Outer Limits 4x4 Board

I have made some progress in mounting Sanden 508 on a 1HZ. I recieved an enquiry about my mount from a member on another forum and thought I would post up my prototype for people to see how I have done it. It has been on the vehicle for over 5000km and, although I have not used the compressor function yet (have not had time to set it up), the air con runs without any problems (and I use that all the time). Mine is in a HZJ75 and although it fits with a factory snorkel configured air filter housing, I needed to modify the housing on my model to fit it all in. There is HEAPS more room in that area on the 80, which would make for a realistic DIY project for the mechanically minded. I made my original knock up by modifying and extending the factory air con bracket and would reccommend this method for those of you only doing a one off (instead of trying to make a bracket from scratch). You need to move the factory air con unit to the right of the vehicle and forward to line up with the front belt groove on the Sanden (I believe it was 16mm, but confirm it for yourself.) This allows the Sanden to snuggle down between the factory unit and the rocker cover. The Sanden is belt driven off the crank, as the factory unit was previously. I remounted the factory belt tensioner to tension this belt, however it is at the opposite end to the original configuration and has to be pushed to tighten rather than by the bolt. I will customise it at some stage. I used extra washers between the bracket and the engine under the mounting blocks. Mine was rough because it was only to make a jig. If you pay a bit more attention to detail, it could be pretty neat.



Once I got the positions right, I used it to make a jig.




Then fabbed the new prototype bracket



I since moved the tensioner mounts and slotted out the holes and added a couple of washers to space it out a bit. I will be changing the jig to suit the 80's increased clearance. The belts are hard to fit on the 75 version so I will use the extra space to increase the adjustment for fitting and tensioning the belts.



A major tip is to buy your belts first and have them there to check that you can fit them and tension them properly. The Sanden rolls away from the factory air con comp towards the rocker cover to tension the belt. Space is very limited in this HZJ75 application and you can appreciate why the HZJ80 extra clearance will make adjustment so much easier.

I hope to spend some more time on it over the wet.

Some installed pics, less tensioner. Note temp modified air intake, to be replaced with a repositioned mandrel bend that clears the pipes.