would get rid of the power going to the Compressor or the Dryer?

i don't know exactly what needs to be removed from under the dash, i'm thinking that you get at the stuff from behind the glove compartment, but like i said, i'm not sure, sorry
when i do my engine swap (hopefully in a couple of months or so) i'll see what i can get at when i do that.

and for the power issue, i just disconnected my battery, i always do when i'm working on anything engine related, just plain 'ol safe! :)

[Tarmac Terrorist]

Okay...
Removed my A/C This week-end! The removal took me about 2 Hours, but that's because I was Cleaning my car, and changing my oil at the same time...
Everything under the hood came out smoothly, very easy and very straight forward with the how to written above!
Under the dash was pretty easy as well!
Remove the glove box, remove the 2 Bolts holding the A/C Box in place, wiggle it out. From here You will need a friend to feed the A/C line from the engine bay through the firewall... there are 2 Lines, one splits just before the firewall, the other on the A/C Core...
Once you get the lines fed through the firewall, there are 5-6 Screws to remove to seperate the "Air Box". Once seperated the A/C core comes right out!
Join the box back together, block the A/C lines off with some Duct Tape, then put the foam back on, I stuck mine with some 2-Way Tape.
Reinstall box, and the Glove Box, and Voila!
A/C is removed... and really... only about 30 min of work to get the box out.
I also removed my Relay for the A/C from the Fuse box under the hood.
Haven't driven the car long enough to notice any real benefits... but i'm sure in the long run my car will be happier :)

[KZL_99ES]

well awesome! thanks for the help with the a/c core behind the firewall!

[Tarmac Terrorist]

well awesome! thanks for the help with the a/c core behind the firewall!
You are already 1/2 way there because you cut your line!
You won't need a friend to feed the line to you... just to hold your beer (2thumbs)
Now... to sell the stuff... better get some pics I think...

[bogka]

Got a quick question that I may repost and give some more info on:

My wife's 2000 Protege had her alt belt bust and fly all over the engine bay. Well after installing both belts new, I found that her A/C did not work (or did not blow cold).

Now, I look at the A/C Compressor and notice that there is a wiring harness comeing out of the front of it with three (3) wires total. Two of the wires are connected to each other with plastic connectors, however there is a third wire that has about a foot of slack on it that is not connected to anything! (Its a male connector with a plastic sheath)

Background information: The Clutch does not engage while the A/C is on. With a tap on it with my finger while the engine is running it will make about a half of a rotation

Could this third "unexplained" plug be the power for the clutch electromagnets? If so, please somewhere tell me where it is supposed to plug into. I'm at my wits ends. I'll try to take a couple of pictures tomorrow to illustrate what I'm talking about. (This AC problem just HAS to be a simple one!)

Thanks--Matt

[Tarmac Terrorist]

Now, I look at the A/C Compressor and notice that there is a wiring harness comeing out of the front of it with three (3) wires total. Two of the wires are connected to each other with plastic connectors, however there is a third wire that has about a foot of slack on it that is not connected to anything! (Its a male connector with a plastic sheath)

Background information: The Clutch does not engage while the A/C is on. With a tap on it with my finger while the engine is running it will make about a half of a rotation

Could this third "unexplained" plug be the power for the clutch electromagnets? If so, please somewhere tell me where it is supposed to plug into. I'm at my wits ends. I'll try to take a couple of pictures tomorrow to illustrate what I'm talking about. (This AC problem just HAS to be a simple one!)

Thanks--Matt
When I disconnected mine, there was a single wire near the Coolant hose I believe?? Sound About right? The "female" end should be right around there...

[StealthWyvern]

When I disconnected mine, there was a single wire near the Coolant hose I believe?? Sound About right? The "female" end should be right around there...

sounds like the right wire to me, we are talkign about the one facing the ad right off the compressor right? If that one wire is not hooked up your AC will not blow cold air.

[bogka]

Heres some pics showing what I'm looking at. I'm just stumped. ((Second glance, the "mystery" connector looks to be a female one... Any clues guys? I really don't want to take her to the shop in all honesty.

Thanks

[HKPRO5]

Awesome thread. I put my supercharger in place of the ac compressor. I'm going to take out the box
Behind the glove compartment tonight. Is there enough room to relocate the battey there? Oddesey small or optima?

[KZL_99ES]

i'm sure one of those small Braille batteries would fit in there; but i honestly don't know since i haven't taken the box out yet.

[Cleverfrog]

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