Endless Air on D4D (1KD-FTE)

[Johnnos Brisbane Lurker Find all posts View Profile Close Johnnos Brisbane]

Hi All,

I had abit of spare time on my hands so decided to have a go at installing an Endless Air on my D4D. I searched but couldn't find if it had been done before and if so, how hard it would be.

While the compressor bracket was quite tricky, the rest was reasonably straight forward. I would assume a commercial installation would be prohibitive simply due to the labour involved with the bracket fabrication.

Rather than add another belt, I positioned the compressor such that I could simply use a longer serpentine belt which keeps things nice & neat. (sounds simple hey?)

I used a Sanden 507 ($40) like most people but made my own tank (approx 9litres). I've got 3 outlets: one at the tank under the driver, one at the rear towbar coupling (for trailer fills) and one under the bonnet (together with pressure switch and relief valve).

It took me awhile to eliminate all the minor leaks but it all works well now and holds pressure indefinately. It will inflate a standard tyre from 18psi to 35psi simply from the tank (ie without the compressor running) in about 6 seconds. I haven't yet timed a tyre fill from complete empty is pretty quick.

Anyway, the pictures below show the story and anyone in Brisbane is welcome to have a look (I might bring it to the next Tech day, couldn't make the last one).

All up, I think it took about 30-40 hours and about $400.

Andrew

All the parts:


Compressor


Again


Pressure Switch & Guage

[leachy_9 Advanced Member Find all posts View Profile Close leachy_9]

Re: Endless Air on D4D (1KD-FTE)

Great work,

You didn't happen to make a drawing of the bracket did you?

Leachy

[mersenne Junior Member Find all posts View Profile Close mersenne]

Re: Endless Air on D4D (1KD-FTE)

That is awesome Andrew. I like the multiple outlets.
Top job.
What vehicle is the compressor off please?

[Johnnos Brisbane Lurker Find all posts View Profile Close Johnnos Brisbane]

Re: Endless Air on D4D (1KD-FTE)

Hi All,

Leachy, I haven't measured the bracket yet but will do so in the next month or so. I've had a few requests for the bracket measurements so I'll do so and let you know.

Mersenne, the compressor was off an 82 Sigma (I think) but it came with a V pulley which I changed over to 10 Groove Poly belt (sourced from local auto air-con workshop). I don't think Sanden ever produced a 6 groove pulley for the 507 compressor but I think they did for the SD508. (you can see I haven't used all the pulley). If doing another one, I would search for an SD508 with 6 groove pulley which I think was used on Western Star trucks. (I don't know what car came with SD508 and 6 groove poly drive. Perhaps someone on here does).

Cheers

Andrew

[rhs58 Senior Member Find all posts View Profile Close rhs58]

Re: Endless Air on D4D (1KD-FTE)

Neat work.
Looking at your reservoir tank reminded me of a guy who used the hollow bullbar tubing as his tank. just had an outlet either side.
Always wondered how a pressurized bullbar would go in a bingle though.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Re: Endless Air on D4D (1KD-FTE)

Always wondered how a pressurized bullbar would go in a bingle though.

[SM10 Lurker Find all posts View Profile Close SM10]

Re: Endless Air on D4D (1KD-FTE)

How close does the compressor come to the exhaust manifold, and how accessible is the engine oil dipstick once the compressor is fitted?

[Johnnos Brisbane Lurker Find all posts View Profile Close Johnnos Brisbane]

Re: Endless Air on D4D (1KD-FTE)

Hi SM10,

I did have to modify the front intercooler bracket to clear the compressor but from memory, the exhaust manifold didn't present any problems. The dipstick did require slight adjustment so it clears the base of the compressor. The dipstick is a slightly more restricted than standard but doesn't present any major problem.

I do have to remove the compressor in the next few days to fix a slight leak at the pressure outlet so I'll take some photos then and post them for closer inspection.

Andrew

[DocK Member Find all posts View Profile Close DocK]

Re: Endless Air on D4D (1KD-FTE)

Andrew - that is an impressive setup. I would really like to give this one a go myself. I have a very small seiko-seiki compressor that is tiny by comparison to the sanden and I thought I would mod it up, brackets and all. The advantage of this little thing is it fits with plenty of room to spare so nothing else will need to change. My problem was what serpentive belt to use. I would be really interested to know what belt you used, what vehicle it came from, if you could post or PM me on that I would appreciate it. The other thing that concerned me was altering the angle of the belt on the air conditioner compressor. Did it make any difference to the performance of the air con unit or create any problems with slippage?
Thanks
DocK

[karrathaprado2 Senior Member Find all posts View Profile Close karrathaprado2]

Re: Endless Air on D4D (1KD-FTE)

Same here if you cold also include the drawing of the bracket? or Some pictures of the braket too.

[Johnnos Brisbane Lurker Find all posts View Profile Close Johnnos Brisbane]

Re: Endless Air on D4D (1KD-FTE)

Hi All,

Sorry I've been quiet for awhile. I plan to remove the compressor and measure up the bracket plus take a few photos tomorrow. WIll provide an update in the next few days.

Andrew

[karrathaprado2 Senior Member Find all posts View Profile Close karrathaprado2]

Re: Endless Air on D4D (1KD-FTE)

You the MAN :lol: Cannot Wait~!!!! thank you for your time

[Johnnos Brisbane Lurker Find all posts View Profile Close Johnnos Brisbane]

Re: Endless Air on D4D (1KD-FTE)

Hi All,

I've removed & measured up the bracket plus taken a few photos. There's been a few questions so I'll answer them first:

DocK asked changed contact angle with air-con compressor and new belt length: I too was worried about the changed contact area for the factory air-con compressor and did quite abit of research on that topic. But then I noticed the sticker on the top of the air filter box. Check yours and you will see that it shows the belt path for 4 different configurations. The standard D4D in the Prado is "Type 1" but you will see that "Type 3" shows a different engine with another pulley in the same location I put my compressor. I suspect this might be to also drive a compressor in a light truck application. So I figured that routing the belt via that path was quite OK given that some other D4D configuration already does it. (check out the sticker on your air-filter and you'll see what I mean.

Now for belt length. I've used a 1935mm belt which is approx 300mm longer than standard (from memory). I sourced the belt from a standard bearing supply shop but there was only one belt in approx that length. The next nearest belt was approx 100mm longer or shorter and that would have made this installation impossible. So, it happens by luck that there is a standard belt at the exact length I needed (will it wasn't the exact length, I adjusted my compressor location to allow me to use that standard belt).

Dock, if you plan to use a different compressor, then you need to note that this belt length suits the compressor location and pulley size of my Sanden. A different size pulley or location will require a different belt (which will be hard to source). The Sanden pulley is 120mm dia.

I've measured & drawn the bracket plus taken some pics. The pics should show below. If you want a diagram of the bracket, pm me and I'll email it. It's an improved version of my bracket so slightly different to my pics but I haven't made one to the drawing yet so I'd rather not post it here until someone has tested the drawing is correct.

The base plate is pretty straight forward but the location of the mounting holes are critical. The relative position to each other is the most important part. I've shown some 'ears' for mounting of the compressor but there's no need to follow my diagram for them. You can just make up your own to suit your own compressor.

It's important to note that I used a Sanden SD7 with a 10 groove pulley so my compressor sits 11mm back from where it would with a standard 7 groove pulley (they never made a 7 groove pulley for SD7, only SD8). You'll see that in my pictures further above. I hope that makes sense.

Anyway, PM me if you want a bracket drawing or want to talk to me about it. It's probably best to discuss over the phone with anyone planning to do this so PM me for mobile number.

Let me know if you need more info. Bracket pictures are below.

Andrew

[leachy_9 Advanced Member Find all posts View Profile Close leachy_9]

Re: Endless Air on D4D (1KD-FTE)

Awesome,

I'm off to find a compressor

Leachy

[DocK Member Find all posts View Profile Close DocK]

Re: Endless Air on D4D (1KD-FTE)

Great job and thanks Andrew for your response - as luck would have it the sieko-seiki compressor has nearly the same pulley size 115mm. I think I will be able to use the belt tensioner and position the compressor in a way that allows for the slightly smaller size. I did note the belt diagram and went to the Toyota Spare Parts counter and said could I have a type 3 belt - it is not listed in their catelogue so they were completely at a loss to know what it was or where to find it. I have nearly gathered all the bits and pieces and ready to give it a whirl.
Cheers
DocK