A/C installation

[pikeperkins]

Dumb question of the day.....I looked in the FAQ and found nothing but has anyone installed A/C in a non-A/C car from a donor car? Is this feasible or am I asking for trouble?

[Guest Anonymous]

go from there. If you have a tii it takes a special pulley to drive the A/C compressor belt that is NLA and is very expensive usually. There were other types such as Frigiking and Clardy as well as some companies such as vintage air that offer complete kits.

shermanmartinez@hotmail.com

[pikeperkins]

Thanks Sherman! I'm contemplating buying a non-A/C car but I have my resto project that has the Behr A/C and was wondering what it would take (both non-tii cars). The Florida Summer would make a non-A/C car hard to take......

[BarryA]

Hobie Dave for one of his Sanden/Sankyo compressor to M10 block compressor mounts, and also think seriously about biting the bullet and sticking with R12 refrigerant ('02 a/c systems are borderline to start with, and R134 just doesn't cool as well as R12, especially in a system that was designed for Freon).

You might also want to consider a light tint on all the side and rear windows to cut down on heat gain, and (if you have the headliner out) adding thermal barrier insulation on the inside of the roof panel for the same reason.

[02hobiedave]

I referbed my whole A/C system reusing only the evaporator for inside the cabin and the associated electrical. I replaced everything else hoses, fittings, dryer, condenser, rotary compressor and new bracket. It was relatively easy once I got into the job. So I kept the stock look but all the benefits of a modern system. I bought most of my stuff from http://www.nostalgicairparts.com/air-conditioning/universal-r-134a-hose-kit-with-drier-359.php They are located in Tampa real nice guys will bend over backwards to help. I also sell a custom A/C bracket that mounts to the M10 block. It uses the sanden rotary compressor. Let me know if you are interested or if you need any help. Always like to talk about BMW's and work on them.

dave.hobiedave@gmail.com

[mcaden]

Dave's bracket for the rotary compressor mounts up nicely to your engine block and is very well made. Sanden or Sanden-like compressors are readily available and are fairly cheap - just type a search for "Sanden 508" into EBay (most people have not had good luck with the York compressor on a long term basis). Finally, I converted from R12 to R134 and I have had no problems whatsover and notice little difference in temp or output (but, please remember the A/C in these cars can't be compared to the output of a modern system).

Good luck.

-Marc

[thehackmechanic]

I have done this from scratch in a 3.0CS that did not have a/c. It is not for the faint of heart. It ain't rocket science, but it is a lot of work. If you look at it in bites, it's much easier to swallow. There are basically ten steps:

1) Choice of R12 (Freon) or R134a. This is the first step as it'll affect what compressor you buy (the fittings are different) and what lubricant you use in the system. If you're in a hot hot hot climate, stick with freon. It's still widely available.

2) Installation of new rotary-style compressor to block. Don't even think of using that old York piston compressor. You'll need the bracket folks are talking about. You'll also need to make sure your crankshaft pulley has a groove for the a/c belt. Don't take that for granted. Rare part for a tii, if I remember correctly.

3) Installation of condenser in front of radiator and electric fan in front of condenser. You can go with one from an '02 or retrofit the largest generic one you can stuff in there.

4) Installation of evaporator assembly inside car. I'd strongly recommend the Behr one for a factory look. I'd strongly recommend replacing the expansion valve while you have it out. Don't forget to verify there's a properly positioned hole on the transmission tunnel to drain it or else you'll have one smelly mildewed car right quick.

5) Installation of console around evaporator assembly. The non-a/c console has to be replaced. Again, the one that goes with the Behr system has the best factory look IMHO.

6) Drilling of holes through the nose and firewall to run the hoses. Scared yet? Those punches, the ones where you drill a small pilot hole then position the two halves of the punches on either side and ratchet them together, work great. Look at an existing a/c'd 02 for guidance on where the holes should go. Take photos and measure. Have a beer to help lower your blood pressure once you've done it. Paint the inside edges of the holes with Wurth zinc-rich primer or equivalent.

7) Fabrication of new hoses. If you can buy a whole a/c system out of a junked car, you can use the old hoses as templates, or you can have them all cut to length. There are very few shops here in Boston that do that kind of work (it doesn't get that hot here), but if you're in a hot climate, you should be able to find a shop who will cut each hose long, crimp one fitting on, thread it through, cut it to length, and crimp the other fitting on. If you're using R134A, you need new barrier hoses, but you'd be short-sighted not to use new hoses even if you're using Freon.

8) Installation of receiver/dryer on passenger side of engine compartment. Trivial. Again, look at an existing installation.

9) Wiring of compressor, fans, and switches. Fairly straightforward.

10) Adding of oil, evacuating, and charging it up. Utter joy when it blows cold.

Be aware that some of the newer compressors come without any kind of charging fittings on them (allowing them to be used for either R12 or R134a). That means that the fittings have to be elsewhere, like spliced into the hoses that plumb the compressor. If you don't do that, you'll have no way to get anything into the system. Ask me how I know... :^)

For all of these reasons, resurrecting a dead system is far easer than a from-scratch installation.

Good luck. It's a great project that enormously increases the enjoyment of the car by increasing the opportunities to drive it in comfort; at least that was my experience. Virtually all modern cars have a/c. We get spoiled. And it's not like it's sacrilege on a 2002; it was available.

--Rob

[thehackmechanic]

Forgot to say that I did essentially what Dave did -- started with a stock evaporator assembly and console but used aftermarket components for everything else. I sized the biggest condenser and fan I could fit inside the nose, and also used an aftermarket compressor, hoses, fan, and receiver. I then used R134, which works ok here in Boston. It takes a little while to get cold, but then it's ok.

It is entirely a matter of taste whether you want to go with a generic or aftermarket evaporator assembly and whether you like the way it and the console you wind up with looks. Unlike on a 3.0CS, where the a/c version of the console is as rare as hen's teeth, both the evaporator assembly and the a/c console are not unobtanium for an '02.

One year I spoke with Carl Nelson about all this, and he said he uses stock components (meaning evaporator and condenser), charges them with Freon, and has happy customers. R134? Customers not happy. Done.

[mcaden]

Rob's pont no. 7 is an important one. There aren't as many places around anymore that do the high compression fittings you'll need for your hoses. As you know, in the DC area it is HOT... and I had to look hard to locate one or two places. Perhaps in Florida, it will be easier to find someone. Good luck on your install.

-Marc

[02hobiedave]

I found the two compression fittings at an old A/C shop in Altamonte They let me look through the bins for the one's I needed. Its better when you can take the evaporator with you to have the right fit. Let me know if I can help.

[pikeperkins]

Thanks for the input everyone. This looks like it could turn into a FAQ! I might find out today about the non-A/C '02. If I don't buy it, it's back to the grind on the one I already have. Thanks again!