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2002 Tdi Diesel Conversion, First Test Drive


couttsdesign

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http://www.youtube.com/watch?v=uVvfwFEUxss

 

Check out the first test drive of my 2002 diesel.  Coolant and exhaust not hooked up and brakes were really soft, so I just went around the block.....but it works!  You can hear the turbo winding up throughout the video.  Sounds pretty cool!  My goal is to show it next month at the Socal Vintage show.  Wish me luck!

1973 3.0 CS sahara

2000 VW Golf TDI

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Very cool, and I am also curious about the details, isn't the TDI motor usually (always?) hooked up to a FWD drivetrain on VWs? what tranny did you use? Also like the wife's(?) little "oh my god" as it goes down the street on its own power for the first time.

Lincoln, NE

74 2002

68 Triumph TR250

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Thanks for the enthusiastic interest.  I have build threads on this forum as well as the TDI club forum for those looking for more info. Please note, I had a baby recently so my build threads haven't been updated for a few months.  here are links to the build threads and my photobucket account....

 

http://s1178.photobucket.com/user/couttsdesign/library/1975%20BMW%202002%20TDI%20Engine%20Conversion?sort=2&page=1

http://forums.tdiclub.com/showthread.php?t=359959&highlight=1975+bmw

http://www.bmw2002faq.com/topic/120815-diesel-conversion-vw-tdi-19-alh/?hl=diesel+conversion

 

Some of the info has changed since I first started those build threads so I'll give a brief overview here and try to answer your questions.  

-The engine is from a 2001 VW Jetta TDI, engine code ALH.  

-Transmission is a Toyota W158.  Connected to the engine via an adapter plate from this company...http://www.acmeadapters.com/.  There is more detailed information in my build threads regarding the Toyota tranny and bellhousing.

-Differential is 2.93 LSD from an e30 with a cover from an E36.  I had to modify the rear subframe to accommodate this differential.  I'd say this may be one of the most limiting factors of this swap.  Stock 2002 differentials will result in RPM's that are too high for everyday driving.  The TDI MAX RPM is about 5000.  Most driving is between 1800 and 3000 RPM, and highway cruising max efficiency is right around 2000-2400 RPM.

-Modern TDI engine's should not be run on veggie oil or WVO.  Biodiesel is fine.  I'd love to swap an older Mercedes engine, like from the 190D to run veggie oil.  Someone DO IT!

-Custom driveshaft

-Custom motor mounts

-OIL filter housing is the other major limiting factor in this swap.  The stock filter housing interferes with the steering box and probably the brake booster.  I had to build a bracket to relocate the filter housing.  

 

Yeah, I am in Belmont Shore....and my wife's reaction truly is priceless....BUT, this may be the world's first diesel conversion, so maybe her reaction is justified...."Oh my god...it actually works!" hahaha :rolleyes:

1973 3.0 CS sahara

2000 VW Golf TDI

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How about a dumb Q, what is the fire extinguisher thing hangin and swinging in front of the radiator? Please put some coolant in this thing before the show, everyone will want a ride, maybe the Oh my God is her thinkin she will get the garage parking back? That was my exes biggest joy of seeing my 70 roll out of the covered parking, there is a reason why she is the ex. Great fab work on rear subframe.

Happy Trails to u~ Dave Miller
76 Golf~Rhiannon~BM Mascot~*~97 328is~Silver Ghost~*~68 1600~Wisperin Beast~*~70-02~Bumble Beast~*~76 02~Beast~

Keep smilin all the way

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How about a dumb Q, what is the fire extinguisher thing hangin and swinging in front of the radiator? Please put some coolant in this thing before the show, everyone will want a ride, maybe the Oh my God is her thinkin she will get the garage parking back? That was my exes biggest joy of seeing my 70 roll out of the covered parking, there is a reason why she is the ex. Great fab work on rear subframe.

 

That would be the intercooler and associated piping.  Normally, you would see the intercooler piping also on the driver side, but it's not hooked up in the video.  Putting in coolant will be a bit of a pain in the ass.  There is very little space in some areas to run coolant lines. Also, the engine requires cooling of the oil via engine coolant, so i need to run coolant lines to the relocated oil filter housing.  Also, I'll be using a temperature controlled cooling fan that I will need to figure out.

 

My 73 CS coupe will go back in the garage ASAP.....sorry wifey :P

 

EDIT: the "fire extinguisher thingy" is the intake.  It's the tallest point in the engine bay and I'm hoping the hood will clear this. 

Edited by couttsdesign

1973 3.0 CS sahara

2000 VW Golf TDI

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http://www.youtube.com/watch?v=uVvfwFEUxss

 

Check out the first test drive of my 2002 diesel.  Coolant and exhaust not hooked up and brakes were really soft, so I just went around the block.....but it works!  You can hear the turbo winding up throughout the video.  Sounds pretty cool!  My goal is to show it next month at the Socal Vintage show.  Wish me luck!

Congrats, couttsdesign!   I love this, and would love to know more!  I think there are lots of other folks who would be interested in seeing your work, so .......

http://baurspotting.blogspot.com/2013/09/bmw-2002-diesel.html

 

We would like to get the word out!  Baurspotting has been read in 142 countries around the globe.  Who da thought!  Curious minds love to hear about this stuff, evidently! 

http://baurspotting.blogspot.com/2013/05/update-baurspottings-growing-global.html

 

Kudos!

Edited by tomscat1

Tom

Connecticut

Home for Feral BMWs

1973 2002 Malaga (with frosting), 1982 323i Baur

1991 325ix (winter), 1977 320i (carbed), 1989 325ix

1989 325iC (summer), 1979 323i (project), 1978 320i (parts)

http://baurspotting.blogspot.com/

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