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Parts/Tools
Socket Wrench and Sockets
+ Screwdriver
Locking Wrenches
Instructions
Why remove the Air Conditioning?
There would be either one of two reason. One is it is broken so you need to get out the components in order to replace it. The other reason is you are like me and just roll down the windows in the summer anyway so why drive around with weight you don't need.
Removal
First off all these directions are written assuming your system has no freon in it. If it does you need to take it to a place and have it drained, just letting it spray out is supposedly illegal and probably not good for the environment. Most of the hoses for the AC come apart by taking 2 locking wrenches, lock one wrench on one of the nuts and the other on the other nut, twist in opposite directions and the couplings should come apart without too much trouble. If they are hard to separate try heating them up with a torch, that usually loosens them up. Watch out as there are lots of important wires you could melt so use a piece of metal as a shield if need be. Removing most hoses is pretty straight forward so I'm not going to get deep into it. To remove some of the hoses taking off the front bulkhead (the bar which the hood latch goes into).
Compressor
The biggest heaviest part of the AC is the compressor. It sort of resembles an alternator and is hidden down next to the header. It has a belt connected to it. Simply use a wrench to turn the nut until the belt is loose then slip it off. Next you will need to remove the fan to get at the compressor. To remove the fan (the one right in front of the header, which is the only one you need to remove) undo the 2 bolts connecting it to the radiator support. Un-clip all the clips holding the wire harness to the fan. Now undo the plug that connects the harness to the fan, you flip up the little clip on the top then just pull it apart, should come off very easy. You need to shimmy the fan to the right because there is a piece of metal bent around the lip of the radiator. Once that is loose it should wiggle freely yet still be attached somehow. On the bottom is a rubber bushing and peg that fits into a metal opening. You need to simply pull up on the fan until it pops out. Shouldn't be too hard.
Fan and it's wire harness (green plug)...
Space with fan and heat sheild removed...
Now with the fan out you can remove the heat shield for the header, it is attached with 4 bolts, 2 at the top, 1 in the middle, and one at the bottom. That should just fall off after that. Now you should have a straight shot right at the compressor. First I would remove the wires that go from the harness to the compressor. Look at the fat black parts of the wire, they are actually male and female plugs, pull it apart and they should come right apart. The compressor is held onto a bracket. There are 4 bolts which are pretty obvious which hold the compressor to the bracket. Undo those 4. You can only undo them so far but you can't pull them out because the radiator is too close, not a big deal, just unbolt them as much as you can. By the time you unbolt the 4th one the compressor should fall off (common sense allows you to anticipate that). The compressor should just barely squeeze out of the openings you have made for it. You will notice it's pretty damn big and heavy. Now you can remove the compressor bracket, it also has 4 obvious bolts. Together the weight of the compressor is a lot. Your car will love you for removing it.
The giant metal beast that is the compressor...
Dryer
Another easy to remove part is the Dryer. It is right next to the coolant reservior. Pull out the coolant reservior (it slides right out). Undo the bolts on the bracket that hold the dryer to the car. Use the locking wrenches to remove the lines that connect to it. After that just pull out the dryer. It doesn't weigh much at all but you sure did free up a lot of room over there. I also took this time to remove the reservior and clean it out with hot water as sludge builds up inside it and could be sucked inside your engine. So I cleaned it out and filled it with brand new coolant. Cleaning it also makes it easier to see the Min and Max level markings.
Look at the space you freed up. The dark space is where the compressor would have been, and the area between the coolant reservior and the windshield washer fluid is where the dryer would have been...
Condensor
The condensor is located at the very front of the car right in front of the radiator and behind the bumper. To get this out it helps to remove the front bumper (2 bolts behind each bumper lense, 2 screws in each fender well, 2 bolts under the bumper). Once the bumper is off you can remove the lines there. To remove the condensor you need to unbolt the radiator support brackets. Once those are off push the radiator back as far as you can. There will be 2 bolts holding the condensor to the car. Undo those bolts then push back the condensor and remove it by lifting it straight out. Once that is out bolt back up the radiator.
Evaporator
The evaporator is the only part of the A/C actually inside the car. To remove it take off the glove box by removing the 2 screws on the bottom of it that hold it to the dash. Once that is out remove the metal brace in the front of the evaporator and heater core, it's held on by 4 bolts. Once that is out of the way undo the 2 brackets supporting the Evaporator, they come off with a screwdriver, just look to the tops of the silver metal brackets for these screws. Once they are off push them down. Now undo the 2 bolts that hold the Evaporator to the firewall, they are at the top left and bottom right of the Evaporator. With those out pull on the Evaporator until it slides off, should be pretty easy.
The problem with removing the evaporator is that it creates a link from the heatercore to the air tunnels throughout the dash, by removing the evaporator you remove the link from the heater to these tunnels. Not a big problem. You can either go to a junkyard and rip out the tube from a non-A/C car and use that, or simply gut your Evaporator which is what I chose to do. Remove all the screws and clips you see along the middle of the Evaporator housing. Then just lift the insides out of the Evaporator. Put the housing back together. Use duct tape to cover up all the holes that are left over...
Evaporator Housing...
Evaporator Insides...
Evaporator Patched with Duct Tape...
If you don't feel like ghetto-rigging up your heating system you can do like I did later on and go to the Junkyard and rip the non-A/C Tube out of a non-A/C car and just use that, they sold it to me for about $2.
Now you are done. This How-To should tell you how to do everything to get out the A/C. I believe you probably saved about 40lbs of dead weight from the car.
Notes
It is said that the compressor weighs about 40lbs since when you hold it it seems really heavy. It is not 40lbs, more like 17lbs with it's bracket, but that is still a lot...
Another tip is don't junk your compressor if it worked before. The compressors go for $50 or more on eBay so go ahead and make some money off of it.
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