LT 2.4 Petrol engine to 2.5 TDI conversion |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Thanks! 1.9 can be harder by the way
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Canada LT28
Vanorak Joined: 03 Jan 10 Location: Toronto Status: Offline Points: 1632 |
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Very Cool Mechano,
Still not ready to put the 1.9tdi in the truck yet. We will see how it is different from the 2.5 |
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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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Hi All,
Here is what I did lately: The ALTERNATOR I was looking for a place to fit the alternator, as I said the original LT location and mount can not be used as the alternator would hit the turbo. However there is no other place possible, this photo shows how the engine looks when the hood is closed. upper right corner would be used by water hoses. So I decided to use the original location by moving the alternator forward. TDI engine is 9cm shorter than the 6cyl LT engine, so If I lengthen the original mount by 9cm the alternator would be placed where it was on the original LT engine. So I designed this part and have it machined on CNC mill: And have it welded to the original mount: To use the alternator at this location, the pulley must also be relocated, so I decided to make a spacer to go between the original LT pulley and the cooling fan which would also be the new pulley for the alternator, this way the cooling fan will be at the original LT location: I have designed that and have it machined on CNC lathe & mill So here is how it looks like when all mounted on the engine: This way the alternator easily clears the turbo and the fan sits in the shroud at its original location. If I didn't use the spacer pulley, it would be necessary to extend the shroud. Now I need to make a custom tensioner for the alternator, that will be something like this: |
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readie
Groupie Joined: 06 Sep 10 Location: winchester Status: Offline Points: 108 |
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Hi there - thanks for your reply..in the end I took the pipe off and back to pirtek who reconned it in the first place - they redid it perfectly doing all sorts of wierd and wonderful things with solder and joints - and I was able to get it back on no trouble..and leak-free which is great news!
Cheers Andy |
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1988 LT35 140K 2.4dt
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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possibly, I don't know. Eren
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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 don't know how the original 2.4TD is. The 2.5 TDI had a steel pipe from the turbo to the engine block not to the sump. As I have made a blocking plate on the engine block which also secures the engine mount (can be seen in earlier post, CAD drawing also photo) I had to route the oil return to the sump. I have cut the TDI steel pipe, which is mounted to the turbo with two M6 bolts. I bought suitable unions both for the steel pipe and the sump, and cut the rubber hose for the length I needed. The hose is a high pressure one actually, so I can have the ends pressed and get rid of the jubilees however I don't thing that would be necessary. Eren
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readie
Groupie Joined: 06 Sep 10 Location: winchester Status: Offline Points: 108 |
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Ah, I have just seen your pic of the other end of the oil return pipe, but it does not look like my 1988 2.4td!
With all the hassle I have had it did occur to me to have a decent rubber hose with jubilee clips like you have but I guess the important thing is the connections both ends. I can definitely do it the turbo end, but I need to think about joining it to the other (your first pic)..mmm
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1988 LT35 140K 2.4dt
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readie
Groupie Joined: 06 Sep 10 Location: winchester Status: Offline Points: 108 |
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Wow, this is exactly what my problem is! I had a leak coming from my original oil return pipe, and my mechanic had it reconditioned, but it now leaks from the union nearer the turbo side. It's a nightmare to even get to the nuts to tighten them, but I see you have just used a rubber hose with a jubilee! What's happening the other end..how did you secure it?
looking forward to hearing from you! andy
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1988 LT35 140K 2.4dt
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mcbkat
Yardie Joined: 08 Sep 09 Location: Holland Status: Offline Points: 384 |
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Is there a weight difference between 5 and 6 cylinder?
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De Vries LT45 4X4, De Vries LT40 4x4
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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Little update:
I just made the turbo oil return pipe, I also have the power steering hoses lengthened as the 5cyl engine is shorter..
Edited by mechano - 09 May 11 at 14:50 |
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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,
Here are the updates: 2 weeks ago with the help of Can (cnycl) we put the transmission back in. I had to modify the clutch cable because the clutch lever is 1 inch backwards now as the dimensions of the dual mass flywheel is different as I described before. So I have cut the original cable and I have put a beetle clutch cable into the LT cable sleeve. The beetle clutch cable is very long, I have cut it to the length I needed than I made a ball with a hole at the centre on the lathe and have it welded on the cable. The new ball on the clutch cable is placed 1 inch far. Last weekend I started working on the exhaust. I have drawn the exhaust flange for the turbo and have it laser cut, I bought some stainless steel bellows and a vibration absorption flex pipe. Cutting welding next .... After this, I have run the engine with the electronics laying around as seen in the video to hear the exhaust and test the clutch, all went OK and the sound of the 5cyl TDI is sweet
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mcbkat
Yardie Joined: 08 Sep 09 Location: Holland Status: Offline Points: 384 |
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Or make a 2.5 mTDI
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De Vries LT45 4X4, De Vries LT40 4x4
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mcbkat
Yardie Joined: 08 Sep 09 Location: Holland Status: Offline Points: 384 |
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Nice fit!
But with all that wiring, I'll stick with a 6 cylinder... Stefan |
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De Vries LT45 4X4, De Vries LT40 4x4
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stonio
Groupie Joined: 11 Apr 11 Location: Lancs Status: Offline Points: 49 |
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Amazing I am in awe I truly am, a 2.5tdi would be sweet unfortunately I have 0.1% of mechanical knowledge. I can do it I just don't know how to yet!
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LT31 2.4 Petrol 1984 Camper Conversion - My Obsession
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cnycl
Groupie Joined: 22 Dec 09 Location: Istanbul/Turkey Status: Offline Points: 118 |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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thanks! I have very limited time working on this project.. just made the oil feed pipe of the turbo Edited by mechano - 05 May 11 at 10:17 |
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vwjetta
Not Quite Newbie Joined: 09 Jun 10 Location: burton on trent Status: Offline Points: 37 |
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too much skills guys
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1965 Datsun spl 310
1967 MGB roadster 1979 Dodge Spacevan 1983 french filth LNA 1989 Volvo 760 GLE 1990 Volkswagen Jetta 1990 Nissan Bluebird 1990 Volkswagen LT35 1984 MZ TS125 |
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mechano
Not Quite Newbie Joined: 15 Jan 10 Location: Ankara / Turkey Status: Offline Points: 37 |
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here it is: |
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t'onion
Vanorak Joined: 12 May 05 Location: Sheffield Status: Offline Points: 1419 |
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also have you got a photo of the underside , mainly around the sump area when fitted to the van
Edited by t'onion - 01 Apr 11 at 15:24 |
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LT28 Westfalia FloRida, 2.4 diesel
miserable fooker |
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t'onion
Vanorak Joined: 12 May 05 Location: Sheffield Status: Offline Points: 1419 |
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so will you be making up kits for us all to buy or will this be a one off
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LT28 Westfalia FloRida, 2.4 diesel
miserable fooker |
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