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Karmann LT 75hp DW to 116hp 2,5TDI AAT Conversion

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Buss Marius View Drop Down
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    Posted: 31 Aug 18 at 13:00
Sinse July 1st of 2015 we have had a -87 Karmann LT L With the mighty 75hp 2,4 NA Diesel. It has worked but it is noisy and slow. we bought it in Tromsø so had a Nice 2000km drive home, taking us 10 days and 10 ferries. in 2016 we foloved the vest coast of S, DK, D, NL, B and France. then to CH and the vest coast of CH, Chamonix for 12 days and then North throug CH and D and from the South point of Sweden to Norway, a total of 6500km. Last year it was the Rhine and Moselle Valley. then Luxembourg, Belgium and NL, before heading home. a total of 4500km. This year we only did a little weekend trip to the west coast, and on the way back the clutch stoped working. The cable is OK so exatly what it is i dont know. We manage to drive it 350km home crossing 5 Valleys With a lot of zig-zag roads. We then desided to get a stronger engine, as the engine has to get out, both to change the cambelt and repair the clutch.
Yesterday i tok the plain from Oslo to Bergen and picked up my "New" Audi A6 C4 -94 model With a 116hp AAT engine. It is a bit sad to let such a good car become an engine donor, But the engine seems to be wery good. no oil consumtion to talk about it is dry and Nice. Compaired to the ACV engine in my T4 the Power is mutch more spread out over a wider rpm register, witch i think is better for the LT witch i think wil be running on a little high rpm.

I have some mecanical skils, but am not trained in anny way, so we wil se how this ends up. How ever i have changed the engine in my T4 so is not a total beginner.
I hawe already bought an exhaust manifold from an Volvo 850 TDI as it gives more room to instal the alternator.
But may bee the first thing i need to learn is how to post picktures.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Buss Marius View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 04 Sep 18 at 11:48
The AAT engine is out of the A6 4C donor. Not a to big jobb. But i stil have to take out the wiring. Do any one know where to get a Wiring diagram?
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LTCamper89 Quote  Post ReplyReply Direct Link To This Post Posted: 04 Sep 18 at 12:26
https://erwin.audi.com/erwin/showHome.do

If it works like the VW site, everything should be in there.
1989 LT28 2.4D    Saviour of 6Music, well one of them. Now playing http://www.bbc.co.uk/radio/player/bbc_6music

VW LT Camper not Cramper

....at least the roof is not rusting away....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ottoMan Quote  Post ReplyReply Direct Link To This Post Posted: 13 Oct 18 at 09:11
Hey Buss Marius, any news ? How's the conversion going ?
1980 Pop Top LT28 2.0 Petrol converted by Karroseriefabrik Voll von Wurzburg
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 19 at 12:14
The Conversion is moving at a very slow pace. I have the main part of the wiring harnes out. The problem of getting it out isn't just to get it out, but to get it out without cutting any cables you need. Stil the Imobiliser and some relays are in the donor. But it is/was moving slovely ahead. The snow and ice in our drive was gone 2 weeks ago so now it is time to work on cars, but it could stil be freezing in the mornings. I/we have 4 other cars. A -89 T3 Syncro poptop is a Project that is even slower moving, but from time to time some Things hapends. Diesel tank is out, and of cours tranny, belypan is out and i have to overhaul the Power steering and make the last 3 brake pipes. I had hoped to swap it With the LT that is in Storage 150km away, to get more work Space in the garage. The Prius is no problems, The Electric Miev had to get New brake pipes to get throu MOT, and that job is finished. I had to Rerout them around the batteries insted of abow the batteries. On Our T4 Caravelle TDI there are some problems With the rear brakes and that almost brought al projects to a dead stop, when i was under the car and it rolled of the blocks it was stading on and squiceed me lying under the car. After a trip to the local hospital i was transfered With an Ambulance to Norways biggest hospital in Oslo. After a night in Intencive care unit i am now in the Gastro curgical section where i have to stay until Sunday. Then i hope to get home. there are injuries to my spleen and kidney. However i have half way broken most of my ribs so i wil have problems with lifting for 5-6 weeks i think. In the meen time i have time to sort more of the Electric chalenges and do the last planing befor the engine is taken out of the LT.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 19 at 12:51
Among the questions i have for the Conversion is how much i have to get the RPM's Down to make it run at reasonable RPM's at cruising speed of 100 km/h
I am considering buying a Volvo M46 gearbox with 4+overdrive. It fits to the engine and it will lower the RPM's With 21%. I run 15 inch alu Wheels from a transit. The tyres are 3% bigger than original 185R 14C tyres. If i go up another 2% on the rear tyres i wil have redused RPM's With 25% With this combination, so i wil run at 3000 insted of 4000. Is that enough? i Don't have a Rew count meeter in the LT so i don't know what RPM,s i run it on. I Did a chech at the german LT-Wiki and it seems the biggest LT rear axle i could get will reduse my RPM's With 15%, However, just to find one that reduses the RPM's With 15% + is for a singel rear Wheel LT and preferably for a LT 28 or 31 non turbo is like the famous needle in the haystack. (I have weight isuses With this LT28 Coacbuildt also so want to save weight)
Volvo has the M46 gearbox and i think it is With a conection to a wiredriven speedometer. Volvo also has a gearbox made by GETRAG AG, The M90 gearbox, that also fits the engine, and it will lower the RPM's With 30%. The M90 was instaled in Volvo 900 and had an Electronic speed sensor at the rear axle, so wil cost a lot of $$$ to work in the LT.
Just before Christmas i got a letter from the Norwegian road and car inspection, that they wil alow me to do this Conversion, so it wil be street legal. I dont have to do anny improvements to chassis, brakes or suspention. However, when i am finshed With the Conversion, i have to take it throug an inspection at their testing fasility.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Monster LT Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 19 at 12:59
3000rpm at 100km/h wow, sounds like a dream! I'm sure if you get it down that low you'll be more than comfortable. Shame these beasts didn't come with a 6th gear.


Edited by Monster LT - 19 Apr 19 at 13:01
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 20 Apr 19 at 22:30
Originally posted by Monster LT Monster LT wrote:

3000rpm at 100km/h wow, sounds like a dream! I'm sure if you get it down that low you'll be more than comfortable. Shame these beasts didn't come with a 6th gear.
I don't realy know what RPMs i have at 100km/h but my rear axle is 4:44 and max speed GPS is 108, so may bee 4400 at 108kmh? that gives around 4100 at 100. With 3100 at 100 i wil have Vmax of around 140 going Down hil. but then it will feels like i am about to blow the house of.
I know there is a LT owner in Germany that has added a Volvo overdrive to his LT 5-speed gerabox.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 21 Apr 19 at 11:29
Reading in the german LT-Freunde.de forum, i see that Bernd did the following things:
Oilpan
shortend the axle in the gearbox
New engine support
Volvo Exhaust manifold, and adapter to fitt the turbo to the Manifold
Moved the Oil filterand Oilpipes to and from turbo.
Power steering pipes lengthened
Water conection to the engine and Electric fan for the radiator.

It seemd he had an easyer job With the electronicks as it was from an Audi 100.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ystei Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jul 19 at 08:25
how is the project going on?? :) 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jul 19 at 22:06
Originally posted by Ystei Ystei wrote:

how is the project going on?? :) 
Not wery much happening. The LT was taken out of winter Storage last week. The Winter Storage is 130km from where we live, but only 35km from the border to Sweden. We went 120km into Sweden, to a car dismantler in the city of Trollhättan (The home of SAAB) and bought a Volvo M46 overdrive gearbox, from a Volvo 240 Diesel. The plan is to mate it to the AAT engine. That way the rpm's wil be reduced with 21%. Since i work about 65 hours a week until 05 of August i haven't time to do much work on the LT, but it is at least at home, and i hope to get the cower under the engine, well it is more under the gearbox, off, to study how it looks and do more planing. Does a M46 and the gear shift mecanism fitt under there? How will i make the gear shift mecanism? Is it possible to use the 240mm dubbel mas flywheel from the Audi, witch is already on the engine, or do i have to use the 228mm flywheel from the old 2,4 Diesel engien? The Diesel engine in a Volvo leans about the same to the right as the engine did in the LT from -78 to -83, 7 degrees. in a Post -83 LT the engine leans 27 degres to the right, so the gearbox wil be 20 degres on the side, but what about the overdrive unit. Shoud i turn it 1/8 back, and is it possible to do that, so it is almost in its correct position. One million questions, that i try to find answers to before i start. We might go for a week of camping before i start taking the engine out, but mid August the engine wil be out of the LT.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ystei Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jul 19 at 22:10
cool! All I can say is good luck and good summer! :D
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jul 19 at 13:40
Yesterday we tried to mate the Volvo M46 gearbox to the Audi engine. A guy on the Norwegian Volvo forum said there was not room for a 240mm Clutch in the M46 bellhousing. We tried to mate them but the axle in the M46 is to long. we tok of the Bellhousing, but the pipe around the axle is to long. We then tok of the pressureplatte and friction plate and the bellhousing alignes to the engine, with 6 out of 10 holes. the 4 lower holes does not aligne, but one of them might be drilled. Then i wil have 3 in a row that are not bolted. i have to grind Down a little bit on the pipe around the axle, but not a major problem i hope.
The Audi gearbox had 23 teeth and the Volvo M46 has 22 teeth, so i need to sourch a 240mm friction plate With 22 teeth
Today i took of the protection under gearbox and engine on the LT. It hasn't been of for years i think. The one under the gearbox was full of Oil and shit and also a lot of oil on the gaerbox. I think the oil comes from the engine or has been spilled when refilling oil to the engine. Next week i wil take the LT to the washing area at the local petrol station and try washing every thing underneeth. Later i wil bring the covers in the T4 and Wash them too.
From what i could see there should bee room to Connect the gearshift mecanism to the M46 without to much problems, the clutch cable is almost exactly the same lenght, so may bee i wouldn't need to buy a new one. The LT gearbox is about 5cm longer than the LT one.
It seems my Worst fears has not happend, so this looks really promesing
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 13 Aug 19 at 16:28
iacta alea est. The dice has been thrown and there is now way back. The old engine is out. It took about 6 hours.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ystei Quote  Post ReplyReply Direct Link To This Post Posted: 02 Sep 19 at 14:22
cool! Exited to see next steps! Keep us updated!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 02 Sep 19 at 16:41
I feel that most of this job is in my head. It is a lot of "problems" to sort out. I just found out that i wil use the gearbox Mount for the T3 gearbox, on the Volvo M46 gearbox. I think i have found out how to make the gearlinkage to the gearbox. i will use the Stock Audi flywheel, but need a 240mm clutch disk that fits the M46 gearbox With 22 splines, the Audi has 23 :-( that i stil hasn't found. Biltema has an electrick fan that is 16 inch, so should fit the hole for the fan quite well, it is around 39-40cm
My experience With Welding dates back 15 days, so i am waiting for a friend who is an experienced welder, to help me weld the bellypan and oil pickup. He will be home next week, so hope to do it on sunday or monday. The engien Mounts i think i wil be able to weld myself. I just found out i had "forgotten" how to get the oil feder pipe to the turbo. I think i can use the hole for the oil pressure sensor and then move the oil pressure sensor for the warning lamp, to the New adaptor, on top of the oil filter, where i already plan to mount the sensors for oil temp and pressure gauges. it is just one bolt i have to unbolt to get the exhaus manifold of, then i can put the Volvo manifold on. I hope to testfit the New engine on Friday, With the uncut bellypan from the 6 pot engine on, to protect the underside. And then i will start With the Electronics......    
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 24 Sep 19 at 19:18
Today i mated the Volvo M46 gearbox to the TDI engine in the engine compartement and found out that i am not finished maken engine brackets. The TDI engine was mated to the LT gearbox, and every thing was fine, but when i mated the M46 to the TDI it touched the anti roll bar, so now i will make new holes so the engine wil sitt 12mm further forwards in the enginebay. Luckily it is just to drill New 10mm holes 12mm from the old ones. It wil only be 2mm of steel betwen the holes, but i will weld up the old ones. After i had taken the M46 gearbox out it took about 5 minutes to get the TDI out. Tomorrow i wil go to a hyadraulic spares and tubes specialist and make pipes for oil to and from the Turbo and from the syclon filter, to the bellypan. I wil also remove the "bulge" on the underside of the bellypan. Now the TDI rests on that bulge, so when it is removed it wil ba almost 2cm of clerance. On the 2,4 engine this bulge is in front of the cross member. I wil also get help from a friend tomorrow to change the cambelts, so if every thing goes acording to plan, the TDI wil be back in the LT tomorrow and i will not have to take the engine out again
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Ystei Quote  Post ReplyReply Direct Link To This Post Posted: 28 Sep 19 at 00:21
Awesome!! Congratulations on the progress! Photos?? :)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote nooberdoober Quote  Post ReplyReply Direct Link To This Post Posted: 09 Oct 19 at 12:01
Marius it's most definitely time you gave us a look at the progress!  
I got me a 2.4 straight Six......and it's a soundin JUICY!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Buss Marius Quote  Post ReplyReply Direct Link To This Post Posted: 10 Oct 19 at 22:09
I have newer ever posted a pickture before, anywhere. So this wil be a test.
87 Karmann LT L 2,4D. 89 T3 Syncro Reimo 1,9TD. 2000 T4 Caravelle TDI
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