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LT 2.4 Petrol engine to 2.5 TDI conversion

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Alevaro View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Alevaro Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 11 at 07:43
And where the sound of the new engine? LOL
VW LT-28 1984 Kastenwagen ACT 2.4L
http://oldbusclub.ru/viewtopic.php?f=16&t=830
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 11 at 11:25
I checked the engine compartment and the front end (engine carrier) is really in the middle 
so placing the engine behind it is very hard I guess.

do you really have no chance other than the 1,9 Tdi?
as you can easily use the stock LT tranny with a 5 or a V6 V8 engine from VW-Audi ...


Originally posted by Canada LT28 Canada LT28 wrote:

Hi Guys,

Eren, regarding the 1.9tdi, I will be cutting the prop shaft back to either put in a laycock overdrive (if i can find one at a reasonable cost) or a friend has a BMW 318 tranny that we are looking at putting in. Either way, Can I make the engine placement back far enough to still fit in and also miss the front end?
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 11 at 11:30
Very little update:

I have the engine mount welded and test fitted, 
I need to drill the 4th hole at top and make a spacer to go between the mount and engine
As I am working with aluminium I have to have the parts welded to a specialist, 
this really takes long time to cut grind test than have it welded than come back and see it doesn't fit, grind bend re-weld .....


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 11 at 12:53
Audi only started to import TDIs to Canada and USA this year so engines are rare and I think it is only the 2L that is here (so far). VW is the only "car" company that sells a 4 cyn diesel here. Now that smart diesels are gone and MB engines don't have the fuel economy, there is nothing else. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 11 at 12:55
I will use the stock tranny an maybe move it back a bit if it helps to get the new engine in.
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 14 Feb 11 at 13:13
I guess earlier 5 cyl diesel Audis were imported to Canada in 80s ?
but those engines are indirect injection and are no better than the stock LT diesel, 
those engines can be converted to direct injection (tdi) using a tdi head and pistons, someone in Canada did but long story...


Originally posted by Canada LT28 Canada LT28 wrote:

Audi only started to import TDIs to Canada and USA this year so engines are rare and I think it is only the 2L that is here (so far). VW is the only "car" company that sells a 4 cyn diesel here. Now that smart diesels are gone and MB engines don't have the fuel economy, there is nothing else. 
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 11 at 12:02
Hi All,

I worked on the engine wiring loom to make it ready for a test-run before I put the engine to LT.

Apart from the main relay, glow plug relay and the engine mount control relay, there are two more high current relays in engine wiring that I couldn't figure out. I don't have the factory repair manual so the only wiring diagram I have is the Haynes which is very simple and many details are missing.

I guess those relays will not be used and I will remove them.
I will also remove the engine mount control relay as I am using the LT engine mounts which are simple rubber parts unlike the A6's electric controlled ones.

This is an OBD1 engine so the communication socket is just a wire terminal in the fuse box.
So as to scan the engine with Vag-Com with the OBD2 lead that I have, I bought an OBD2 socket from a T4 in junk-yard, and connected it to the "k-line" of the engine wiring.

The good news is, with the OBD2 socket I was able to connect to ECU and the Immobilizer control unit with vag-com and see the error codes.
I also programmed the ECU for cruise control, as I will install a turn signal stalk from a T3 with cruise (hope the stalk will fit to LT)

So the wiring is now ready to test run the engine, we will see...




Edited by mechano - 22 Feb 11 at 22:08
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Post Options Post Options   Thanks (0) Thanks(0)   Quote GT500 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Feb 11 at 08:27
If you need to know what your extra relays are for post a pic of them and I'll tell you. If I can...

Rob
Rob... The only LT on 18" wheels.
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 27 Feb 11 at 19:18
The LT transmission has a long input shaft which sticks into the crankshaft so it has a needle bearing in the crankshaft.
However the A6 has the needle bearing in the flywheel, I guess the audi tranny has a shorter input shaft.

There is a sleeve in the crankshaft of the TDI, I have cut & removed it:
 
and installed a needle bearing which is 24mm outside & 18mm inside diameter:



I have shortened (cut & weld) the oil pickup tube of the 6cyl to fit to TDI:







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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 27 Feb 11 at 19:42
Before installing the oil-pan, I removed the valve cover & cleaned inside, also cleaned the cover.

Look at this part, I guess this an example what makes Audi different:





After bolting the oil-pan, putting in oil, hooking up the electronics & fuel lines, I removed the glow-plugs and spun the engine with the starter for the oil pressure to build up and to bleed the fuel pump.



I checked the system with vag-com & noticed that the speed sensor is not reading while cranking so the management is not sending fuel to injectors (injection quantity was reading 0mg/stroke)

obviously I was not able to start the engine, 
I removed the speed sensor to see If there was anything wrong that I can see, nothing..

It is strange that when I remove the sensor ECU doesn't throw an error code Ermm

I also don't have the airflow sensor at the moment as it was damaged in the crashed car, but this should not be a problem to start the engine ? 
At least I know that it is possible to run the engine in low-performance mode without the flow meter in later TDIs (with new hot wire sensors).
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Post Options Post Options   Thanks (0) Thanks(0)   Quote light Quote  Post ReplyReply Direct Link To This Post Posted: 27 Feb 11 at 21:00
Immobiliser?
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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 27 Feb 11 at 21:09
Originally posted by light light wrote:

Immobiliser?

working, no error codes..
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 07 Mar 11 at 20:36
Ok, I solved it. The engine is running now.

The problem was, (it is not actually a problem..) that you have to crank the engine within around 30 seconds after you turn the ignition on. If you don't the ECU cuts the fuel.

After turning the ignition on (connecting a wire in this situation) I wasted time connecting the vag-com checking everything and when I tried to start the engine it wouldn't.

During the accident of the A6 many wires are damaged:
-the engine speed sensor wire G28, 
-the wire of the knock sensor on the injector G80
-the advance-retard actuator's wire  N108

I have repaired the the G28 cable-connector problem and I guess (did not test) the 30 second wait problem is gone, as the ECU will now sense when I am cranking and probably will supply fuel again.

Engine is running roughly at idle, with N108 error code which wont clear, this is I guess due to bad wiring (broken connector) again.

Also I found-out that this engine would run with or without the airflow meter like later TDIs.

I will sort-out the clutch (to use the dual-mass TDI flywheel and pressure plate of TDI)  and put the engine in LT than I will finalize the wiring on the bus.
 
here is the youtube link: http://www.youtube.com/watch?v=OCkiIaIvLHE  Wink




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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 11 at 12:42
Hi All,

After replacing timing belts & tensioners & crankshaft seals, I tried mounting the engine to tranny to see how the A6 clutch will be.
It simply won't fit, the release bearing support shaft will hit the clutch disc, so I took the bellhousing off and shortened the support shaft.



After this I was able to mount the engine and tranny.
The clutch lever has now moved 25mm backwards (measured where the cable is attached), so I have to arrange smt. (weld - extend) so the cable will fit.

I have put the TDI in:



The pump now hits the back-side of the engine bay, but I guess it will clear when I install the tranny as it would tilt the engine to front of the bus a little, we will see.

5 cyl engine is short:


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Post Options Post Options   Thanks (0) Thanks(0)   Quote mat_the_cat Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 11 at 14:30
ClapThumbs Up
Nice bit of work there! Look forwards to completed photos (and maybe a video?)

I wonder if you can make a pie warming shelf to occupy all that wasted space in from of the engine?LOL I can just about squeeze in a sausage roll on top of my coolant tank, nice and warm after a few miles!
Mid engined, 6 cylinder, turbocharged 2 seater - it can only be a VW LT!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote t'onion Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 11 at 15:08
so will you be making up kits for us all to buy or will this be a one off Unhappy
LT28 Westfalia FloRida, 2.4 diesel

miserable fooker



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Post Options Post Options   Thanks (0) Thanks(0)   Quote t'onion Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 11 at 15:23
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
LT28 Westfalia FloRida, 2.4 diesel

miserable fooker



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mechano View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr 11 at 08:13
here it is:





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Post Options Post Options   Thanks (0) Thanks(0)   Quote vwjetta Quote  Post ReplyReply Direct Link To This Post Posted: 22 Apr 11 at 12:24
too much skills guysEvil Smile Clap
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 22 Apr 11 at 12:45
Originally posted by vwjetta vwjetta wrote:

too much skills guysEvil Smile Clap

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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