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LT 2.4 Petrol engine to 2.5 TDI conversion

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GT500 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote GT500 Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jun 11 at 09:42
Why didn't you try the fly by wire throttle above the LTs pedal? It fits perfect and gets the stupid long cable away. 
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: 21 Jun 11 at 19:44
Originally posted by GT500 GT500 wrote:

Why didn't you try the fly by wire throttle above the LTs pedal? It fits perfect and gets the stupid long cable away. 


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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 21 Jun 11 at 20:04
Originally posted by Canada LT28 Canada LT28 wrote:

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.

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 Smile)

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 Evil Smile



Edited by mechano - 21 Jun 11 at 20:05
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Jun 11 at 11:57
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 22 Jun 11 at 12:53
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.
94 LT28 Doka 2.4D
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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: 23 Jun 11 at 09:10
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...Unhappy
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 Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 23 Jun 11 at 11:04
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. 
94 LT28 Doka 2.4D
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87 T3 soon to be a camper
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rocky332 Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jul 11 at 14:18
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jul 11 at 14:28
Originally posted by Rocky332 Rocky332 wrote:

Hello,

My LT: http://www.youtube.com/watch?v=s5CRkvxUyt0

Gruß Bernd aus Germany

wow, you are the first one I've seen who made the same conversion, great!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rocky332 Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jul 11 at 18:14
Originally posted by mechano mechano wrote:

Originally posted by Rocky332 Rocky332 wrote:

Hello,

My LT: http://www.youtube.com/watch?v=s5CRkvxUyt0

Gruß Bernd aus Germany

wow, you are the first one I've seen who made the same conversion, great!


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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mcbkat Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jul 11 at 18:46
Hallo LT-Freund Wink.

Pictures please! (Bilder bitte!)

Stefan
De Vries LT45 4X4, De Vries LT40 4x4
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Rocky332 Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jul 11 at 19:05
Originally posted by mcbkat mcbkat wrote:

Hallo LT-Freund Wink.

Pictures please! (Bilder bitte!)

Stefan


Hello,

Once I have more time I set the pictures.

greeting

Bernd

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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 07 Jul 11 at 10:52
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote mechano Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jul 11 at 11:47
Testing the tacho:

one of the lifters is noisy, which disappeared later
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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: 13 Jul 11 at 10:11
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!
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 Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jul 11 at 10:53
There are lots of aftermarket tachs out there but I guess most people want it to look as original as possible.
94 LT28 Doka 2.4D
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87 T3 soon to be a camper
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 13 Jul 11 at 10:54
Originally posted by mat_the_cat mat_the_cat wrote:

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!


What did they charge for it?
94 LT28 Doka 2.4D
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87 T3 soon to be a camper
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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: 14 Jul 11 at 09:50
Originally posted by Canada LT28 Canada LT28 wrote:

What did they charge for it?

Too much! I think it was about £250...


Edited by mat_the_cat - 14 Jul 11 at 10:13
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 Canada LT28 Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jul 11 at 11:23
Ouch and that probably wasn't the whole cluster.
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 mat_the_cat Quote  Post ReplyReply Direct Link To This Post Posted: 14 Jul 11 at 11:54
Sadly no, this is all I got:



I had some unexpected money, so I casually enquired about availability. Once I found they were still available I just couldn't stop myself!Embarrassed
Mid engined, 6 cylinder, turbocharged 2 seater - it can only be a VW LT!
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