Removing AC From Cosworth Supercharged NC, Alternator too

Installations instructions for MonsterFlow intakes, Big Brake Kits, shocks and more.

Removing AC From Cosworth Supercharged NC, Alternator too

Postby Brian » Sun Feb 13, 2011 3:00 pm

We did this removal of the Air Conditioning on our own Cosworth Supercharged 2007 about a year ago to remove weight from the front end. Got a request to post the notes. Here they are. The key to this is that Mazda/Ford already makes an Idler/Pulley replacement for this block which is the "New Pulley" in diagram below. LF17-15-940E is the current part number. Pretty sure that I got said new pulley from Mazda Comp, it is a standard part for the markets that have no A/C and goes on the block in place of the compressor (used in markets that don't need A/C like Canada, etc). Perhaps the next person to do this job can expand on the notes here by adding that part number.

2015 Update (For 2.5 Liter Customers see THIS THREAD).
Attachments
Cosworth_AIRCON-Removal.jpg
Cosworth_AIRCON-Removal.jpg (33.97 KiB)
Removing_AC_MX5.jpg
Removing_AC_MX5.jpg (137.77 KiB)
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby grey_NC » Mon Feb 14, 2011 11:18 pm

So I'm guessing we get the new belt from mazda?
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby Brian » Mon Feb 14, 2011 11:19 pm

Nope...I would not expect Mazda to have it. Your normal auto parts store for that.
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby grey_NC » Mon Feb 14, 2011 11:34 pm

So i just go to any auto parts store and give them the part # for the serpentine belt?
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby Brian » Mon Feb 14, 2011 11:35 pm

yes, it was an 'off the shelf' item at our local Napa Auto.

Or, I just put that "belt K060798" in Froogle and found it for sale online at a dozen places for about $20 in ten seconds.
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby grey_NC » Mon Feb 14, 2011 11:38 pm

I seee I see, so there's no specific brand I'll have to ask for eh? just as long as I have the part# is fine?

anyways thanks alot brian! hope I'll have a smooth install
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Re: Removing Air Conditioning From Cosworth Supercharged NC

Postby Brian » Mon Feb 14, 2011 11:42 pm

I prefer the Gates brand....but it don't matter much.
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby Brian » Tue Feb 15, 2011 11:34 am

And if you drop heavy 100 amp factory Alternator in favor of tiny 40 Amp Edge unit (to save another 10 pounds), then belt becomes K060810.
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NC-Alternator.jpg
NC-Alternator.jpg (82.79 KiB)
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby grey_NC » Tue Feb 15, 2011 4:37 pm

Brian,

So I went to my local autoparts store and gave them the belt # they asked me if I wanted the one with or without supercharger. 1 is 5mm longer than the other, which one am I supposed to get?
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby Brian » Tue Feb 15, 2011 5:16 pm

You get "belt K060798".....which is 13/16 x 80 3/8 OC........or 20mm x 2040 mm OC

Now that I have said that, I wonder if all your pulley sizes are the same on Canadian models as they are on the models we have here? I seem to recall that this was an issue with the Cosworth install on cars in Europe. Thus, before you buy the belt you might want to get further into your install and then measure and double check the length is what you actually need up there. Take a string and wrap it around the path to double check the length, then measure the string, etc.
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby v67gsr » Sat Feb 19, 2011 10:10 am

Morning Brian.

I have couple questions about the installation.

1) I am quite lost with the "Tree" adapter. IMO, we don't really need that. The header hard line can connect directly to T stat housing upper exit. Then the throttle coolant tube can also route directly from engine head to throttle body. The "tree" adapter seem like am "extra" piece of unnecessary parts in the whole coolant network. Did you use that "tree"?

2) I have problem with the hoses came with the kit. Especially when dealing with the connections to the front mount inter-cooler. The hoses are too big. Seem to me it will not seal even with hose clamp. How did you deal with that?

Those are my problem so far. Next stage will be dropping the supercharger in place. Hopefully everything will be nice and smooth.

Thanks for any input.
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby v67gsr » Sat Feb 19, 2011 10:24 am

One more thing

The S/C unit is a lot heavier compare to stock manifold and runners. All that weight will hold and mount onto the engine head. I wonder if you have any kind of additional mount to form the S/C to the block for extra support?

Thanks
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby Brian » Sat Feb 19, 2011 11:16 am

Very right on that silly tree thing....we didn't use it.

I don't recall issue with the hose diameter to intercooler.

Didn't make any extra support brackets and racing it since 2008 we have not had issues.
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby v67gsr » Sun Feb 20, 2011 3:39 pm

Thx Brian

The installation was not as smooth as we would like. That tree thing wasted us quite a bit of time.

We spend a lot of time finding the best routing location for all tubes under the compressor. On top of that, we need to but a new smaller diameter hose (much more flexible) to work with the smaller than expect inter-cooler coupling, and we also have to machine 4 hose couplings reducer to work with the new hoses. Overall, installation was easy. Car fire up nicely and not problem spotted for the 15 minutes of idle and 5 minutes of driving in the parking lot. I will do some data logging tomorrow for further diagnostic.

Once again, thanks for all your input..
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Re: Removing AC From Cosworth Supercharged NC, Alternator to

Postby Brian » Sun Feb 20, 2011 5:27 pm

Congrats on the install. Very satisfying when it is all in the car starts!
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