an ISO 900:2008 Registered Company 967-68 Mercury Cougar Condenser Kit with Drier (0067) 8865 Goll St. San Antonio, TX 78266 Phone: 20-654-77 Fax: 20-654-33 90332 REV A /7/4, PG OF 3
Table of Contents Thank you for purchasing this condenser kit from Vintage Air. When installing these components as part of a complete SureFit system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel. Cover... Table of Contents... 2 Packing List/Parts Disclaimer... 3 Core Support Measurements... 4 Engine Compartment Disassembly, Drier Bracket Installation... 5 Condenser Mounting Bracket Installation, Drier Installation... 6 Lubricating O-rings, Hardline Installation... 7 Condenser Assembly... 8 Core Support Modification... 9 Condenser Assembly and Fan Shroud Installation... 0 Hardline Installation (Cont.), Binary Switch Installation and Final Steps... Core Support Modification Template... 2 Packing List... 3 2 90332 REV A /7/4, PG 2 OF 3
No.. 2. 3. 4. 5. 6. 7. 8. 9. 0.. 2. 3. 4. 5. 6. 7. 8. 9. 20. 2. 22. 23. Qty. 2 2 2 3 2 5 4 4 Part No. 03765-VUC 0732-VUC 073-VUB 65998-VUB 642073 642070 642069 08085 0864-PFL 08086 8260-VUB 8249-VUB 33857-VUF 33858-VUF 8247-VUB 079-VUS 2335-VUW 3334-VUI 8287-VUB 825-VUB 852-VUB 8287 8978-VUB Packing List: Condenser Kit (0067) 967-68 Mercury Cougar Description Condenser, 4 x 20, Parallel Flow Drier Drier Clamp Bracket, Universal Drier, 4 ¾ Bracket, Hardline Support Bracket, Condenser, Driver Side Bracket, Condenser, Passenger Side Hardline, #6 Drier/Core Hardline, #6 Drier/Condenser Hardline, #8 Condenser Nut with Star Washer, 0-24 Screw, 0-24 x 3/8, Pan Head O-ring, #6 O-ring, #8 Screw, #0 x /2, Sheet Metal Binary Switch, Male Compressor Lead Grommet, 2-Hole, 3/8 x /2 Bolt, /4-20 x /2, Hex Washer,.32 ID x.750 OD, Flat Nut with Star Washer, /4-20 Bolt, /4-20 x 3/4, Hex U-nut, /4-20 ** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 5 days. After 5 days, Vintage Air will not be responsible for missing or damaged items. 3 4 6 7 2 5 0 9 2 3 4 5 6 8 7 8 9 20 2 22 23 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 3 90332 REV A /7/4, PG 3 OF 3
Core Support Measurements This kit was developed based on the measurements below, which were taken from a 968 Ford Mustang with Factory Air core support. 24 2 ½ 2 ½ ½ Passenger Side Driver Side 4 90332 REV A /7/4, PG 4 OF 3
Engine Compartment Disassembly NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams. Perform the Following:. Disconnect battery. 2. Drain radiator. 3. Remove radiator (retain). 4. Remove OEM fan and fan shroud (retain).. Drier Bracket Installation Install the drier mounting bracket onto the condenser using (4) 0-24 x 3/8 pan head screws and (4) 0-24 nuts with star washers (See Figure, below). NOTE: Brackets mount through the st and 3rd holes in the condenser. (4) 0-24 Nuts with Star Washers Front View #8 Fitting Drier Bracket 65998-VUB Figure #6 Fitting (4) 0-24 x 3/8 Pan Head Screws 5 90332 REV A /7/4, PG 5 OF 3
Condenser Mounting Bracket Installation. Install the condenser mounting brackets onto the condenser using (8) 0-24 x 3/8 pan head screws and (8) 0-24 nuts with star washers (See Figure 2, below). NOTE: Brackets mount through the st and 2nd holes on the condenser. (8) 0-24 Nuts with Star Washers #8 Fitting Driver Side Condenser Bracket 642070 Rear View Passenger Side Condenser Bracket 642069 #6 Fitting Figure 2 (8) 0-24 x 3/8 Pan Head Screws Drier Installation. Install the drier clamps onto the drier as shown in Figure 3, below. 2. Using (2) #0 x /2 sheet metal screws, install the drier onto the drier mounting bracket in the 6th and 7th holes from the bottom of the bracket as shown in Figure 3, below. NOTE: Refrigerant flow though drier is IN from condenser, OUT to evaporator. 7th Hole 6th Hole Figure 3 Flow (2) #0 x /2 Sheet Metal Screws (2) Drier Clamps 6 90332 REV A /7/4, PG 6 OF 3
Lubricating O-rings #6 O-ring O-ring Male Insert Female Nut For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil. Figure 4 O-ring Figure ## #8 O-ring #0 O-ring Supplied Oil for O-rings NOTE: Standard torque specifications: #6: to 3 ft-lb. #8: 5 to 20 ft-lb. #0: 2 to 27 ft-lb. O-ring Installs Over Male Insert to Swaged Lip Hold With This Wrench Twist With This Wrench Hardline Installation. Lubricate (2) #6 O-rings as shown Figure 4, above, and install the #6 drier/condenser hardline as shown in Figure 5, below. Tighten fittings as shown in Figure 4, above. #6 O-ring #6 Drier/Condenser Hardline 0864-PFL Flow Figure 5 #6 O-ring 7 90332 REV A /7/4, PG 7 OF 3
. Compare your condenser assembly to the images below. Condenser Assembly Passenger Side Condenser Bracket 642069 st & 3rd Holes Driver Side Condenser Bracket 642070 Front View In #6 Drier/Condenser Hardline 0864-PFL Drier Clamp Flow Drier Drier Mounting Bracket 65998-VUB st & 3rd Holes 2 ½ st & 2nd Holes st & 2nd Holes Rear View 2 ½ st & 2nd Holes st & 2nd Holes 4 x 20 Condenser 8 90332 REV A /7/4, PG 8 OF 3
BACKSIDE OF CORE SUPPORT DRILL /4 HOLE SAW WITH AC OEM OPENING EDGE OF CORE SUPPORT OEM HOLE DRILL /4 HOLE SAW WITHOUT AC Core Support Modification With A/C:. Using the template provided on Page 2, drill a /4 hole (See Figure 6a, below). 2. Install the hardline support bracket on the back side of the core support using a /4-20 x /2 bolt, flat washer and /4-20 nut with star washer as shown in Figure 6b, below. 3. Install the 2-hole grommet onto the hardline support bracket as shown in Figure 6b, below. Without A/C: Option :. Weld the knock-out plate to the core support as shown in Figure 7a, below. 2. Using the template provided on Page 2, drill a ¼ hole in the core support. 3. Install the 2-hole grommet in the hole as shown in Figure 7b, below. Option 2:. Knock out the plate on the core support (See Figure 7a, below). 2. Using the template provided on Page 2, drill a /4 hole. Install hardline support bracket on the back side of the core support using a /4-20 x /2 bolt, flat washer and /4-20 nut with star washer. 3. Install the 2-hole grommet onto the hardline support bracket as shown in Figure 6b, below. Hardline Support Bracket 2-Hole Grommet With A/C Template View From Front of Core Support Figure 6b View From Engine Compartment Passenger Side Figure 6 Driver Side Figure 6a Without A/C Knock-out Plate View From Front of Core Support Figure 7a Passenger Side Figure 7 Driver Side 9 Figure 7b 90332 REV A /7/4, PG 9 OF 3
Condenser Assembly and Fan Shroud Installation. Install (4) /4-20 U-nuts on the core support as shown in Figure 8, below. 2. Install condenser assembly between the radiator and the core support as shown in Figure 8, below. 3. Secure the condenser assembly to the core support using (4) /4-20 x 3/4 hex bolts and (4) flat washers as shown in Figure 9, below. 4. Reinstall the fan shroud and radiator using the OEM hardware as shown in Figure 9, below. Condenser Assembly Core Support (4) /4-20 U-nuts Figure 8 Core Support Radiator Fan Shroud Condenser Assembly (4) Flat Washers OEM Bolts (4) /4-20 x 3/4 Hex Bolts Figure 9 0 90332 REV A /7/4, PG 0 OF 3
. Hardline Installation (Cont.) Lubricate a #6 and #8 O-ring as shown in Figure 4, Page 7. Install the #6 drier/core hardline and the #8 condenser hardline as shown in Figure 0, below. Tighten fittings as shown in Figure 4, Page 7. #8 O-ring #8 Condenser Hardline 08086 Grille 2-Hole Grommet Figure 0 #6 O-ring #6 Drier/Core Hardline 08085 Binary Switch Installation and Final Steps. Install the binary switch onto the drier as shown in Figure, below. 2. Reinstall and/or reconnect all remaining items removed or disconnected in Steps -4 of the Engine Compartment Disassembly instructions on Page 5. This concludes the condenser kit portion of your installation. Binary Switch Figure 90332 REV A /7/4, PG OF 3
Core Support Modification Template Cut along the dotted line Center Punch & Drill ¼ Hole (Without A/C) OEM Opening Back Side of Core Support Edge of Core Support Center Punch & Drill /4 Hole OEM Hole (With A/C) NOTE: Due to printing variances, measure the line below before using this template. If template is scaled properly, the line should measure 6 inches. 2 90332 REV A /7/4, PG 2 OF 3
No.. 2. 3. 4. 5. 6. 7. 8. 9. 0.. 2. 3. 4. 5. 6. 7. 8. 9. 20. 2. 22. 23. Qty. 2 2 2 3 2 5 4 4 Part No. 03765-VUC 0732-VUC 073-VUB 65998-VUB 642073 642070 642069 08085 0864-PFL 08086 8260-VUB 8249-VUB 33857-VUF 33858-VUF 8247-VUB 079-VUS 2335-VUW 3334-VUI 8287-VUB 825-VUB 852-VUB 8287 8978-VUB Packing List: Condenser Kit (0067) 967-68 Mercury Cougar Description Condenser, 4 x 20, Parallel Flow Drier Drier Clamp Bracket, Universal Drier, 4 ¾ Bracket, Hardline Support Bracket, Condenser, Driver Side Bracket, Condenser, Passenger Side Hardline, #6 Drier/Core Hardline, #6 Drier/Condenser Hardline, #8 Condenser Nut with Star Washer, 0-24 Screw, 0-24 x 3/8, Pan Head O-ring, #6 O-ring, #8 Screw, #0 x /2, Sheet Metal Binary Switch, Male Compressor Lead Grommet, 2-Hole, 3/8 x /2 Bolt, /4-20 x /2, Hex Washer,.32 ID x.750 OD, Flat Nut with Star Washer, /4-20 Bolt, /4-20 x 3/4, Hex U-nut, /4-20 Checked By: Packed By: Date: 3 4 6 7 2 5 0 9 2 3 4 5 6 8 7 8 9 20 2 22 23 3 90332 REV A /7/4, PG 3 OF 3