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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 8th, 2011, 11:48   #1
pemtek
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Default Elise TDI

Hi,

I have collected together some parts to get on with a conversion for my Elise with hopefully about a 200bhp PD engine.

ATD PD engine with loom and EDC15+ ecu
6 speed gearbox
530d turbo
pd130 injectors

The Elise currently has a b16 turbo engine which has recently catastrophically failed due to a fuel pump failure. So I thought a Diesel engine would be fun in such a lightweight car approximately 700kg.

What i currently need is a schematic to get the engine running, I have searched around but cant find anything useful. I am an electronic engineer so the wiring is not a problem once I have the schematics.

I have already removed the immo from the ECU and hopefully the EGR but I will only know if that is successful once it has been run.

The engine mounts to fit the engine are basically identical to a common conversion of putting the VAG 1.8t engine in Elises which I have been involved in previously.

Thanks

Phil
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Old February 12th, 2011, 05:14   #2
Pat Dolan
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That is one swap that makes a LOT of sense to me.

You might be best off with a Robert Bentley repair manual (here is one in print to suit PD Jettas....Passat didn't seem to cover diesel). This is essentially the North American factory manual with very few exclusions. It DOES mean PD100, but is PD. Current flow diagrams are included, but you may not find detail on what is INSIDE of the wiring harness for ECU. Essentially, you have a choice of taking the VW insturment cluster and integrating or having the immobilization feature deleted by a tuner.

I have thought a fair bit about building a TDI powered solo racer, and the problem that I see in this kind of car is the horribly slow response time of turbo and VNT vanes to throttle input. If you are that adventurous, I would suggest compounding with a positive displacement supercharger (obviously opening up the ability to dump in a LOT more fuel as well - done with aftermarket injector bits and programming).

Keep us posted...wish I was in the UK now (you can't imagine what an Elise sells for in Canada).
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Old February 12th, 2011, 15:09   #3
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Someone was working on a diesel Elise a few years back; see if you can find the thread on the forum, there was a lot of good information about the swap, although I'm not sure if he ever finished it.
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Old February 12th, 2011, 15:32   #4
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That sounds like a superb idea, the thought crossed my mind recently when I was thinking of my old mk1 mr2 I used to own. It'd be interesting to see how you get on
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Old February 12th, 2011, 20:55   #5
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You could also wait and see if this gets released

http://www.volkswagen.co.uk/volkswagen-world/news/122
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Old February 13th, 2011, 08:16   #6
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Seatman: the Bluesport may be a wonderful car, but it will not be anywhere NEAR the handling of a Elise. You need to try one to see what I mean. It is actually not a very nice street car unless you live on VERY smoothe roads and are a bit of a glutton for punishment.
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Old February 13th, 2011, 15:27   #7
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I've seen them around where I live and yeh I agree they handle superb. I've watched them coming round tight bends toward me as well and have also spoke to other people who have them and driven them and I wouldn't dream of arguing about their capabilities but I still think it's interesting that vw are building a mid engined tdi. It'll be very interesting to see what effect the extra weight has on the elise too.
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Old February 19th, 2011, 09:04   #8
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Hi,

sorry for my slow response I have been away on business in Chicago and Phoenix AZ for the past week.

The Elise's are starting to go up in price here at the moment even the GM / Vauxhall versions are starting to increase.

Mine is the lightest model made as it is an S1 and also does not have the moulded in boot / trunk..

I have two 230 Kompressor superchargers in my garage although I have no idea if one of these would be big enough for a compound setup. I am fairly sure I could get hold of the compound turbos from a 335d BMW quite cheaply as a friend of mine has a smashed engine from a crashed car.

Here is the car in its current guise before fuel pump failure: >

croft race circuit >

http://www.youtube.com/watch?v=m6udo7eXM7w
http://www.youtube.com/watch?v=Kvl6O...eature=related
http://www.youtube.com/watch?v=oP2Ia...eature=related
http://www.youtube.com/watch?v=1_bQC...eature=related

Some photos taken at Anglesey early days before I added the forged internals and had literally just got it running.

http://s889.photobucket.com/albums/ac93/pemtek/Elise/

Probably only about 250 bhp here being followed by a Honda K20 engine powered Elise before one of my water pipes removes itself!

http://www.youtube.com/watch?v=8hvOrfbUJyY

Tomorrow I am going to spend all day stripping the Honda engine out of the car ready to get the TDI in its new home!

Phil
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Old February 19th, 2011, 10:28   #9
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When you do, be sure to post some pictures of the process...it's always great to be able to see the engineering that goes into these projects.
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Old February 19th, 2011, 12:04   #10
pemtek
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Cool Elise TDI

I have to fabricate mounts, drive shafts, exhaust, water pipes, boost pipes, fuel pipes, loom etc etc.

I will document what I can.

The car has to be finished for Easter weekend as I have already paid for a track day at Anglesey circuit with the Exiges group.

I am going to be busy!
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Old March 16th, 2011, 17:21   #11
pemtek
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Default moving on

Hi,

quick update and a question..

The engine is now in the engine bay and I am just finishing off the engine mounts.

Water piping is sorted as is the fuel pipes except for the fuel cooler.

The question I have is the loom i got with the engine didnt seem to use the in tank fuel pump wiring? Is this normal? Am I missing something?

Thanks

Phil
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Old March 17th, 2011, 15:23   #12
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I'll answer if you post some pictures . Usually the pump wiring is in the body's harness, if you look at a wiring diagram usually the fuel pump is fused off the power supply relay. I don't have my computer with my diagrams in front of me for an absolute answer, but I'm pretty sure that's the case.
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Old March 20th, 2011, 17:53   #13
pemtek
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Cool

thanks for that I will go looking.

http://s889.photobucket.com/albums/a...k/elise%20tdi/

I will take more photos tomorrow and post them up, I have been in the garage all day from 8am until 11:50pm...

Today I made the driveshafts, well everything other than welding. I cut and machined a set of original elise s1 shafts and joined them to sections of cut and machined golf shafts that came with the latest gearbox. I drilled the middle and threaded it with an M6 thread to I could screw the two halves together so there was no gap between them because the welding process cannot support more than a 3 thou air gap.

Tomorrow they are being EB welded (electron beam welded) together so hopefully they should not snap!

Tomorrow I am going to start the wiring. Should be easy once I get going, I have wired many conversions before.

Phil
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Old March 20th, 2011, 19:01   #14
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I really dig your rear engine mount!! ...very elegant and simple!!
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Old March 21st, 2011, 02:49   #15
pemtek
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Thanks,

I like making things, i am actually an electronics engineer but I have a pretty decent workshop at home. Lathe, miller, plasma cutter,chop saws, ac dc tig, mig, big bandsaw, press etc etc

With regard to the mount I just made a template from card once I was happy I used the bandsaw to cut it out. There is another similar at the front. The bush is actually a lower wishbone bush from a ford ka (hateful small car). Maybe a bit stiff and make my teeth fall out I used the same on the Honda engine and it was ok.

I have the day off today so more work on the car but tomorrow I am off to Donnington to a trackday. (obviously not in my Elise)

Phil
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