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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old February 4th, 2017, 13:50   #16
Rlfdavin
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Pics of AC bracket? I'm wanting to swap TDI into my 4runner but AC is a must
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Old February 17th, 2017, 09:24   #17
dbywaters
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Quote:
Originally Posted by frambach View Post
I can't seem to get the VW pedal 'just right' against the Toyota floorboard. I'm going to look at doing something like this.

dbywaters, can you explain in some more detail how you setup the pulley and throttle pedal in general?
I carefully drilled the vw aluminum cable connector to accept the Toyota cable, the rest was mounting it in a way that it aligned with the mount. Actually pretty simple to do...

Doug
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5 speed, converted 12/07
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Old February 17th, 2017, 10:59   #18
frambach
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I'm not clear on where you sourced the 'vw aluminum cable connector' though.?
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Old February 23rd, 2017, 08:22   #19
dbywaters
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Default Connector on TPS

I modified the aluminum bell-crank on the VW TPS to accept the Toyota throttle cable. This required some careful drilling and notching to allow insertion of the cable end, but it seems to work very well.

Doug
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Old February 25th, 2017, 12:02   #20
frambach
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I'm left to put the info together and say that you must have sourced this bellcrank from another VW since the ALH is a drive-by-wire.

I only mess with TDI's. I'm not versed in all things VW...
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Old March 2nd, 2017, 06:49   #21
dbywaters
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Smile Maybe I should have called it something different

What I refer to as a bell crank is the semi circular aluminum piece which the 98 throttle position sending unit is actuated. The TDI I installed is drive by wire, the VW actuator located within the throttle pedal assemble utilizes a short cable connecting the sending unit (cylindrical variable resistor of sorts) to the throttle pedal.
I disassembled the components and using a metal cutting saw I cut apart the bracket which the sending unit is mounted and used only part of the bracket required to mount the sending unit to the inside of the fender.
I then carefully modified the aluminum actuator arm (what I refer to as a "bell crank") that is connected to the position sending unit so could remove the existing cable and accept the Toyota throttle cable end. I will try to post a picture.
Yes, my TDI is drive by wire...

4th fill-up, 31mpg... :-)
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Old March 2nd, 2017, 09:13   #22
Hasenwerk
 
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Be careful! The potentiometer isn't water proof! I found this out the hard way miles from home.
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Old April 14th, 2017, 07:38   #23
dbywaters
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Default Some early conversion photos..

I found some photos of mounts and such I made for the t100 conversion, they can be found here

http://s163.photobucket.com/user/dby...library/Toyota
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Old April 21st, 2017, 06:25   #24
dbywaters
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Default Bead Roller

I built my own crimp tool to create beads on aluminum tube ends. I made it from a crimp tool designed for TV Coax connectors and a small bolt. I welded the bolt in one of the crimp openings, ground and filed it to a shape close the bead shape . I mounted the tool in a vice and with the help of a cheater tube on the handle I was able to create acceptable (to me) beads on the ends of charge air tubing. You can see a video in the link below.

https://youtu.be/uNhY97Yu75g
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Old April 22nd, 2017, 12:58   #25
dbywaters
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Smile I now have A/C in the T100!

Other than mounting the toyota compressor there are two additional hurdles to cross to have A/C in the conversion. 1st is to fool the A/C amplifier circuit board (located on top of the Evaporator behind the glove box) to think the engine is running and the 2nd is to make electric fans cycle when the Head pressure reaches maximum rather than have them run continuously.

I wanted to retain the amplifier board as it incorporates temperature and pressure cycling of the compressor rather than have it run continuously. In researching the circuit board I found it also cycles the compressor if the engine RPM is too low... well I did not tie in my TDI ECM to the Tach signal.. so I had to find a bypass. I found that putting a voltage on pin2 of the IC Chip on the circuit board effectively bypasses the RPM cutout. I added a resistor to drop the voltage some, the image below shows the resistor and wiring I added to fake out the RPM... and also, simply turning the dial to its lowest setting did not allow the A/C to operate.




The second hurdle is to control the radiator fans. I am using the VW radiator and fans from the New Beetle donor car, so I retained the radiator mounted thermostat for fan low-speed. I believe this will be adequate to keep engine temps in-check. I added a relay to power the high speed fans. I then installed a thermostat with sensing bulb from Advance Auto Parts to trigger the relay. I secured the sensing bulb to the aluminum line leaving the condenser and headed to the firewall.... I am not certain this is the best place but it works for now. My thinking is while traveling down the road the air passing through the condenser will keep the refrigerant temp lower than my setpoint and the fans will not need to run, but if I slow up or at a stop the fans will turn on and cycle on high speed. Time will tell if this will work out. I made a You Tube Video showing the components and operation. I hope this helps out someone else, I have several videos related to motor home and the TDI on my channel.

https://youtu.be/_ke1PPFofww

Doug
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Old April 22nd, 2017, 19:30   #26
Motohead1
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Nice work around.
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Old April 22nd, 2017, 19:58   #27
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weird, my AC works fine without touching the amplifier ... i just mounted the ac compressor ... i did splice a wire from the ac button to the fan relay so my fans run when the ac system is on
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Old April 23rd, 2017, 06:00   #28
dbywaters
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Quote:
Originally Posted by jimbote View Post
weird, my AC works fine without touching the amplifier ... i just mounted the ac compressor ... i did splice a wire from the ac button to the fan relay so my fans run when the ac system is on
I wish that was the case for me... I spent the better part of a Saturday morning trying to find a solution on the web and reverse engineering the circuitry on the amplifier board, I never found a pin-out for the chip on the board..that would been helpful.

Doug
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