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LT 2.4 Petrol engine to 2.5 TDI conversion

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cnycl View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cnycl Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 11 at 18:01
Mechano posted TDI in LT video.
Here it comes.

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stonio View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote stonio Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 11 at 19:21
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!
LT31 2.4 Petrol 1984 Camper Conversion - My Obsession
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mcbkat Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 11 at 19:39
Nice fit! Clap
But with all that wiring, I'll stick with a 6 cylinder...

Stefan
De Vries LT45 4X4, De Vries LT40 4x4
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mcbkat Quote  Post ReplyReply Direct Link To This Post Posted: 04 May 11 at 19:40
Or make a 2.5 mTDI
De Vries LT45 4X4, De Vries LT40 4x4
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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: 05 May 11 at 10:12
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 Thumbs Up 
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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: 09 May 11 at 14:48
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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mcbkat View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mcbkat Quote  Post ReplyReply Direct Link To This Post Posted: 09 May 11 at 16:07
Is there a weight difference between 5 and 6 cylinder?
De Vries LT45 4X4, De Vries LT40 4x4
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readie View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote readie Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 11 at 20:37
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
1988 LT35 140K 2.4dt
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Post Options Post Options   Thanks (0) Thanks(0)   Quote readie Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 11 at 20:44
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
1988 LT35 140K 2.4dt
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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: 17 May 11 at 10:10
Originally posted by readie readie wrote:

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


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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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: 17 May 11 at 10:11
Originally posted by mcbkat mcbkat wrote:

Is there a weight difference between 5 and 6 cylinder?

possibly, I don't know.

Eren
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Post Options Post Options   Thanks (0) Thanks(0)   Quote readie Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 11 at 11:23
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
1988 LT35 140K 2.4dt
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jun 11 at 12:09
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jun 11 at 19:08
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

94 LT28 Doka 2.4D
Slow and built to stay that way
87 T3 soon to be a camper
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 11 at 20:12
Originally posted by Canada LT28 Canada LT28 wrote:

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


Thanks! 1.9 can be harder by the wayConfused
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 11 at 20:26
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 11 at 20:50
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 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: 16 Jun 11 at 20:52
Here is an overview of the current stage:


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cnycl View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote cnycl Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 11 at 21:22
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jun 11 at 22:50
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.
94 LT28 Doka 2.4D
Slow and built to stay that way
87 T3 soon to be a camper
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