MeanMini A/C re-installation problems

[wheming]

Sometimes I feel like i just can't catch a break.. I know we've all been there.
Anyway here's the skinny...

Been working and parts gathering to reinstall a/c on Mini so she can be more fully enjoyed yearround.
I finished installing my new parallel flow condenser in front of the radiator since the intercooler takes up what was the original condenser's stock location. Now i just need some extended hose pieces made.
http://img.tapatalk.com/1888e4c3-e4a8-1b20.jpg

So I figured i'd test fit some core components to get the fit down before i set all my new stuff.
Well the 89 compressor has the hose attachments right in a spot where it interfears with the intercooler plumbing. And this doesn't really look like i can change this section enough, since i used a tight 90 bend.
http://img.tapatalk.com/1888e4c3-e583-abfe.jpg

So I test fit the newer (next gen) minivan like a 92-93 compressor that i had collected at a junkyard. As i thought it looks to allow more room. Problem is there are some electrical connections i need to know about.
There is the clutch, but there is another 2 wire connector on the compressor:
http://img.tapatalk.com/1888e4c3-e68b-2898.jpg
And then on the expansion valve there is a two wire sensor (the low pressure switch?) and a 3 wire connector.
http://img.tapatalk.com/1888e4c3-e715-45a6.jpg
Also at the condeser outlet (high press liquid) line there is another 2 wire switch:
http://img.tapatalk.com/1888e4c3-e783-1f71.jpg

So i guess what i'd like to know is can i use this setup with the 89 wiring, and what would i need to do? The only wires on the 89 system is the low pressure switch and the clutch.
I've got a new 89 expansion valve, but it does not have the low pressure swith built in. I guess i probably could machine a port in it and tap it for that switch.
But what are the 3 wire connector on the 92-93 expansion valve and the 2 wire connector at the compressor?

Does anyone have a copy of the engine wiring for a 93 minivan with 2.5L?
Thanks for any assistance.



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[wheming]

Trying to rework that intercooler outlet plumbing might give me a bit of clearance. But i'm afraid it won't be enough with the engine movements.
The 92-93 compressor also has a different hose setup which would be much better for this new condenser. I could attach a new end to the compressor discharge hose and attach directly to the condenser with no additional jumper hose.
The condenser outlet will still require a jumper to go from the condenser outlet to the spot where the stock condenser connector is (next to the right side headlight bucket).



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[black86glhs]

What sensors would normally be on your van? Don't worry about any sensors that are extra compared to what your van would use. Leave the other sensors connected, but don't worry about hooking them up.

[turbovanman²]

R134A runs at higher pressures so they added a high pressure cut out switch's for safety on the compressor, the other switch is probably the cycling switch.

You should cycling switch coming off the metal line at the firewall.

As for your lines, I had the same issue and bent, moddified them to clear the IC piping.

[wheming]

In the 89 lines, there is a switch in the low pressure side (exiting the evaporator). that is the only switch on the 89. So on the 93 compressor and lines, the low pressure switch is the one on the compressor? Or that is a high pressure cutout?
On the 93 the expansion valve has a switch what looks like on the high pressure liquid line area. I'll have to look closely to see if that is ported to before the valve on on the low side (low pressure liquid, evaporator inlet).

If the high pressure cutout switch is normslly closed and opens on high pressure, i could just run it in series with the clutch power. so high pressure disengages clutch.

Its that 3 wire connector on the 93 expansion valve that has me puzzled.
I better break out my multimeter and do a bit of checking...



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[turbovanman²]

All the 89 had was a cycling switch, its in the middle of the firewall, so that's all you need. I'll had to go over the wiring for the later one to see what switch is the cycling switch.

Apparantley you can use the 93 expansion valve as its rated for 134a, but with my stock system running 134a, I have no issues with it not being cold.

[wheming]

True. I have 134a in my Spirit and didn't change expansion valves.

You're right on the 93 expansion valve. I'll have to use that since that switch is ported to after the valve (low side).
http://img.tapatalk.com/1888e4c3-1153-7c88.jpg
As for that 3 wire thingy on the 93 expansion valve, that is just a temperature sensor. It may do some switching, IDK,
http://img.tapatalk.com/1888e4c3-11aa-57db.jpg
And the switch at the compressor is normally closed. So i could just run the clutch power through a relay and have the primary be in series with this switch to keep the safety feature.

Ok. I think i have a clear path forward! Thanks Simon!



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[turbovanman²]

Yep, the high pressure switch is NC, so when it trips, it turns off the compressor so you could do that with a relay. That temp sensor is most likely for a car with electric HVAC so the computer knows what temp the system is.

[wheming]

There this fit is a little better.
And the compressor discharge line is more suited to where i need it to go (just to the side of the radiator in the top middle of the support).
http://img.tapatalk.com/1888e4c3-0c5b-3499.jpg
There's a bit more clearance than the first pic showed. And the aluminum bends a bit easier.
http://img.tapatalk.com/1888e4c3-0c71-0d86.jpg

Now just need to order a reman compressor, see if i can fine a new low side hose, and an expansion valve. I was able to find a new high side hose.

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[turbovanman²]

Awesome, you can also heat up the compressor lines a bit to help bend them or have them rewelded if need be.


BTW, where did you get that condensor?

[black86glhs]

I have a new mopar expansion valve for sale. Don't know if it is one you can use, but thought I would throw it out there.

[wheming]

BTW, where did you get that condensor?

Www.racewayparts.com/parallelflowcondensers.aspx

This is the 14x18 (HxW) $123
I found an identical looking one elsewhere for cheaper (like $85) but it did not have mounting points on all 4 sides.



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[wheming]

I have a new mopar expansion valve for sale. Don't know if it is one you can use, but thought I would throw it out there.

Do you have a pic or part number? Would need to verify its the one i need. It is for 134a?



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[black86glhs]

Part #4176999
I'm not sure. It should work either way. I have converted them and not changed any thing and they work fine.

[wheming]

Looks like a different PN than the one i have here. Does it have the port for the low pressure switch?

If so, how much with shipping to 27527?
Found an aftermarket one of what i need on ebay for $16.73 with free shipping.



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[black86glhs]

http://www.turbo-mopar.com/forums/showthread.php?67427-various-parts&p=941320&highlight=#post941320

I (http://www.turbo-mopar.com/forums/showthread.php?67427-various-parts&p=941320&highlight=#post941320)s the bolt on the side where the switch would go?

I have mine listed at $30 shipped, so the ebay one is a bargain.

[wheming]

Yeah that bolt on the side gets removed and the low press switch threads in there. There should be an oring under the bolt too.

I've looked at so many on ebay and they all look the same but they have different numbers.
I'll probably just order the ebay one since it shows that it is for the proper engine.


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[black86glhs]

I don't blame you. I don't want to sell you something that won't work.

[wheming]

No worries.
I appreciate it. I wouldn't have known you had one if you hadn't mentioned.



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