Jonny Retrofit Posted January 15, 2024 Posted January 15, 2024 SAFETY FIRST Although the installation of the components can be safely undertaken on a DIY basis, when it comes to filling and commissioning of the system, it is essential to seek professional assistance. Air conditioning hoses run at high pressure and must be correctly crimped and pressure tested with the correct equipment. We recommend that the initial filling and commissioning of the system is carried out by a qualified air conditioning engineer. We absolutely DO NOT recommend that the system is filled from ‘cans’ of R134a. Step away from the ebay or Harbour Freight DIY fill kit and seek professional help.
classicretrofit Posted January 15, 2024 Posted January 15, 2024 ElectroCooler Kit The kit you have purchased contains the following parts: • Electric A/C compressor and control ECU. • Condenser, fan and shroud assembly. • Replacement blower unit, housing modern fan and evaporator. • Lightweight narrow wall hose set with custom fittings. • ECU wiring loom and sundries. We don’t provide: • 60mm / 40mm air ducting (we recommend genuine Webasto aluminium/paper hose) • Duct clips. A selection of 60mm and 40mm is advisable. We like the Porsche ones! • Rubber grommets (for routing hoses and wiring) • ‘Oetiker’ crimp pliers / pincers • Replacement washer bottle but we do have a kit available for the Boxster/996 bottle. Tools and sundries needed: • Good quality set of allen keys • Standard wrenches and socket set. • Side cutters • Small selection of male and female spade terminals (6.8mm) • Crimp tool for above • Selection of cable ties ( 300mm) for general use • Hose cutters (although a clean set of garden shears are excellent for this purpose) • Sharp knife (for cutting duct) Accessories: Check out the website for the latest accessories for your kit. Please note that 911s are METRIC. All our fastenings are METRIC. Please don’t use Imperial tools and fastenings on these cars or we will report you to the Porsche Gods.
classicretrofit Posted January 20, 2024 Posted January 20, 2024 Parts List If you think any of the parts are missing from your kit, please email us before you start installation. Large box: • Blower unit + accessories • 2 x 60mm T piece • 50mm duct x 500mm (to make footwell ‘snorkels’) • Hood Inlet restrictor gasket • 4m x A/C hose #6 • 4m x A/C hose #8 • A/C fittings pack • Receiver / Drier • Drier horseshoe bracket Small box: • Compressor • Compressor bracket kit • Battery cable and insulation • ECU • Main Harness (Grey connector) • Main Harness (Black connector) • Fan Relay Harness • Button Harness • Temperature Sensor Harness • USB setup/programming cable • Fuse holder with 80A fuse
classicretrofit Posted January 20, 2024 Posted January 20, 2024 Basic Requirements - Chassis The kit has been designed to fit 911s where there is space under the front left headlamp for the condenser. Early cars (pre 1969) have lots of space here. Later, ‘impact bumper’ cars (’74 to ’89) have a large washer bottle under the left fender which must be removed to accommodate the condenser. Cars with two batteries (1969 to 1973) have limited space under the left headlamp, so may either require removal of the left hand battery box or positioning of the condenser ahead or behind the rear wheel. Please note that the rear mounted configuration has not been tested by us and that brackets and a stone guard will have to be fabricated. We do hope to have an off-the-shelf solution for these cars in due course. Please see the Appendix for some pictures of rear fender installs. The following table shows compatibility: Year Model Alternator Other requirements 1965 – 1968 Short wheel base Update to high output unit. Provide holes in bulkhead for air ducts. Alternatively use ‘half kit’ with standard Porsche Smuggler’s box evaporator/blower (LHD only). 1969 – 1973 Long wheel base ‘Long hood’ Update to high output unit. Delete LH battery box or use alternative rear condenser placement. 1974 – 1983 ‘Short hood’ ‘impact bumper’ Update to high output unit. None. 1984 – 1989 Carrera 3.2. Update to high output unit for hotter climates. * Modification to inset foglight and valence bracket. See Appendix F
classicretrofit Posted January 20, 2024 Posted January 20, 2024 Preparation The installation is not difficult, but some areas of the car (e.g. around the blower) are cramped and awkward to work in. Take your time and be methodical. The install can be undertaken with common workshop tools. The only special tool required is the hose crimp tool. The hose crimps are ‘oetiker’ ear clamps. The tool required is readily available, cheap to buy and referred to as ‘Oetiker pliers or pincers’. Disconnect vehicle battery You will be connecting some fairly high current wires so please make sure the vehicle is electrically safe to work on. If the vehicle already has factory or dealer fitted air conditioning, these parts need to be removed prior to the fitment of the kit. This includes: · Remove the engine driven compressor and bracket. · Remove the front and rear condensers. · Remove all hoses and the drier. · Remove the evaporator unit from the ‘smuggler’s box’. · Removal of A/C specific hoses in under the scuttle area.
classicretrofit Posted January 21, 2024 Posted January 21, 2024 Pipework fitting identification The following graphic is to aid identification of the pipework fittings. The actual number of items, such as the blue plastic clip fitting guides, may vary in your kit.
classicretrofit Posted January 21, 2024 Posted January 21, 2024 Parts List: For RS stock numbers listed - please go to uk.rs-online.com Photo Description Mfr Part Number RS Stock Code PFL PCB Case Deutsch EEC-325X4B 724-2557 Contactor (optional): 12V Extra Heavy Duty Make/Break Relay - 120A Albright Engineers SW60-360P n/a DTM Series, 12 Way Plug Connector, with Crimp Termination. Grey Deutsch DTM0612SA 724-2576 DTM Series, 12 Way Plug Connector, with Crimp Termination. Black Deutsch DTM0612SB 724-2579 DTM Series Wedge Lock For Use With 12 Way Plug Deutsch WM12S 724-2573 0462 Crimp Contact, Female, Crimp, Nickel Plating 20 - 24 AWG Deutsch 0462-201-20141 425-822 Crimp Tool DT Series, HD10 Series, HD30 Series, HDP20 Series, 20 → 12 AWG Wire Size HDT-48-00 425-973 Uninsulated Tin Plated Tubular Ring Terminal, M5 Stud Size, 16 mm² RS Pro 122-5002 Uninsulated Tin Plated Tubular Ring Terminal, M6 Stud Size, 16 mm² RS Pro 531-043 100A Midi fuse holder Littelfuse 04980921GXM5
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