HDJ62

[seatosummit]

I am looking for advice on routing the air conditioning hoses between the condenser and the compressor / drier. I am fearful that I might need to cut a bit of my battery tray to accommodate the lines.

The 3FE connections to the 1HD-T compressor makes for some odd unions. The actual fittings appear to mate, but the hose bends are wild. Fortunately, there does not appear to be any interaction between the hard line and the compressor pulley, but it clears by millimeters.

 

[seatosummit]

I cut the battery tray by about 3/4" and I was able to get the AC hoses routed correctly.

The connections to the top of the compressor are definitely not designed for the bends of the AC lines, but miraculously nothing collides with anything. It looks a little wonky, as you can see above, but it works!

I swapped all of the o-rings out with new green ones, found an appropriate drier, added PAG 46 oil to the compressor, torqued all of the connections and filled it with refrigerant. After a bit of initial let down when it started squealing 20 minutes in, I retensioned and all seems to be well. Getting 41F at the vents

Pretty stoked as it has been hot as hell. I need to find a mount for the drier, likely will just use something generic.

All for now!

Cheers,
A

 

[seatosummit]

I was having trouble with the belt staying properly tensioned. Turns out that the belt that came with the truck from PO was too large.

I ended up buying a Gates 9490 off of Amazon and it works well. Bit tight, but I was ultimately able to convince it to go on.

Anybody know what the tensioner nut should be torqued to? I have an aftermarket tensioner and don't want to torque to the point of breaking the fastener.

Other odd quark that I have been dealing with: I can't get the tank to properly fill with fuel. I can only manage to get about a half tank in before it foams up the point of clicking the fill nozzle off. With diesel at $8.20/gal half tank is plenty! But it is still annoying, so I conducted an experiment: I opened the fuel sending unit while filling the tank and it allowed me to put a full ~20gals in. So, this leads me to believe it is definitely a ventilation issue.

No doubt a result of something weird happening during the diesel conversion.

For those of you with factory diesel tanks, can you describe the routing of the vent hose off of your tank to your filler? I have a charcoal canister that I of course no longer need.

I also teed in the return line from injector pump to the hose that goes into the filler neck...I'm sure that isn't kosher, but I thought at the time I was having issues with aeration from the return line landing on the fuel filter. That symptom was ultimately due to the fuel cut off solenoid being the wrong voltage...

Cheers,

Austin

 

[Eurasiaoverland]

From the filler pipe, there is a vent/pressure equalising hose (the thickest hose in your second picture) which goes from a welded pipe high on the filler pipe down to the metal tube plate (the thing in your second photo that the hoses are connected to) to a large pie on the tank. There are four other vent hoses from the fuel tank to this tube plate (from memory 3x 6 mm, and 1x 10 mm hoses) which vent various baffled chambers of the tank.

The lowermost of the hoses (a 6 mm hose), which on yours is cut and plugged, connects onto a metal pipe which runs formward and ends in a grommet in the front side of a box section on the underside of the body. This is the vent for the plastic vent manifold which is in the rear RH quarter of the body.

The four tank vent hoses (the 3x 6 mm and 1x 10 mm I mentioned above) connect to 10 mm hoses on the inner side of the tube plate which then connect to the bottom of the plastic vent manifold.

 

[seatosummit]

From the filler pipe, there is a vent/pressure equalising hose (the thickest hose in your second picture) which goes from a welded pipe high on the filler pipe down to the metal tube plate (the thing in your second photo that the hoses are connected to) to a large pie on the tank. There are four other vent hoses from the fuel tank to this tube plate (from memory 3x 6 mm, and 1x 10 mm hoses) which vent various baffled chambers of the tank.

The lowermost of the hoses (a 6 mm hose), which on yours is cut and plugged, connects onto a metal pipe which runs formward and ends in a grommet in the front side of a box section on the underside of the body. This is the vent for the plastic vent manifold which is in the rear RH quarter of the body.

The four tank vent hoses (the 3x 6 mm and 1x 10 mm I mentioned above) connect to 10 mm hoses on the inner side of the tube plate which then connect to the bottom of the plastic vent manifold.

Awesome, thank you for the intel. I will reference this as I dig into this next weekend.