Endless Air system on GU 4.2 turbo diesel

[Big Red]

I drained the oil, drill and tapped a 1/8 BSP thread into the oil port and fitted a grease nipple to a Sanden S6626 8 Cu Ft/min air conditioning compressor then filled with 140 gms of Castrol LMX Lithium bearing grease.


Using an Endless Air A13 mounting kit i mounted the compressor to the Drivers side bottom front of engine.

Fitting instructions for Nissan GU 4.2 Diesel:

1. Remove 2 lower 12mm bolts from drivers side engine mount.
2. Disconnect steel vacuum tube from Vacuum Pump and swing out of the way.
3. Remove 2 bolts from the bottom of the Air Conditioning Compressor [passenger side] and keep bolts.
4. Bolt Endless Air Compressor to bracket [painted yellow in pic, has curved mounts for compressor] with grease nipple down with Bolts and Nuts supplied.
5. If using a rear entry compressor use 2 M&F elbows supplied. [mine has side entry O ring fittings so I used 90 degree knuckles to face pipework horizontally to the rear]
6. Unbolt 2 power steering tubes from chassis cross member and shift out of the way.
7. On Intercooled Vehicles the tube chassis member will need to be modified to clear the compressor [photo 5] with a ball pane hammer.
8. Fit the Bracket with compressor attached to engine using two longer 12mm bolts supplied with new drive belt hanging on compressor pulley.
9. Fit second bracket [green in photo, long bracket with pinched shape] to lower section of Air Conditioner mounting using the 2 Allen Head bolts supplied.
10. Using the 2 bolts from step 3 bolt both brackets together with Nyloc Nuts supplied, leave all bolts loose until all bolts are in place then tighten.
11. Cut the metal Vacuum tube at mid point of tube cross member and replace with vacuum hose and clips supplied, The Vacuum hose passes through the large hole in the compressor bracket.
12. Remove Alternator Belt and run new 13A1535 belt [supplied] from step 8 around Alternator and Crankshaft Pulleys and tension.
13. Run inlet and outlet hoses to complete installation, check clearance of hoses over the top of the front Axle.

[Big Red]

[Big Red]

Once I fitted the new belt I noticed there is not much contact of the Alternator/Endless Air belt on the Crankshaft Pulley. [see white marks]


The Alternator/Endless Air belt and the Power Steering and belt both go round the Water Pump Pulley so some extra contact is available for the Alternator/Endless Air belt although there is not much contact of the Power Steering belt on the Water Pump Pulley. [see white marks]


There is a danger that if the Power Steering belt loses grip there is not enough contact to run the Alternator so I will keep the old 13A1155 Alternator belt and the old spare in the car as well as a spare 13A1535 Alternator/Endless Air belt.

[Big Red]

Fitted a switch panel into the overhead console to control the clutch.
Ran the wires down behind the A pillar trim.

[Big Red]

The diff and the panhard rod run close to the compressor outlets and have hit the connections enough to bend the pipe fittings so i will have to find a rear entry compressor and try that instead before it actually breaks off a pipe.

[Big Red]

Found a 7 piston compressor to replace the 5 piston compressor as it was easier to find a rear port head.


Sanden 8030


when I changed the damaged head over and while I had it apart I drill and tapped the oil return hole to block the grease from getting sucked through into the suction and pumped out the discharge pipe.


Have ordered some 3/8 UNF grease nipples so when they arrive I can fill it with 140 Grm of Castrol LXM bearing grease

[Big Red]

Fitted the new compressor which gave me heaps more clearance.

[Big Red]

I fitted a small air tank under the canopy and fitted an air distributor block so I could fit a couple of air outlets, a 90 to 120 pressure switch and a 140 psi pressure relief valve