A/C maintenance

The A/C compressor in my 2002 Galant ES froze up several months ago. As a result, I also have no power steering. I've gotten estimates ranging from $800 to $1200 to do the job for my car. I've got virtually no automotive tools (I can be pretty handy, though)nor a manual. How much would it run and what all would I need to do the job myself?

Depending on where the compressor is, it can be a 10 minute job or a 3 day job. Some of those FWD transverse engine bays are a pain in the butt. I've seen cars that you had to partially disassemble the transmission to get the alternator off.

But, if it looks like its in an easy place, all you'll need is a basic set of tools; sockets, end wrenches, pliers. Kinda your standard Craftsman tool set.

The question I have is... why does a frozen A/C compressor cause you to lose power steering? If the compressor froze, just don't turn on the A/C and the pulley will free-wheel. If in doubt, pull the wire off the pulley clutch so the car doesn't engage it on its own (like if you turn on the defroster).

If you need the car, just put a belt on it, disconnect the wire to the compressor, and worry about it when you have time.

If its the 4-cylinder model, it looks pretty easy to change. A few bolts and its done. Just be careful with the R-134a in there. You're not supposed to vent it to the atmosphere, but a lot of people do anyway. A friend of mine has the same issue, and nobody can seem to get me a bypass belt to run only the power steering pump. She's too cheap to just buy a new compressor.

Does anyone know if this is a cycling clutch type compressor? It seemed pretty tightly locked up, so I just assumed it was a variable displacement style.

Is there such a thing as a bypass belt? Who carries them? Why wouldn't the compressor free-wheel? I'm guessing that's a problem with the bearings.

I found this in a 01' Galant service manual, should be the same for 02:
http://my.core.com/%7Eczeck1/mitgal24acps.gif

As you can see here, what is needed to by-pass the a/c is the belt and tensioner pulley from a non-a/c car. With a little luck, you may be able to tilt back the compressor brackets just enough to clear the belt, and not have to take it off.


Does anyone know if this is a cycling clutch type compressor?
The manual says it is. Try unplugging the trigger wire first and see if the belt freewheels. If yes, the electrical side of the system is faulty and is keeping the clutch on. If not, my first guess is the clutch went bad and is jammed in the engaged position. Unfortunately, like most a/c compressors, this unit requires special factory service tools to get the blasted clutch off.

Not that it matters, really. Think about it, if the clutch is stuck on, doesn't that mean the a/c will simply run all the time? Big deal, I can turn up the temp control if it's too cold, right?

WRONG

Even on the hottest days, the compressor cycles on and off at regular intervals. Running the a/c system on a 100% duty cycle beats the crap out of the compressor and it'll eventually burn up the bearings and stick solid.
So that gives us a logical diagnosis: clutch became stuck in engaged position, ran a/c compressor 100% of the time, prematurely wore compressor. The only possibility? Maybe not... but it's logical that's what happened.

Please do not try to repair the A/C yourself. It requires special equipment costing thousands of dollars to properly recover a system, then evacuate and recharge it after it is opened and repairs are made. It can not be done correctly without that equipment. Any do-it-yourself tips you get from anyone are shoddy hack jobs that will result in a system that won't work at all, or at best won't work very good and not for very long. You might as well take the few hundred bucks you'd spend on the compressor and use it as toilet paper.

Besides, refrigerant is dangerous. Improperly charging a system can cause pressures to become excessive and lines to rupture. When exposed to the atmosphere, R134-a acts like a heat magnet, absorbing heat from anything it get near - like you skin - you could easily end up in the ER with some nasty frostbite.

Here's another good reason not to try fixing it yourself:

"Federal law dictates that a fine of up to $25,000 may be levied on people convicted of venting refrigerant into the atmosphere. Additionally, the EPA may pay up to $10,000 for information or services leading to a criminal conviction of the violation of these laws."
And the best for last:

"Inhalation of concentrated refrigerant fumes is dangerous and can result in death; cases of fatal cardiac arrhythmia have been reported in people accidentally subjected to high levels of refrigerant."

So, if you really want cold air, $800 is not so bad after reading that, is it?
If you choose to forgo A/C and save money by just by-passing the system, and the AC compressor is in the way of the rerouted belt, wire it securely to the frame or body where it won't interfere with moving parts. Another method would be to take it to a shop and have them recover the refrigerant from the system. You can then safely and legally remove the compressor at home. An honest shop will charge you very little (maybe nothing) to do this, as they can recycle and sell your old refrigerant when they repair a leak and recharge another customer's a/c.

New development. As I was unhooking wires from the compressor, I came across a certain unknown, flat, square component. Possibly magnetic. I'm not sure. In any case the downstream wire seems to disappear into the pulley hub itself. Is it possible that this wire got loose and entangled itself around the pulley thus seizing it up? And if that's the case, can I get away with doinhttp://i472.photobucket.com/albums/rr85/sailor86_bucket/th_Accompressorwire002.jpg (http://s472.photobucket.com/albums/rr85/sailor86_bucket/?action=view&current=Accompressorwire002.jpg)g it myself?

A single small gauge wire isn't going to stop a pulley driven by a 100 plus horsepower engine. It'd rip that wire to shreds first. That sure looks like it could be the compressor clutch trigger wire, though.... It may have wiggled loose and got caught in the clutch, keeping it from disengaging.

Well, irrelevant. The compressor is already wrecked if it doesn't turn.
You have no choice but to pay for a repair, or get the non-a/c tensioner assembly and shorter belt to by-pass it.

One more thought, you could in theory have a bad clutch replaced now, giving you a freewheeling clutch (have the wire tied off to the side, and of course unhooked!) and then have the compressor done later when you have some extra cash. This would get power steering back.

You'd need to find a A/C shop or dealer for that, since most independent general repair shops won't have the special tools to pull the clutch.