Technical Service Bulletin Installing Front A/C Condenser

To increase cooling capacity on all cars with factory air conditioner, front condenser may be installed.

Parts Required

Kit (Part No. 911.573.911.00)

Reference Part No. Quantity Description Reference Part No. Quantity Description

1 911.624.013.00 1 Blower 8a 911.573.056.00 1 Condenser

2 911.573.154.01 1 Hose 8b 911.573.058.00 1 Protective screen

3 911.573.515.00 1 Gasket Screen

4 900.075.071.02 2 Hex bolt 9 911.501.581.01 1 Blower panel

5 911.573.513.01 2 Spacer 10 911.612.080.01 1 Electrical

6 901.573.148.00 2 Gasket harness

7 911.573.055.00 1 Protective 11 911.615.109.01 1 Relay

bow

Reference Part No.* Quantity Description

12 ………….. 5 ½ ft 13/32” suction

13 ………….. 1 Splicer kit (hose connector and 2 clamps)

14 ………….. 1 Hose termination and clamp (to connect suction hose to . condenser)

15 ………….. 6 Cable clamps (for holding 13/32” suction hose in place)

………….. 41 oz. freon 12

Work sequence

Discharge air conditioning system
Open front hood
Remove spare tire and jack
Disconnect battery ground cable
Place small template between jack support and washer pump on front apron and mark area to be cut out
Cut out rectangular section using air chisel snips or nibbler

*Parts to be obtained locally

Note:

Remove all metal shavings and paint all cut edges after each cutting and drilling operation

Raise car on lift
Place large template in place between front crossmember and apron, and mark area to be cut out.
Cut out rectangular section using air chisel or suitable tool
Lower car
Install gasket in cutout in front apron
Place blower panel in position over cutout in floor of luggage area
Drill 1/8 in. pop-rivet mounting holes through panel and floor approximately 1½ in. apart around periphery
Lift out blower panel and place strip calk around mounting flange
Put blower panel in place and install 1/8” X ¼” pop rivets
Spray paint blower panel
Install blower suction flange A into previously installed gasket (use Silicone spray to assist in assembly)

Insert blower mount into blower panel and align openings. Drill 4 1/8” holes
Lift blower enough to place and install 4 sheet metal screws
Raise car on left
Hold condenser squarely over cut-out with hose connections to left (driver’s side)
Mark 3 mounting holes
Remove condenser and drill the three ¼ in. holes
Install condenser together with protective cover using two 6 X 20 mm machine screws, lock washers and nuts on passenger side and one sheet metal screw on driver’s side
Remove two front suspension arm mounting bolts and discard
Attach protective bow at these points with bolts, using spacers between now and suspension arm mount. Do not tighten bolts full at this time.
Remove left front wheel
Route hose and suction extension hose from fender well to front condenser.

Connect both hoses to front condenser using hose termination and clamp to connect extension hose. Use gasket on connector of hose.
Cut suction hose from rear condenser
Remove hose connector and discard
Attach connector on hose in place of discarded connector. Use gasket on connector.

Splice extension hose to cut suction hose from rear condenser, using connector and two clamps from splicer kit.
Splice extension hose to cut suction hose from rear condenser, using connector and two clamps from splicer kit.
Secure both hoses to fender well
Replace left front wheel
Locate and mark center mounting hole for protective bow from within luggage compartment as follows:

A = 15-13/16 in.

B = 1 in.

Drill 10 mm hole for M 8 X 20 hex head bolt
Place lock washer and flat washer on bolt and install in protective bow from inside luggage compartment. Tighten securely.
Securely tighten protective bow end mounting bolts from underneath. Torque to 2.5 mkg (18 ft lbs)
Remove fuse panel cover
Install socket of electrical harness from behind panel.
Install relay in socket
Run cable with white plastic connector and screw lug along existing cable harness toward front of car
Run other cable behind fuse panel
Fasten red/green wire with bare tinned end under screw on fuse S20
Find white wire connector joining heavy green wire to smaller diameter black wire and located toward left rear of luggage compartment. Pull connector apart to insert green wire from harness. One green lead from harness plugs into connector. Green lead removed from connector plugs into terminal on remaining free green wire of harness.
Secure electrical cable harness under fasteners
Connect together the white plastic connectors from cable harness and from blower
Fasten screw terminal lug from harness to common ground
Reconnect battery ground cable
Replace spare tire and jack
Recharge air conditioning system with 41 oz. of Freon

Note:

Electrical wiring is in accordance with 911 Workshop Manual Vol. VI, page 0.1- 3/39

Klassik ATS