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Fitting Air Conditioning to an ABL

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15K views 30 replies 8 participants last post by  dalejg  
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#1 · (Edited)
So, last year when using our T4 camper I suffered heatstroke whilst driving and was rather sick by the roadside. I swore to investigate fitting aircon to the 1.9TD ABL engine.

A bit of investigation revealed that the ABL has an aircon compressor bracket that is the same as the Golf Mk3 AHU 1Z engine bracket: 028903139T

It was fitted to the 1996 ABL engine:
182968



ABL and AHU share the same outer block so it fits using the 4-bolt bracket like this:

--><!--

Fuel, exhaust, cooling A/c compressor connecting and mounting parts for compressor 4-cylinder: AAM,ABF,ACC, ADY,AEP,AEK, ADZ,AFT,AGG, diesel eng.: AAZ,1Z,AFN for 1996 Volkswagen Golf Europe market
www.oemepc.com www.oemepc.com


Clearly this will be a long project but i've done airconm work in the past on various other cars and have gauges, refrigerant, vacuum pump etc etc.

I'm only going for the simple system, not climatronic and i'm happy to fit an aftermarket evaporator inside the cab.

I'm really keen to hear other peoples experience especially the TDI 1Z conversion team who may have done this in the past.


:):):)
 
#3 ·
I hope your van is not lowered, the compressor (or bracket) will grind away nicely against tarmac 🤪

the one issue that stoped my intrest in t4 / 1.9 engine aircon was the position of the ac 'pump' as the factory bracket positions it low and t4 engines lean foreward:(

Rich.
 
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#7 ·
Wow, so 11 months passed and I am finally progresing this. The new bracket bolted up perfectly and the compresser bolted to that too. My ABL alternator wouldn't fit as it has the slider type mounting hole so i've bought a new alternator to suit. I've got a 6pk1500 ish belt to go on an i've replaced the tensioner pulley too. Most of the Golf aircon pipes didnt fit at all so i've bought a set of early T4 parts including the condnensor, hoses and drier.

The condensor I bought was from a long-nose T4 and is a bit too big to fit without moving the PAS cooler pipe.

For the interior i've bought a universal evaporator system as it came with its own expansion valve, fans and wiring. Its pretty similar to this one:
www.carbuilder.com

Universal Air Conditioning Unit 360mm

If you already have a heater and you just want to install Air Conditioning in you car, here's a compact yet powerful underdash package. Size 360mm x 290mm x 150mm - Straightforward installation with our detailed instructions. Cooling capacity 10,800 BTU. Maximum air flow 200 cfm. Universal kit...
www.carbuilder.com www.carbuilder.com

fingers crossed all the other parts arrive and i can start bolting it together next week.
 
#8 ·
chiron77 said:
The condensor I bought was from a long-nose T4 and is a bit too big to fit without moving the PAS cooler pipe.
Click to expand...
delete the pas cooler, run / reroute straight from the rack to reservoir as the cooler is not needed in UK weather (y)

not had it on my van for ~8 years:cool:

Rich.
 
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#11 ·
So i'm having a very bad day.

In the post arrived my new alternator, and a 1994 condensor, stack of hoses and a drier. Brilliant! I'll have this fitted and running by lunchtime.....


Nope. The serpentine belt has no viable route around the water pump compressor, alternator and new tensioner.

Image


its clear the tensioner is meant to run on the back of the belt to take up the slack between the crank pulley and the alternator. Problem is that the water pump is then not in line between the crank and compressor so won't get turned.
 

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#21 ·
chiron77 said:
So i'm having a very bad day.

In the post arrived my new alternator, and a 1994 condensor, stack of hoses and a drier. Brilliant! I'll have this fitted and running by lunchtime.....


Nope. The serpentine belt has no viable route around the water pump compressor, alternator and new tensioner.

Image


its clear the tensioner is meant to run on the back of the belt to take up the slack between the crank pulley and the alternator. Problem is that the water pump is then not in line between the crank and compressor so won't get turned.
Click to expand...
Hello I have a request .Could you share new alternator number ( from picture above) .
I will be grateful
 
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#12 ·
I'm wondering if the bracket I bought was just totally incompatible for this application.
My bracket is an 037903143C from a petrol Golf Mk3. What I think I should have bought is a 028903139T but i'm struggling to see any difference between them.

Meanwhile the condensor and piping has gone in.
195495
 
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#15 ·
#19 ·
correct BUT this might conflict with the t4's pas pump crank drive pulley & it's distance from the multi-vee alternator / ac belt may not be compatable :unsure:

I've got a few spare car ac type crank / waterpump pulleys in the garage (in my vag stash!) will have a dig later & compare(y)

Rich.
 
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#20 ·
Here is a picture of the problem I have; the red bungee represents the belt with the Golf mk3 tdi bracket. The waterpump isnt contacted by the belt at all. Its about a 3 mm gap.
195603


The Golf Mk3 solution is to fit the V-belt pulley to the waterpump and drive it, and the power-steering pump) off the V-pulley on the crank like this:

195604

I've located and bought a V-pulley for the waterpump p/n 037121031A
Not sure when i'll have a chance to fit it yet.


So i've also found a potential alternative: On tdiclub.com somebody has modified the existing bracket, removing the sprung tentioner and boss and adding a mount with a timing belt tensioner like this:

1Z/AHU Power Steering Delete With AC, How To Drive Water Pump?

I am doing a TDI conversion and will have to delete the power steering pump due to clearance issues, but I plan on using the factory AC compressor and was curious if it was possible to run this set up? The water pump and p/s pump run off of the V-belt, while the AC compressor, alternator...
forums.tdiclub.com forums.tdiclub.com
195605
 
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#24 ·
Well, a other year passes and I made another attempt at fitting the compressor and alternator. This time I bought a V-belt pulley for the waterpump. The plan was to run the waterpump with the V belt for the power steering.

However, it didn't work as the pulley I bought didn't line up with the PS pulley.


So I think the only way to do this is like in the link above - cut off the golf mk3 spring tensioner and fabricate a mount for an eccentric tensioner. I've bought a smaller smooth pulley for the water pump.
 
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#29 ·
Parking this here for next attempt:

1Z/AHU Power Steering Delete With AC, How To Drive Water Pump?

I am doing a TDI conversion and will have to delete the power steering pump due to clearance issues, but I plan on using the factory AC compressor and was curious if it was possible to run this set up? The water pump and p/s pump run off of the V-belt, while the AC compressor, alternator...
forums.tdiclub.com forums.tdiclub.com


I may also look at a smaller clutch pulley for the compressor to, that might allow the belt to contact the underside of the waterpump pulley without needing an additional tensioner to pull the belt up between the pump and compressor.
 
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