bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 15, 2023 11:26:51 GMT -5
I know it's cheaper to just buy another car with A/C, but let's assume I don't want to do that. Is it possible to add A/C to my zx2, and if so, what parts do I need to get it done. I want to do a lot more to the car, so if I ever get the time, A/C is just one part of a more extensive work session.
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Post by TheEvilZX2 on May 15, 2023 11:28:25 GMT -5
Did your car have AC to begin with and it's just not working? To complicate things there's two styles of AC compressors that came in these cars, sometime in 2002 (or maybe it was by option, dareall may know that for sure) it seems they started using the scroll type compressor. FS10 style compressor kit : www.rockauto.com/en/moreinfo.php?pk=10682480&cc=1420513&pt=17507Scroll style compressor kit: www.rockauto.com/en/moreinfo.php?pk=10682728&cc=1420513&pt=17507I've never added AC to a ZX2 without it, I seem to be more likely to remove AC, all mine have come with AC. My daily 2002 silver car is FS10 style and my wife's 2002 green car is the scroll type Hope this may help
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 15, 2023 11:49:37 GMT -5
My car does not have A/C, but I think the plug for the little canister down by the passenger headlight is for the system. I have a compressor off another car, but it's really the stuff behind the dash I'm concerned about.
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Post by TheEvilZX2 on May 15, 2023 13:21:57 GMT -5
Yeah I'm thinking you'll need the evaporator in the HVAC box for sure then, and the piping/hoses to connect everything. Plus the pressure sensors.
Does your climate control have AC as an option on it? If not guess you'll need another climate control?
Honestly I've never seen a factory non AC ZX2 in person lol
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 15, 2023 14:08:27 GMT -5
I seem to remember the evaporator with the box as being hard to find. I was thinking it might have to be cut open? Do they sell them in the box?
Yeah mine is the only ZX2 I have seen without A/C. It's been fine so far, but I can ride motorcycles if I want to be hot. My car should be comfortable...
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Post by TheEvilZX2 on May 15, 2023 15:11:37 GMT -5
yeah, all i see is just the evaporator as well : www.rockauto.com/en/catalog/ford,2002,escort,2.0l+l4+dohc,1420502,heat+&+air+conditioning,a/c+evaporator+core,6768 got any junkyards nearby??
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 15, 2023 19:30:21 GMT -5
I'm thinking about buying another car and driving it until I have the time to really get into my main ZX2. I'd rather not spend too mucj time in the JY if I can avoid it. When I took some of the parts out of another car, the evaporator seems to be sealed in the HVAC box, and my guess is that you have to dremel it open to replace it. Not sure though. It has been a few years.
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Post by TheEvilZX2 on May 16, 2023 8:08:25 GMT -5
Never had the ZX2 HVAC open so I can't say for sure, but every HVAC box I've ever worked on just unbolted or snapped apart so that stuff could be replaced. Pulling the dash is usually the most work
I hear ya on the time piece but if I was going to pursue this I'd pull the whole HVAC box and swap it. Just get everything AC related from that vehicle
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 16, 2023 9:59:44 GMT -5
That's what I'll probably do then. Just have to find the time and spare cash 😂. I'll probably come back and update if I ever get started on it.
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 21, 2023 10:18:15 GMT -5
I got the HVAC box from the junkyard and pulled some of the other required components. I ordered some other stuff online. All told it looks like it's gonna be $500 or so. Now I just have to start praying the car is entirely wired for it. I can't wait to sit happily in traffic with the A/C on so high I'm freezing my ass off.
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Post by dareall on May 22, 2023 4:12:26 GMT -5
only the cheapest of the cheap zx2 did not have ac. It was one of the few options put one most all of them. Because of this, the wiring should already be in the car. Of the 3 cools I have had, they all had the wiring which made the install of ac on one of them as easy as installing the parts.
Remember, you will also have to change your radio to the version with the ac selection and the switch for it
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on May 22, 2023 9:29:08 GMT -5
The car in the junkyard I pulled from was the second most optioned ZX2 I have ever seen. Sad to see it in the junkyard. I almost took the whole radio, but I ended up stripping it and just taking the switches and faceplate. Removing the dash was easier than I expected, but I'm not looking forward to doing it on my car. It's so easy to break stuff.
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jun 3, 2023 18:55:06 GMT -5
I have everything I need to add the parts except for one hose. It was FUBAR from the car I was pulling from in the JY. It's the hose that runs along the firewall from the evaporator to the condensor. I don't see if on rock auto or advance. Does anyone know where I can find one?
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jun 25, 2023 16:18:31 GMT -5
I was able to get another one of those long hoses, but now I have an issue getting a new high pressure cutoff switch. There was a 3 prong switch installed on the steel line I got from the JY, but it will not plug into the connector my car has. The connector on my car is too large. It looks like a 4 Pin connector instead of the 3 pin. I was able to find the part numbers on Rock Auto, as they have one of the bigger kinds hiding among the normal ones. When I look it up on Ebay, it says that it is for a 1993 Taurus. Did Ford just randomly throw connectors in these cars? The one for the accumulator fits fine.
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Post by TheEvilZX2 on Jun 26, 2023 4:49:25 GMT -5
What year is your car? And do you recall what year the car was that everything came out of?
Wondering if this may be a difference of pre 99.5 and post 99.5 wiring. But honestly I'm not certain.
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jun 28, 2023 19:16:57 GMT -5
My car is a 2000 model year. I pulled all the parts off of a 1999. I feel like this is the issue. While RockAuto is great at showing parts, I don't think they got the years right for the connector. The 1999 car uses a 3 terminal connector and a 3 terminal sensor. I think you are right with 2000 being the year for the A/C change. For some reason though, the internet only remembers the 4 terminal connector and the 3 terminal sensor. It's really weird. EBay, RockAuto, and Google all show the same thing. The only way I was able to find something that MIGHT fit is using a 2003 ZX2 as the search subject. That returned both of the connectors. When I plug in the part numbers (F2CZ19D594A, F3DZ19D594A, F58H19D594AA, F5CH19D594AA, F5CZ19D594AA, FSCZ190594AA) into EBay, it returns 4 terminal connectors for cars, vans, and trucks from the mid 90s. Maybe Ford decided it was unlikely dealers would add A/C to the non-A/C cars and they just spliced in some connectors they had laying around. Whatever the reason is, it makes finding one a bit of a bitch. I might have to head back to the JY again
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Post by TheEvilZX2 on Jun 28, 2023 19:48:41 GMT -5
although the article is for wiring in a post 99.5 PCM into a pre 99.5 it has wiring diagrams for that early 3 wire sensor : mega.nz/folder/ff4HjSYL#2VpS8agwGe0b5Rjtu8FDyQ/file/HH4xjJSKbasically youd have to reverse engineer this article. im sure its doable if you want to figure it out, or get post 99.5 stuff
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jun 30, 2023 14:39:09 GMT -5
Thanks for the article. It actually clears somethings up for me. I was able to source a newer style cutoff sensor. It plugged right in. Last night I put in the radiator, put the belt back on, plugged in the sensors, filled the coolant system, and charged the A/C. Now I am finding that the A/C compressor clutch won't engage. The engine fan is not running all the time, so at least I know that the new sensor appears to be working. What seems to be happening is the compressor is not being told to turn on by the computer. Do I need a CCRM from an A/C car as well?
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Post by TheEvilZX2 on Jun 30, 2023 19:06:22 GMT -5
that would make sense, CCRM has the AC relay....OR if theyre not different between AC and NON AC its highly possible that the AC relay itself is bad, ive had many fail. (edit: probably non existent in a NON AC car how would it be worn out/bad now that im reading what i typed lol, leaving it in here anyhow)
ive head of folks have removing the wires for AC relay going to the CCRM and wired for a normal bosch style relay
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jun 30, 2023 20:48:51 GMT -5
So, I changed the CCRM to a known A/C type and the center of the compressor started to move here and there. I'm making progress. I think I'm gonna take it for a drive and see how it goes...
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bws678
Trainee ZX2ner
Posts: 66
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Post by bws678 on Jul 1, 2023 0:03:18 GMT -5
Okay, I got it working. In the end it was the fact that the car will always disengage the clutch if the pressure ever drops below 25psi. I went thru a whole can of the refrigerant and FINALLY got cold A/C. THANK YOU for all the help. I'll keep this thread updated with further results (if there are any).
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