by entrax » Tue Apr 07, 2015 10:40 pm
So to be able to drive my car and installing bits and pieces at the same time, some planning had to be done:
All of this so far should allow you to keep driving the car:
1.) Install interior a/c box/evaporator
2.) Install lines from evaporator to condenser
3.) Install compressor
This will not and should be done together:
4.) Install underbody lines
5.) Install condenser.
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Sorry for the lack of photos, but here's the rest of it:
2.) Install lines from evaporator to condenser:
- from a/c box, install 3 lines that runs across the frunk, remove rubber grommet where the a/c line goes through (near under abs brick)
- remove LF wheel, fender liner, install the line that goes around the LF strut rod, install the receiver+line piece separately, then once in place, bolt the two lines together at the receiver.
- this should mean that your condenser line to evaporator in the cabin is complete
- reinstall fender liner and wheel.
3.) Install Compressor and Pulley:
Preparation
- Jack up passenger side of car
- Remove rear all undertrays (to stay removed until completion of A/C install)
Compressor
- Remove right side "cancer bar".
- Place compressor loosely around the installation area. BE CAREFUL. the compressor is finicky to hold, the pulley free-spins as the magnet clutch is not engaged, and it can start weighing down on you when you're trying to install this.
- Install bottom two long bolts for Compressor > Engine block. Finger tight then remove bolt approx. 5 turns (this allows enough play to install upper bolt)
Pulley/Bracket
- Remove the pulley from the bracket. This is needed so you can put in the bolt that bolts onto the block sideways.
- Remove intercooler piping and install bracket.
- Bolt on upper bolt through bracket + compressor.
- Tighten lower 2 compressor bolts.
- Install pulley and belt.
4 and 5 should be done together
4.)Underbody Lines
Driver's side a/c line:
- Install the other side of the evaporator line (the one that goes through the hole in the frunk where your heater lines go)
- Handbrake assembly under the car: remove two driver's side bolts, loosen two passenger side bolts to allow handbrake assembly to hang.
- Remove driver's side handbrake line FROM the bracket assembly under the car. do not mess with the rear caliper, there is no need.
- support beam under the fuel tank: remove 1 driver's side bolt, loosen 1 passenger side bolt to allow bracket to hang.
- mechanical speedo: separate the mid-section piece where it separates. make sure to keep the pin safe!!!
- install driver's side long a/c line. this line needs to go over 5 things:
1.)the big driver's side coolant hose right at the bottom of the engine-to-cabin firewall.
2.)speedo line
3.)RL handbrake line
4.)support beam under fuel tank
5.)handbrake bracket assembly
- there are 3 brackets for this line. remove the one closest to the back of the car to allow enough space to fit between the firewall and the coolant hose. the line goes in between the clutch slave hard line and the coolant hose. i found that rotating the rest of the line all the way out past the driver's side door helps. slip the line over the RL handbrake line, slip the line over the speedo cable, slip it over the support beam and handbrake assembly.
- reinstall the last bracket to the line, bolt on the first 2 brackets to the body of the car (pre threaded), thread on a/c line that goes to the frunk
- reinstall speedo cable, reinstall handbrake assembly, reinstall support beam and handbrake assembly.
Passenger's side A/C line
- repeat above, except of course on the passenger side.
- items to disturb include: passenger side of the handbrake assembly, support beam, RR handbrake line
Lines that go into the Compressor
-the last bracket for both lines are bolted together to a previous unused M6 stud at the bottom of the cabin-engine firewall, beside the passenger side coolant hard line
- install "soft lines" that go from the end of the hard lines to the compressor.
5.) Condenser
- remove FR tie rod (either at the hub or where it gets adjusted for alignments), turn the wheel all the way to the left.
- install the twisty line that goes from the condenser to the long passenger side hard line.
- this is very tricky. starting from the passenger side hard line, this line goes over the unibody frame where the steering rack bolts onto, over the inner tie rod, in front and around the front strut rod, through a plastic cover that keeps the wiper fluid reservoir clean, then finally into where the condenser goes. take your time. i thought this goes over the tie rod, but under the unibody part, almost bent this line. took me 4 tries to get it. i did this line last because i'm comfortable with how bendable these lines are.
- remove radiator plastic cover, drain radiator, remove both radiator brackets, both radiator coolant hoses (only need to remove the side that goes into the rad)
- push rad back while slipping the condenser in. be careful to not damage any of the fins on either the rad or condenser. two people recommended.
- bolt on both condenser lines. driver's side with extension + ratchet, passenger's side with a ratcheting wrench.
- reinstall all 6 underbody trays.
- reinstall tie rod