R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 AC System Upgrade / Compressor Removal

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Old Mar 24, 2026 | 04:23 PM
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AC System Upgrade / Compressor Removal

Hey NAM!
This all started when I was looking for the location to a split vacuum line! See my post (Need help identifying possible vacuum hose)

Anyway…
The car is in service mode, and everything has been removed. The SC / water pump, thermostat and old plastic housing soon, alternator, belt….You get the idea!
I’m so far in, that I’ve decided to tackle the AC system as well (compressor, condenser, the metal / rubber hose connections, etc)
With so much taken OFF the car already, what’s the easiest (and least costly way) to remove the refrigerant so I can disconnect everything? Obviously I can’t start the car to evacuate the system properly. Was looking for more of a DIY approach. The car has 150K on the clock, and I’m not afraid to get dirty as you can tell!

Give me some “old school” advice so I can get this all removed and make way for new parts!

Thx! You guys are the best!
 
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Old Mar 24, 2026 | 04:43 PM
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Does the A/C work? I’ve had it in service mode, and left the A/C alone.
 
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Old Mar 24, 2026 | 06:01 PM
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Originally Posted by noodlesandsam
Does the A/C work? I’ve had it in service mode, and left the A/C alone.
Yes, the AC works. Doesn’t blow as cold as I think it should LOL, but the hoses behind the radiator / fan / condenser assembly are showing considerable wear. They aren’t the nice looking rubber hoses as when new, and I don’t expect them to be. The compressor is probably original to the car (150k miles) and just like everything else right now, I may as well address these things. Does it need to be replaced? Maybe not. But like I said, I’m already here…It’s coming off one way or another LOL
 

Last edited by jcampbell6768; Mar 24, 2026 at 06:02 PM. Reason: Additional Information
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Old Mar 25, 2026 | 10:18 AM
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um...the only EPA approved method would be to go to a service center and have it evacuated.

the wrong way that i am not recommending would be to release it to the atmosphere. but that's up to you and i am not responsible for you if you do it. lol
 
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Old Mar 25, 2026 | 10:22 AM
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ok you might be going too far. however i know the feeling.

i would say you need to pull vacuum on the ac system. if it holds, run with it. if not, you can start replacing hoses, etc

note: this will not be the last time you are in service mode TRUST ME
 
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Old Mar 25, 2026 | 11:32 AM
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Originally Posted by ssoliman
ok you might be going too far. however i know the feeling.

i would say you need to pull vacuum on the ac system. if it holds, run with it. if not, you can start replacing hoses, etc

note: this will not be the last time you are in service mode TRUST ME
I think you’re right; I am getting a bit carried away! And the further I go, the higher the price! LOL
I’ve got most of the parts I need to complete the project (see my other posts)

I really just need to push pause and get this thing back on the road! HaHa
 
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Old Mar 25, 2026 | 11:35 AM
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Originally Posted by ssoliman
ok you might be going too far. however i know the feeling.

i would say you need to pull vacuum on the ac system. if it holds, run with it. if not, you can start replacing hoses, etc

note: this will not be the last time you are in service mode TRUST ME
Yea, I’m not going to mess with this anymore. I’ve looked for mobile mechanics who can do it, and one guy even said, “If I come out, it’s $120 and I’m just gonna vent it out anyway”

WTF!!!

He’s probably not someone I’d want working on my car! LOL
 
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Old Mar 27, 2026 | 12:23 PM
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If you have A/C gauges, first measure pressure in the system. You may not even have freon in the system. If so, just disconnect the hoses. Back in the day everyone just released it to the environment. If you decide to replace the suction line look for my most recent posts about the gigantic PITA it is to replace that hose. After doing it myself it was probably easier to just remove the engine first. As far as your compressor is concerned, if your A/C clutch engages I doubt you need a new compressor. Even then the A/C clutch (if it's not working) can be replaced without replacing the compressor. If you have no pressure your clutch will not engage (due to a low pressure switch that's part of the system). The clutch, to test it, can be jumped in the fuse box by removing the relay and fabbing a jump wire. More important is to go ahead and replace the condenser/dryer while you're at it.
 

Last edited by cooper48; Mar 27, 2026 at 05:57 PM.
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Old Mar 27, 2026 | 04:50 PM
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Originally Posted by jcampbell6768
Yea, I’m not going to mess with this anymore. I’ve looked for mobile mechanics who can do it, and one guy even said, “If I come out, it’s $120 and I’m just gonna vent it out anyway”

WTF!!!

He’s probably not someone I’d want working on my car! LOL
That's a huge EPA violation! A shop can be fined $35K if they get caught doing that.

As far as how well your car does or does not cool, my R53 cools pretty well up until outside temperatures go over 105 degrees. Where I live, that is basically June - September. So in the 105 - 115+ degree range that we see every summer, the A/C in my car is only good enough to barely stop me from sweating and be barely comfortable, not to mention the engine performance loss due to the additional drag on the little 1.6L engine with the compressor running. I've been through compressors and condensers and I've accepted that R53 will never cool as well as my other cars.
 
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Old Mar 28, 2026 | 06:41 PM
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Originally Posted by ghostwrench
That's a huge EPA violation! A shop can be fined $35K if they get caught doing that.

As far as how well your car does or does not cool, my R53 cools pretty well up until outside temperatures go over 105 degrees. Where I live, that is basically June - September. So in the 105 - 115+ degree range that we see every summer, the A/C in my car is only good enough to barely stop me from sweating and be barely comfortable, not to mention the engine performance loss due to the additional drag on the little 1.6L engine with the compressor running. I've been through compressors and condensers and I've accepted that R53 will never cool as well as my other cars.
I’m in central Florida, close to the Atlantic coast, so I can relate to the temps! LOL
And unfortunately, I don’t have a garage to park in, so the car sits out ALL THE TIME…I usually start the car and open the windows with the AC on high, while I go back inside the house for 5 minutes. HaHa!
 
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Old Mar 28, 2026 | 06:42 PM
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Last edited by jcampbell6768; Mar 28, 2026 at 06:45 PM. Reason: Double Post
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