LT 2.4 Petrol engine to 2.5 TDI conversion |
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mat_the_cat
Vanorak Joined: 06 May 09 Location: North Wales Status: Offline Points: 1862 |
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Is there no end to your talents? Mechanics, electronics, what next?!
Tachos are pretty rare over here, out of all the LTs I've seen I've never seen one with a tacho fitted. Mine has one now but I had to buy it new from VW as I couldn't find a second hand one! |
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Mid engined, 6 cylinder, turbocharged 2 seater - it can only be a VW LT!
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Testing the tacho:
one of the lifters is noisy, which disappeared later
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Hi All,
I worked on the tachometer here are the details. This LT didn't have a tachometer (rev-counter) before. The owner purchased a tacho from a Diesel LT, the diesel tacho uses the signal from the W terminal of the alternator, however in a TDI car the tacho receives a signal from the ECU. To have the tacho working accurately I decided to use the signal from the ECU. I knew that connecting the tacho simply directly to this signal won't work as there are filters inside the tacho to eliminate the spikes of the signal from the alternator (or distributor). ECU provides a 12V square signal which is well within the limits of the SAK 215 chip used in the tacho. The filters lower the signal so the chip wont sense it so I removed the filters which is a capacitor and a resistor to ground and a series resistor to signal. (the blue circles I draw on the tacho circuit) Here are the pictures of the capacitor and the resistor removed and a jumper is made. I have tested the tacho, it was working but reading very low like 1/6 th. After examining the circuit, I noticed the capacitor (red circle in diagram) is 0.047 microfarad which is very lower than the one given in SAK 215 data sheet. Asking an electronics engineer friend, he advised to change it, I tried a 0,47 and saw that it reads high enough. the ECU provides the signal at 41,6Hz @ 1000 rpm so I have adjusted the tacho using the trim-pot in it with the help of the signal generator . It now reads accurate. |
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Rocky332
Newbie Joined: 14 Jun 11 Location: German Status: Offline Points: 4 |
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Hello, Once I have more time I set the pictures. greeting Bernd |
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mcbkat
Yardie Joined: 08 Sep 09 Location: Holland Status: Offline Points: 384 |
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Hallo LT-Freund .
Pictures please! (Bilder bitte!) Stefan |
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De Vries LT45 4X4, De Vries LT40 4x4
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Rocky332
Newbie Joined: 14 Jun 11 Location: German Status: Offline Points: 4 |
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Yes i can not so good speak English, better Gernan. I planned the project in November 2010 and it was started 8 weeks. But I have found this site 6 weeks already, thank you for your tips. 2 things I have done differently, I've installed the gas pedal completely. And the alternator has remained at the original location. I used a Volvo 2.5 TDI exhaust manifold. Since the turbo sits in the back. I send you, or you some pictures. Excuse my bad English, I work with the Google translator. With kind regards Bernd |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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wow, you are the first one I've seen who made the same conversion, great!
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Rocky332
Newbie Joined: 14 Jun 11 Location: German Status: Offline Points: 4 |
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Hello,
My LT: http://www.youtube.com/watch?v=s5CRkvxUyt0 Gruß Bernd aus Germany Edited by Rocky332 - 06 Jul 11 at 14:20 |
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Canada LT28
Vanorak Joined: 03 Jan 10 Location: Toronto Status: Offline Points: 1632 |
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I guess I will have to look for one with a locking diff. Any idea which years that would be and i suppose it could be from a gasser as I was told the ratio are similar or the same. If it wern't for the current gear ratios, which are suitable for city driving, I would stick with the stock tranny, put a generator on the alternator belt and be done with it.
I bought the engine without the wiring and I've shipped over a landy 200tdi pump so the Mtdi, with all its faults will have to do. |
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94 LT28 Doka 2.4D
Slow and built to stay that way 87 T3 soon to be a camper |
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mat_the_cat
Vanorak Joined: 06 May 09 Location: North Wales Status: Offline Points: 1862 |
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Without a locking centre diff though, the output will just take the easiest path - i.e. if it takes less effort to drive the generator then you'll just sit there spinning the generator and not moving forwards...
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Mid engined, 6 cylinder, turbocharged 2 seater - it can only be a VW LT!
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Canada LT28
Vanorak Joined: 03 Jan 10 Location: Toronto Status: Offline Points: 1632 |
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I had thought about doing a 4 wheel drive but i will have to look how to do the front end. Very tempting but I also want to make the plug in hybrid and the front (or rear) outlet might drive a generator.
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94 LT28 Doka 2.4D
Slow and built to stay that way 87 T3 soon to be a camper |
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Canada LT28
Vanorak Joined: 03 Jan 10 Location: Toronto Status: Offline Points: 1632 |
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If there is a V6 TDI it will be from a new Tourag and that will cost a mint. I've got the 1.9 so I will try to make it work. We haven't looked at the tranny options seriously yet as I am still sourcing one at a wrecker and I dont want to put a mortgage on the family dog to get it.
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94 LT28 Doka 2.4D
Slow and built to stay that way 87 T3 soon to be a camper |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Thank you very much! I think for the 1,9 there will be issues with the oil pan, I am not sure If you can follow the route I did as the bolt pattern of the 4cyl oil pan may differ from 5-6 cyl. If you use a LT tranny, an adapter plate would be necessary for sure, with a quattro tranny you wont need it, but how will you cancel the front wheel drive? Some automatic quattro trannies have a front drive shaft outside the tranny, this may be easier to cancel-remove but all quattro tranies have torsen middle differential, this has to be removed also. If you simply lock the front shaft this will probably kill the torsen diff easily. Some very early quattro tranies have an open middle diff with a locker but I guess these are hard to come by and these are for 5cyl engines. I really wonder what sort of solution you thought about this ? (may be: why cancel front wheel drive, make a 4wd LT with independent fron suspension ) For the m-tdi, I personally don't recommend it. I worked on some here before and we were never able to get the performance of the stock electronic TDI engine. I know there are pump specialist who can even get beyond the stock HP and torque figures but again I bet it will never be as smooth and silent like the original electronic engine. All that wiring and electronics are there for a good reason. Any chance you find a V6 TDI engine from a later A6, that will be an option and much more fun Edited by mechano - 21 Jun 11 at 20:05 |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Hi, I wanted to keep the original LT pedal. I have shortened the cable 44cm, as it was too long for the location I have chosen for potentiometer. First I tried not to shorten it and made a loop but the pedal was too heavy, but now it is light and precise. Did yo make a drive by wire conversion also?
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GT500
Groupie Joined: 02 Jul 09 Location: leeds Status: Offline Points: 145 |
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Why didn't you try the fly by wire throttle above the LTs pedal? It fits perfect and gets the stupid long cable away.
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Rob... The only LT on 18" wheels.
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Canada LT28
Vanorak Joined: 03 Jan 10 Location: Toronto Status: Offline Points: 1632 |
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You and Cyncl have a lot of patience and an eye for good work. I only wish i didn't have to spend so much time working so i could spend it on the truck.
How do you think the 1.9tdi will be harder than the 2.5? I will making it an Mtdi so the wiring won't be an issue. We are thinking about using an A4 quattro tranny instead of the the stock one but have not made a final decision yet. |
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94 LT28 Doka 2.4D
Slow and built to stay that way 87 T3 soon to be a camper |
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cnycl
Groupie Joined: 22 Dec 09 Location: Istanbul/Turkey Status: Offline Points: 118 |
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I think it can only be done better in Hannover by Volkswagen.
I'd like to say top work as usual but I know you did not spend so much time on detail in your own syncro tdi conversion. Meco's LT is one lucky LT.
Edited by cnycl - 16 Jun 11 at 21:24 |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Here is an overview of the current stage:
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Next was the accelerator pedal.
The TDI has the "drive by wire" system which is a potentiometer connected to accelerator pedal. To connect the accelerator cable to the potentiometer I pulled a M4 thread to the end of the cable: Than I used this chrome linkage part to connect the cable to the potentiometer's cable which I bought from a pneumatic shop: I decided to use the coil bracket of the LT to mount the potentiometer to the body. As the coil of the petrol engine wont be used any more this is possible. Also the location of the coil looks like a safe and dry place for the potentiometer. This is how the system looks like from the under side: Looking from engine bay upper side: Closer: |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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I worked on the intake and pressure hoses of the turbo.
The air-filter is very big on the LT, as this bus will not be used as a commercial vehicle any more, I decided to use an open type filter with the flow meter inside the filter housing. With a very simple steel bracket, it was possible to mount the flow meter inside the filter housing: I have routed the air from the flow-meter to the turbo intake via silicone-rubber hoses & steel adapter pipes.. Also the pressure route from the turbo to the intake is via rubber hoses & steel adapters as seen above. There is no intercooler at the moment, this will be later added by the owner of the LT after I finish the whole conversion.
Edited by mechano - 16 Jun 11 at 20:28 |
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