hi all,

first - not sure if this is in the right section, so please move if not.

okay, i recently broke one of my 6n polo, this had AC so i removed absolutely everything for that. i want to put this into my current 6n, which has the basic heater blower (no recirc) wiring and plumbing isnt an issue as its all swap over.

BUT my issue is there isnt an opening for the ac pipes to go throught the bulkhead. on the old car there is a rectangle opening and two bolt holes. does anyone know if these are marked out from the inside? as ther are no marking on the engine side.

failing all that, how hard is it to get that black panel off? i am thinking chop a section out, then lay that over the current one in the car, mark it out and cut?

i know its a major job, but I'm not the type of person to back down once its in my head :)

thanks

hey dixy, i am your man.

I did that with original VW aftermarket AC on four or five 6N1 polos.

I have got an VW instruction for that, also for drilling that hole for the pipes.

Including a drilling pattern..... haha but all for a lhd polo, dunno if it is absolutely the same on the other side in your rhd polo.

Are you coming to the poloshow? or do i have to scan everything for you?

cheers

Christian

damn, i thought my stuff was clean

that's awesome Christian, i didn't know VW made a kit. makes me feel better that I'm not the only one doing it then.

i doubt i will be able to make it to the polo show, but there is a chance :) if you could scan a few pages out of it then i will be your freind :) lol. i would imagine the LHD is a mrirror image in this respect. a pattern would be very helpful. was there a reference mark somewhere on the panel? i could really do without having extra holes :)

any help would be awesome.

- also, i notice that your kit above has a different power steering pump, is this necessary? i have it and the pipes etc, i was just going to leave the one thats on there.

thanks again

Look here,

http://vwpolo6n.de/familienpolos/meinzweiter/klima.htm

that's my daily polo which my sister bought new in 06/1997 (17years old now) and sold it to me in 2008.

I did that AC (VW aftermarket) mounting in 2008 as one of the first things.

The pictures before from my black 1996 polo only shows the parts and not the conversion.

I did that in 2003 when vw sold out all AC Kits for really small money. Damned cheap when you think what parts are brandnew and OEM in that kit.
Thats the reason they look that clean, they are brandnew VW Parts, thats all.

More later, i am sorting out some more pics from another conversion/mounting.

VW sold them cos in the instruction (for the VW garage craftsman) they have calculated 8,7 hours.

Mission impossible in that time, and also it was too expensive for such a small car like the polo. So they sold out all kits.

It came in one big package with the measurement of an euro-pallet (800cmx120cm) and 70cm hight.

I took a few and later i have sold them on ebay for much more money, and one i have sold to somebody from the same city where i live, and i mounted the complete AC kit for him. These pics i am still sorting out.
So i mounted quite a couple of these kits.

And i always could keep the not longer needed parts like the powersteeringpump with holder, the watercoolers with the whole frontend and fan and all other parts.

The kits were contenting everything, and i mean EVERYTHING.

From the complete new frontend with bigger watercooler and the 2 speed-fan (1st speed is always on when AC is on!!!), kompressor, all tubes and screws, new airsystem with different fan, deviceholder with new powersteering-pump and so on.....

Even the sticker for the frontend to using just R134a / 700g, the instructiuon manual, three different gloveboxes, the fusebox for the battery in case of having none, two, yes, two different tubes/pipes from the powersteeringpump to the powersteering, cos on the brandnew holder is already mounted a brandnew and different powersteering-pump (cos the alternator gets higher and the (different) pump lower to get space for the compressor) which has different connections....

and for the smaller engines these tube/pipe has got a pressureswitch so that the engine knows when to rev higher when steering while the car is still standing. So with a 1.0 liters engine you take the tube/pipe with that pressureswitch and you throw away or sell the other one. With the 1.4 or 1.6 8V you take the tube/pipe without that pressureswitch and throw the other away or sell it.

Also three different gloveboxes.... they are for the different versions of dashboards... now with less depth.
Man, even a special Paper for the servicebook to complete it with all informations about the "aftermarket"-OEM-AC was in that AC kit.

It also included everything for air circulation, the 2nd switch/button beside the AC switch/button.

That vacuumcontainer with all tubes to cut them yourself as shown in the instruction, the electric valve to close the fresh air hole under the pollenfilter, which you switch via pushing the 2nd switch/button, than valve switches the vacuum to the freshair-flap and closes it. the vacuumcontainer keeps enough vacuum for doing that two more times after switching off the engine.

Also the back-pressure valve to cut off the system from the vacuumsystem of the engine.

It all was for mounting an AC as OEM as possible.

All parts were original and brandnew.
The tubes/wires were closed with plasticplugs to protect them against dirt.

The compressor was closed with a metalplate and already had the right amount of aircondition-oil inside so that the garage which fills the AC just had to fill in the R134a and thats all.

i just organised some ml of aircondition-oil before, so while mounting everything i coated all rubber-O-rings between the AC Pipes with that oil, thats much better instead of mounting them dry.
Even the controlunit for the temperature, the fanspeed and outletchoice was in that lit, cos the version with the AC Switch is damned different to the normal one.

That was brilliant from VW. Some things were unbelievable, but thats what makes THE OEM thought.

I guess what i write here i will also set online in my blog to keep that in my mind.

For the 1st AC in my black polo, a garage filled the 700g R134a into the AC while the engine was running of course..... the freshairfan was on speed 2 and while he was filling up the AC system it started to freeze inside the polo.... god what a nice feeling. Thats costs money.

When i mounted the AC into my blue polo back in 2008, a week later i helped a polofriend mounting his OEM VW AC KIT into his 98 Polo.

His brother was aircondition technician... for buildings and not for cars.

But he had a big bottle of R134a coolant.

With a scale instrument for weighing he new how much was in the bottle.....

With that bottle, without pressure (but running engine) he filled up my AC. He hold the bottle upside down high above the engine and it was floating/sucked into the AC system.... two weightchecks later the AC was filled completely for nothing..... for free..... the same he did on his brothers polo and we were both lucky with our cool polos from that moment on.

back to topic:

The wireloom is special made for the aftermarket AC.

It has got its own complete current flow diagram, and that diagram is according to the original current flow diagram from the polo 98-> with AC from factory on. It is just a single wireloom and the way for that loom is a bit different, that is the only difference you can see campared to an AC from factory on.

So i hope dixy that the donationcar has got the same centralelectrictype as your current polo?

Cos the aftermarket wireloom fits to all polos from 94-99, whithout that wireloom you have to take the whole enginebaywireloom from the centralelectricbox to the enginebay from the donationcars into the current car. So from a polo from 96 you cannot take the loom into a 98 modell.... thats the heaviest thing in your situation i guess.

Cos when you have got everything else.... the most people do not differentiate between the two different types of power supply systems in the mk4.

There are two different ones which are not compatibel.

in worst case you have to get the enginebaywireloom from the scrapyard from a polo from the right year.

More pictures will follow, i will sort out more pics and i guess i will make that OEM-VW-AC-KIT-THING a part of my poloblog..... cos even in germany nobody knows that like you didn't, and the people who knows that don't drive a polo any longer....

and btw, there has to be one more hole for the wateroutlet... the water the AC sucks out of the moist incoming fresh air.

It works all perfect with a current 70A alternator and "small" 45Ah Battery, but with AC from factory on, you got a bigger 61Ah battery and the 90A alternator. The reason is the always in 1st speed running (while AC is on) fan behind the watercooler which needs a lot of power...

To get a bigger battery is a suggestion in the manual, to mention that is also a nice detail.

And haha even for that bigger battery there is an head/coldness isolation for the 61Ah battery in the kit.
Damned, VW was thinking about all damned single parts.

another thing.... the 2 speed-fan behind the watercooler is a 4 point mounted fan.

That fan came from factory with automatic gearbox and fits also with manual gearbox, the normal 3 point mounted fan doesn't fit with automatic gearbox.... so that Kit fits in Automatic gearboxed polos.

Or the new screws to mount the holder for the alternator/kompressor/powersteeringpump on the engineblock, they were all twice. four long screws for the steel engineblocks and four shorter screws for the aluminium engine blocks (or inverse).

did i mentioned that vw damned thought about everything?

If not, They did.

And to answer your questions,

i can only talk about LHD Polos.... i dunno how it is solved in your RHD polos.

So i assume that you also have to take the other power-steering pump with the wire/pipe to the power-steering.

The reason is that the holder has to hold 3 deviced now.... the alternator gehts higher and the power-steering pump lower.... so i hope you took really EVERYTHING from your old polo?

And yes there are parking .... the markings are bolts and holes in the bulkhead.

What do you mean with getting that black panel off? What do you mean with black panel?

come back to you soon, enough text for now.

cheers

Christian

Edited 13 June, 201412 yr by Christian6N

The car from the guy i sold one kit to and mounted it for him....
Just a part of mounting the whole kit, i didn't made pictures from some other parts like the electric stuff and the vacuumstuff for the air circulation system.
So dixy watch the connectors of the powersteering-pump, and where it is mounted now.....





































to be continued...

Edited 13 June, 201412 yr by Christian6N

2nd part:





































That all for tonight, thank you and good night.


cheers

Christian

Edited 13 June, 201412 yr by Christian6N

:D :D

thats awesome chrisitan, you definably know your stuff!

i wish i had known about thos kits at the time, id love to have done it that way. i love taking new things out of boxes

alot of good information there especially about that drainage hole, i didnt even notice that. the black panel i am talking about is the bulkhead panel that you drilled into. to me it looks like its glued on, so i thought maybe i can remove that and use it as a template?but maybe that's unnecessary.

i have literally everything from the car, i dont like throwing anything away .

the car was a 97 1.6 gl so it has the old electric system, so i will have to adapt it. i have a few looms here so i should be able to do it. but i could also throw the engine in there too and just swap everything else over?

on the old car, it has a vaccum hose coming from the brake servo pipe, and went into a cannister in the wheel arch. was this something to do with the AC? i cant figure that out.

also, my plan was to integrate a 6n2 climatronic panel into the 6n, from what i can see the system is very similar, but i would need the 6n2 heater box wiring and actuators because its all electric. i have already made a facsia to use it in the 6n, so i just have to figure out how to fit everything.

i know understand about the power steering pump, the normal one will not work because the top hose is in the way. i also have the 90A alternator and a bigger 040? battery. didn't know the reason for this, but now its clear

thanks for the help christian, i appreciate it

Edited 13 June, 201412 yr by dixy

The instruction.... sorry about that signs in the pics... but they must be.

i will see if i can find the pattern in the original instruction in my cellar.
Cos i already had the instruction scanned on my hdd.
This instruction also answers your questions about that vacuum-parts.

cheers

Christian

it most certainly does... that's awesome

thank you

Anyway, come to the poloshow next week.

cheers

Christian

Pretty inspiring stuff, I would love to put AC in my 6N though sadly I'm not even close to having the skills to pay them particular bills. I'm more at the screwing a door handle back on and being hugely proud of myself

I guess we all need to start somewhere but just out of curiosity, where would one buy an AC kit that would fit a 6N and where would you find a control panel with the A/C / Air flow buttons?

Edited 21 August, 201412 yr by michaeldc

I very much doubt if you would find that kit on any UK dealers parts shelf, you would have to find a 6N in a scrappy that has A/C and remove all the bits inc the control panel

Ouch all the pics are offline....

I have all in my blog, watch

http://www.vwpolo6n.de/christian/2014/07/23/original-nachruestklimaanlage-vw-polo-6n1-und-6n2lupo/

cheers

Christian

Hi there

 

Pretty late to the party - but here goes...

 

Finding the aftermarket parts for an AC for a 6n2 seems easy enough, but also quite expensive.

Couldn't you simply scrap one off an old Passat, Fabia or similar? - they seem very similar, the gauge and knobs on the dash at least.

Anyway. I hope someone has some answers, as this summer's turning into quite the southeuropean experience, and i'd rather not buy a bulky USB plug-in AC.

 

Cheers

 

Mickel