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nzjetboating.com Forums => Tech Library => Engines => Topic started by: mallyxt on September 14, 2019, 15:16:22 PM

Title: Diesel Transplant
Post by: mallyxt on September 14, 2019, 15:16:22 PM
As I enjoy reading other peoples posts I thought it was about time I documented my project
I have a 4.3 rivercraft that is running a 3.8 ecotec v6 and a flow pro 2 stage
After being involved in a couple of other diesel boats
A 4.2 hd ftv landcruiser motor in a 6m with a 9 inch scott
And a 2l ee20 subaru motor in a rakaia marine with 2 stage
I decided to fit one to my boat
After looking at what is available and what I can get running
VW 3l tdi 2l tdi toyota 1kd etc
An impulse Trade me buy got me a mercedes om642 engine
3l common rail v6 engine 225hp 500nm
https://en.wikipedia.org/wiki/Mercedes-Benz_OM642_engine
I found an ecu out of the uk but it was going to be 3.8k
This was a bit much so a long search on Dr google found a man in europe who has made one run in a boat
After tracking him do and a few emails the hunt was on for a donor car


Title: Re: Diesel Transplant
Post by: mallyxt on September 14, 2019, 15:36:53 PM
Boat and motor pictures
Title: Re: Diesel Transplant
Post by: mallyxt on September 14, 2019, 15:56:24 PM
After a bit of searching I found a crashed chrysler 300c in hastings on the manheim auction site
Brought it site unseen just like the first motor
Cost twice what I paid for it to get it to christchurch
Motor and gearbox, wiring, ecu, security parts and front control module removed the rest on Trade me

Title: Re: Diesel Transplant
Post by: mallyxt on September 15, 2019, 19:59:43 PM
Motor and box out
Had a weigh up and the ecotec motor complete weighs in at 205kg complete manifolds heat exchanger ecu
And the Mercedes weighed in at 224kg as removed from car
should get it under 220kg with EGR, swirl flaps  , power steering pump and other bits removed
The diesel is about 60mm longer 100mm narrower 15mm deeper in sump and 50mm lower in height
So plan is to fit it in the same spot as the ecotec
Title: Re: Diesel Transplant
Post by: mallyxt on September 15, 2019, 20:11:11 PM
Test fit enough room and about 20mm under sump 
Mucked around a bit setting up to line up the engine
Used a laser diode from jaycar and a holder I tuned up to mark the rear side of the seat base
Where the centre line of the unit is 
Then drilled a hole and used a bit of rod and a drill to drill another hole in front of seat base
I made up an alignment tool for the back 2 pieces of pipe that slip over unit shaft and fit in spigot of crank
and a pointer at the front to line up front pulley with centre line of unit
Title: Re: Diesel Transplant
Post by: Jimmy Jet on September 15, 2019, 20:36:23 PM
Good bit of out of the box thinking for alignment. Did you know to offset the driveshaft by a degree or 2? This helps the needle rollers turn and not skid which wrecks the uni joints prematurely. The flange faces must remain parallel.
Title: Re: Diesel Transplant
Post by: mallyxt on October 16, 2019, 19:22:23 PM
The flywheel has been a bit of a pain as i wanted to add some weight to the flexi plate for smoother idle
As the Torque converter and the dual mass flywheels they put on these ar large
Problem being is is a nice german shape and has the target for the flywheel position sensor on it
Title: Re: Diesel Transplant
Post by: mallyxt on October 16, 2019, 19:24:23 PM
I got this machined up it can take a centaflex if I decide to fit one but just a plate and conventional drive shaft for now
Title: Re: Diesel Transplant
Post by: mallyxt on October 16, 2019, 19:26:01 PM
A couple more pictures
Title: Re: Diesel Transplant
Post by: mallyxt on October 16, 2019, 19:27:13 PM
I got some blanking plates and other bits cut out
Title: Re: Diesel Transplant
Post by: mallyxt on October 16, 2019, 19:29:35 PM
Rear engine mount a bit of 16mm aluminium
Jig saw with aluminium blades works a treat
Title: Re: Diesel Transplant
Post by: mallyxt on October 17, 2019, 12:59:25 PM
Had an intercooler made to suit the engine
Title: Re: Diesel Transplant
Post by: mallyxt on October 17, 2019, 13:04:41 PM
EGR don't you just love the soot it creates the egr system and swirl flap system is due to be removed
These engine have a couple of oil leak issues 
The seals on the oil cooler which is mounted in the v leak and drop oil looking like rear seal
And the oil vent hose that is connected just in front of the turbo leak
I got an oil cooler seal replacement kit in from ebay
I will do his when I get rid of the EGR parts
Title: Re: Diesel Transplant
Post by: Jeff B on October 17, 2019, 15:44:29 PM
Nice project.
Decent heavy duty stuff there.
Title: Re: Diesel Transplant
Post by: mallyxt on November 05, 2019, 07:31:30 AM
Up to plumbing the intercooler in
I have a sand trap fitted
I am thinking of running from sand trap through the water to air and into Heat exchanger
Got a couple of questions
What do people do to stop fines getting into the water to air as the sand trap will not stop everything
And how do we limit the pressure in the water to air want to limit to 20-25 psi
As advised by the guys at industrial radiators who built the water to air
If it was hydraulics it would be easy i would  run a flow divider and a pressure reducing valve
Cheers
 
 
Title: Re: Diesel Transplant
Post by: Nigel on November 05, 2019, 20:15:47 PM
when I ran the subaru water to air I just teed off the main feed after the sand trap and just used a ball valve to reduce pressure and water went to a telltale so could check that water was flowing through. You dont need a lot of flow to work well as water is always cool from unit. If you were worried about fines you  could put a water filter/strainer after the tap, I never had any issues with fines
Title: Re: Diesel Transplant
Post by: lachlan on November 05, 2019, 22:10:53 PM
Ive run them full pressure off a single stage plenty of times.  Theres not actually that much pressure unless you are restricting the water outlet ...
Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 08:39:14 AM
Going to try with a 2 way split using a T straight ahead to the heat exchanger and the other to the Water to air will see how it performs
Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 08:42:49 AM
As I cannot get a low temp thermostat I modded the 84 degree one to make it adjustable
Will see if I can get it down to the 70 degree mark
This is what the Mercury V6 (VW engine) and the hyundai have
From what information I can find this is what the marine diesel small engines have
Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 08:53:29 AM
I made an exhaust riser from schedule 10 bends
It is going to be water cooled with 3.5" exhaust elbows
Went with the schedule 10 bends for the inner as it is a bit thicker than the 2.5" exhaust tube I could find I got one of the welders at G&T to weld them up as I don't want it to leak
The outer is 3.5" 304 exhaust tube bends cut to fit 
Spent allot of time on the cad program while sitting on planes working out how to get the 3.5" bends to fit over the 2.5 bends and look half decent
With an even gap as they have different centre line radius
Then used some polystyrene packers between the layers to keep them apart while I tacked them up
A bit of petrol melts the polly out
I will weld the outside as it doesn't matter if it leaks
 
Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 08:58:46 AM
Air cleaner done and fitted exhaust outer mocked up cooling pipes ready to be welded
Will box the pod filter to keep heat and water away from it
Has anyone used Header armor
http://www.heatshieldproducts.co.nz/header-armor.html

Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 09:02:02 AM
Stripped the loom out and got rid of 90% of the old loom
Got a we box of bits plugs with wires hanging out

Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 09:03:26 AM
Loom being stripped
Title: Re: Diesel Transplant
Post by: Jimmy Jet on November 10, 2019, 11:12:58 AM
This project is cool. I'm not sure if you are intending to use it in salt water much  or not and you may already know that 304 will chew out very quickly if warm salt water goes through it. As you have the schedule bends on the inner though it will prob eat through the outer tube bends first. Something to watch for.
Title: Re: Diesel Transplant
Post by: mallyxt on November 10, 2019, 11:48:59 AM
Jimmy the closest I get to salt water is the waimak lagoon for water skiing once or twice a year
The schedule 10 is there for that reason
I normally launch at the boat club at the mouth then boat up to the kaiapoi river launching ramp to give it a flush out on the way to load the boat
The water to air has the same issue as it is aluminium so will be looking after it
 
Title: Re: Diesel Transplant
Post by: Jimmy Jet on November 10, 2019, 13:02:20 PM
Sweet as I'm sure you are all over it. The damage actually occurs during use when the hot salt water is flowing through, its quite acidic to s/s when heated. Looking forward to following the project and seeing the results.
Title: Re: Diesel Transplant
Post by: mallyxt on November 19, 2019, 22:04:10 PM
I got the wiring done a bit of a mission working out what I actually need 632 pages in the 300c wiring manual
Biggest problem is the security system
I need the ecu the front control module ignition key and the sensor for the key
I had a bracket folded up and I welded bots on to make them fit
I have a second set of bits so I can change them out once  get them programmed for stand alone
Title: Re: Diesel Transplant
Post by: mallyxt on November 19, 2019, 22:06:55 PM
Just about done
Now to work out my notes from when I originally wired the boat to splice in the new motor and fuse box
Been a couple of mods done in between to confuse myself
Title: Re: Diesel Transplant
Post by: mallyxt on November 19, 2019, 22:10:24 PM
Removed the vacuum pump but forgot about the oil feed to it
Lucky It was spotted by a friend of mine and I made a blank for it
There are no dumb observations or questions from anyone
Title: Re: Diesel Transplant
Post by: mallyxt on November 19, 2019, 22:14:18 PM
Finished the intercooler piping and the water pipe routing
Managed to mount the bosses on the pipes for the sensors without melting anything this time
no molten aluminium puddles
A bit of machine reaming to get the hole size right
Title: Re: Diesel Transplant
Post by: mallyxt on December 15, 2019, 00:22:19 AM
Water cooled riser taking shape it has the 2.5" schedule 10 bends inside and 3.5 exhaust elbows on the outside
Still learning how to tig keep cooking the welds even with argon backing
Title: Re: Diesel Transplant
Post by: mallyxt on December 15, 2019, 00:24:43 AM
Well the water comes out the right bit
A fair bit of mucking around to get the water to flow evenly
And it only leaks where it is supposed to 
Title: Re: Diesel Transplant
Post by: mallyxt on December 15, 2019, 00:29:42 AM
Ordered some header armor from a company in auckland
Hoping it will keep some of the heat out of the engine bay
I have a plan to use a radiator fan above the engine to draw the hot air off the top of the engine
The engine cover will get some modifications to make the air flow where i need it to 
The Mercury and Hyundai v6 engines use a water cooled header and the the pipe work aft of the header is just air cooled to the turbo
Title: Re: Diesel Transplant
Post by: mallyxt on December 15, 2019, 00:45:46 AM
It is getting a  bit cluttered in the back but things going in for the last time
Mother getting all the modified parts fitted and the tacked up parts fully welded
The tig is getting better the aluminium needs lots of preheating for the thicker sections
The hooded BBQ is has been moved from the other other side of the house and is my pre heat oven
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 09:58:42 AM
Motor ready to go back in flywheel fitted and torqued
45nm plus 60 degrees

Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 09:59:56 AM
Motor ready to go back in flywheel fitted and torqued
45nm plus 60 degrees

Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:03:06 AM
Right side of the engine
Fuel pump fitted and exhaust completed
I now need to make a fuel cooler for the return fuel
I will fit this under the heat exchanger on the water inlet pipe
Once i work out how much heat we are generating i will decide if thee hoses need to be pipes
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:05:41 AM
Front of the engine
I have removed the throttle valve that is used in the egr system
Mounted the inlet temp sensor and the boost pressure sensor in the new pipe
Intercooler is fitted and the water lines made
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:08:53 AM
Left side
I took a bung out of the block to fit the oil pressure sender and the LOP switch
I tapped the thermostat housing to fit the temp sensor for the water
Inlet pipe has the ambient pressure sensor and the MAf sensor is mounted to the air cleaner
I will look for a cover for the air cleaner or a better pod once it i running properly
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:12:50 AM
Top of the engine
It is a bit tight to fit things
hose for heat exchanger to exhaust is a bit ugly but it was all I could get over the holiday
I will get a high temp one
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:21:42 AM
Now the fun starts
Engine cranks and starts but we get the 3 second shut down
This is caused by the security system not functioning correctly
Out with the modified set of ecus and in with the standard ones
Same problem
After digging through the wiring diagrams i find that the Rh drive cars have a steering lock module that is connected to the SKIM security system
That is why the first engine came with the steering lock
After wiring this in the engine runs continuously
A quick 45 minute trip to west melton to get the steering lock
And the modified set refitted
This process tool a couple of days and it finally ran continuously on christmas day
Christmas was at our house so I could disappear when i needed to confirm my ideas


Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 10:37:48 AM
This is the steering lock module minus the mechanical parts
I stripped it and hard wired the I am unlocked switch
Now it is in a nice we box mounted in the fuse box
So off to the river to see if it still floats
A couple of water leaks sorted
And run it up
3000 rpm and no boost
Back home to change the turbo actuator
Same fault
I have an OBD link plug in unit that connects to a cell phone
I am using this to see rpm boost etc and it gives some fault codes
Nothing showing 
Off to borrow a scan tool to see what the codes really are
Lots of codes but none that matter according to my man in europe who I  have been calling to talk about the problems
Borrowed another scan tool and found a nice code
B1c32 Airbags deployed
Dr google to the rescue
When the airbags deploy the airbag module sends a message to the engine ECU to shut down
This is a logged fault that stops the engine from starting
I have bypassed the start circuit that normally goes through the ECU
So I was able to start but the engine is in limp mode the Turbo is turned off
Off to see 4 different scan tools so far no one has been able to find where to turn this off with there tools with my set up (no car)
Next step is to get the airbag module and wire it in to see if it needs to be there to turn this off
There are a couple of youtube videos that show this being reset on damaged mercedes cars so it should be able to be done
Talking to europe they have been using ECU's from non crashed cars



Title: Re: Diesel Transplant
Post by: Warwick Marflitt on December 31, 2019, 12:46:23 PM
Don't you just hate all the hooks, knives and traps in using these modern engines... This is why I went to fixing heavy trucks, Marine and mining equipment. You'll get it sorted it's a matter of asking and finding the information. .. keep at it. You're so close to the finish line.....

Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 13:14:56 PM
A very short video
https://youtu.be/_wh-YPBQKn0
Title: Re: Diesel Transplant
Post by: mallyxt on December 31, 2019, 13:20:35 PM
Warwick
stubbornness or stupidity
I haven't quite worked it out yet 
It is just a matter of research and talking to the right people
I fix cranes and construction equipment for a living
They are just as good as keeping there information secret as the automotive industry
I do mechatronic fault finding and repairs down to board level
Does your head in some days but the boating is worth it
 ;D


Title: Re: Diesel Transplant
Post by: mallyxt on January 03, 2020, 18:11:54 PM
Today's mission ducting for the fan I am mounting above the engine
Will see how it goes only problem I can see is when I have my cover on for big water boating
I will find a thermostat for it and have it live when engine shut down
Title: Re: Diesel Transplant
Post by: mallyxt on January 03, 2020, 18:18:17 PM
The most important extra
Heater remounted as the throttle pedal is mounted off the front wall now
A couple of longer hoses needed
Sheet of chequer plate to cover the original position n the floor
 
 
Title: Re: Diesel Transplant
Post by: mallyxt on January 03, 2020, 18:37:15 PM
Looking for a autel maxdas scan tool around christchurch
From what I have read this will reset the Airbags Deployed error that I have in the engine ecu
Have tried several different brands already but have been unsuccessful so far
From the information I have found on Dr google this is the tool to use

 
Title: Re: Diesel Transplant
Post by: lachlan on January 03, 2020, 21:36:28 PM
Is it a vgt with servo control of the vanes ?  Even then it should makesome  boost regardless of the ecus wishes .
If its got an active code for low boost then its clearly expecting boost .
Id be checking for mechanical problems eg  lines crossed or vanes seized 
Title: Re: Diesel Transplant
Post by: mallyxt on January 03, 2020, 22:30:38 PM
Lachlan
The servo control works when we tell it to with the diag tool in test mode
The picture is with the ignition on and the engine not running 
There is a minimal amount of boost in the position it is in (wide open)
When we rev it and manually move the guide vanes it produces boost 
Looks like the engine logs the airbags going off after an accident and you have to reset it
I believe they turn the turbo off when in limp mode also
The other engines that have been run stand alone don't have this code as the ECU's have been taken form a non crashed car
The only reason I can start it is because I have bypassed the start circuit that goes through the ECU
As it wouldn't start initially
Now that I am further along I believe this code is what stopped it starting in the first place
This is the link to one of the write ups to reset the code
https://www.youcanic.com/wiki/car-wont-start-after-accident
Good to know for future repowers


Title: Re: Diesel Transplant
Post by: Warwick Marflitt on January 05, 2020, 22:49:01 PM
Warwick
stubbornness or stupidity
I haven't quite worked it out yet 
It is just a matter of research and talking to the right people
I fix cranes and construction equipment for a living
They are just as good as keeping there information secret as the automotive industry
I do mechatronic fault finding and repairs down to board level
Does your head in some days but the boating is worth it
 ;D

YEAH! hb Walk away and Live to fry fl. another day. hhh hhh hhh
It will be worth it in the end..... Boom up...... 
Title: Re: Diesel Transplant
Post by: lachlan on January 06, 2020, 15:22:49 PM
Fair enough . Atleast youre working it out for yourself and not the facebook mechanics
Title: Re: Diesel Transplant
Post by: mallyxt on January 25, 2020, 11:45:47 AM
Will i tried several scan tools but no luck
So I ordered a BDM100 tool from melbourne  thinking it would be quicker than getting it from china
Over 2 weeks to get here
This is the tool you use to download the program out of the ecu
Only problem is you need to have the ecu open to do it
Problem with this is there is a high probability of damaging the pcb
So the solution is to mill a hole in the side of the cover and use spring probes to contact the board
2 minutes later I had the file
I sent this to europe to have it doctored 
2 days later it arrived back
All good revs to over 4k and turbo actuator actually moves
Title: Re: Diesel Transplant
Post by: mallyxt on January 25, 2020, 11:49:41 AM
Guess I wont be needing these  ;D
Went out for a quick run last night
It gets out of the water good and is starting and running great
Back home to tidy up the wiring and find the water leak
Think it is the sand trap o ring again
Just need to make a fuel cooler to cool the return fuel
The fuel is constantly circulated and is used to cool the common rail high pressure pump
Will post some video once i have a passenger there to help me

Title: Re: Diesel Transplant
Post by: steelo on January 25, 2020, 13:49:37 PM
Well done Mally. You are very resourceful.
Title: Re: Diesel Transplant
Post by: mallyxt on January 25, 2020, 19:33:39 PM
Well out for a play this afternoon
Went with the 100mm hole for a start
put the smaller insert I have in
96mm much better
65km/h up river (head wind)
79kmh down stream (wind assist)
Going to make a 92mm insert to see how it will go
Anything courser than a 27xc flow pro out there
Has anyone had any experience with the 5 blade impellers that marineworx rotorua use
https://marineworxrotorua.co.nz/jet-boat-blades/
see the new video i have uploaded
https://www.youtube.com/watch?v=_wh-YPBQKn0
Title: Re: Diesel Transplant
Post by: Jeff B on January 25, 2020, 19:46:29 PM
Allen M has one of those 5 blade impellers in the back of a 3.9 rover.
Pulled the revs back quite a bit and gives great cruise rpm/punch. Not sure if it's the 21 or 23?
Not sure what it's like compared to the flo pro 27?
Mohawk has one of those on the back of an ls1
Can you try a 3 stage?
Title: Re: Diesel Transplant
Post by: mallyxt on January 25, 2020, 21:13:35 PM
3 stage or a 212 would be the go
But  I want to see how good I can get this setup working only second run tonight
I will get a new hull if  go the 212 route
I am going to play around a bit with this for a start
Going to beg borrow or make a 92mm insert for a start
the jig saw battery is flat so I will continue in the morning with the 22mm plate I have
Got one donut roughed out and the od turned
Will tig them together to give me the 42m depth i need
unless someone has  southern jet style 92mm nozzle I can borrow in north canterbury




Title: Re: Diesel Transplant
Post by: Jeff B on January 26, 2020, 07:59:50 AM
From my testing I found the nozzle diameter changes not that big, compared to impeller change. More fine tuning and smaller helped with slip to a point where you go too small and unit gets more noisy/grumbly/unhappy.
My thinking is that revving to 4000rpm  is not making much more power than at 3500rpm??
Do you have dyno graph?
Those engines poke out huge amounts of torque and you have done an amazing job of getting it this far.
I'm curious how much pump it will handle? pop
Title: Re: Diesel Transplant
Post by: mallyxt on January 26, 2020, 09:51:33 AM
Jeff the curve is flat at that level it recs to rev limiter at 4350 at the moment
This as the closest graph I have found
It is supposed to be tuned to 270hp and 600nm with the dpf and swirl flaps disabled
I haven't removed the swirl flaps yet
It makes the commodore v6 ecotec look a bit sleepy
Thinking I might build a new boat with a 212 or a 912 in it
It had grunt to burn no black smoke so far so I am pleased I persevered with the factory ecu
It runs smooth at idle and even at speed
I will get out again this afternoon and get some more video of the engine running 
The OBDlink I have has been playing up but I think I got the water out of it this morning and remounted it in a better place
Now I need a working  tacho on the dash thinking an OBD one as the alternator switches off under heavy acceleration
A Mercedes thing switch off load accelerate faster
 
 
Title: Re: Diesel Transplant
Post by: mallyxt on January 26, 2020, 20:18:18 PM
Spent a bit of time this afternoon machining up a new insert
2 21mm thick donuts that i machined and then tig welded together
Didn't even need a filler rod and it held together when i machined the taper 
Back down to the river not to much difference by the seat of the pants
78kmh  top speed down stream
Gets out of the water well
86 degrees for water temp and 29 degrees inlet temp
The watercooled elbow gets to 39 degrees
I am going to put back seat in and then take it for a long run to pylons to see how it behaves
Looks like the o ring for the front stator is letting water in so will strip the nit tomorrow some time
Short video
https://studio.youtube.com/video/xYnwynjRfTY/edit   
Title: Re: Diesel Transplant
Post by: steelo on January 26, 2020, 23:09:53 PM
Link not working Mally
Title: Re: Diesel Transplant
Post by: Paul on January 27, 2020, 01:33:51 AM
https://www.youtube.com/watch?v=xYnwynjRfTY
Title: Re: Diesel Transplant
Post by: Jeff B on January 27, 2020, 07:34:38 AM
Looking at that power curve it looks like you are way "under pumped" ? If you are hitting the limiter at 4200rpm then that whole last 1000rpm is wasted? It makes a huge amount at 3000rpm. Then torque is falling away.
I'm thinking even a 3 stage (2.3kw) or 212 with 2.4kw would be under utelised? Probably wants closer to 3kw?
Title: Re: Diesel Transplant
Post by: mallyxt on January 27, 2020, 09:32:49 AM
Jeff
I have had my suspicions that the 2 stage would be to small
Engine proof of concept works now time to go shopping
Going to run it for a bit while I decide what to do
Need to see what its likes and dislikes are 
If I am going to do a 212 it may be time for a new hull
or atleast a new bottom as this one has seen some country
 



Title: Re: Diesel Transplant
Post by: Jeff B on January 29, 2020, 06:54:17 AM
Is it worth converting to 3 stage with some coarse impellers? Would be relatively easy swap to get some hours on the engine?
Would be good to cruise at 2200rpm.
Title: Re: Diesel Transplant
Post by: Jimmy Jet on January 29, 2020, 07:26:25 AM
Good work. Boat gets out quite well. Looking fwd to seeing further results if you change unit. You're onto something.
Title: Re: Diesel Transplant
Post by: SeanC on January 29, 2020, 07:39:31 AM
Who did you use in Europe to modify your ECU file? I've got a mate with a CRD Jeep that wants a few more ponies.
Title: Re: Diesel Transplant
Post by: mallyxt on January 29, 2020, 18:22:28 PM
Sean
Plenty of people can do the updates locally
http://www.quantumtuning.co.nz/car-remap-tuning-remapping.aspx?make=Jeep&range=Grand%20Cherokee
https://chiptuning.co.nz/cars-jeep
 ;D
Title: Re: Diesel Transplant
Post by: Allen M on January 29, 2020, 22:31:17 PM
Allen M has one of those 5 blade impellers in the back of a 3.9 rover.
Pulled the revs back quite a bit and gives great cruise rpm/punch. Not sure if it's the 21 or 23?
Not sure what it's like compared to the flo pro 27?
Mohawk has one of those on the back of an ls1
Can you try a 3 stage?
I’m running a 23 in my boat.
Was doing 5000 with 19 deg 3 Blade Scott and dropped to 4600 with 5 blade Phoenix. Same top speed.  8 kph faster at 3000 rpm
The 5 blader makes noticeably more thrust in the lower rev range if you have the torque to spin it.
Be good to try one behind a good diesel. B))T
Title: Re: Diesel Transplant
Post by: allforham on January 29, 2020, 22:38:11 PM
looks great!sure ill cop some flak but the berkeley in mine seems to go very well behind a diesel. 200ish hp 4cyl with i think an "A" impeller. plenty of options for bigger hp and a fraction of the cost of a 212. i get right on 80kph in a 4m rib id think yours should  have a bit more in it? those v6's have a heap more power than the 4 cyls
Title: Re: Diesel Transplant
Post by: mallyxt on January 30, 2020, 07:14:53 AM
Really need a higher pitch for the 5 blade as this thing has 100 more hp at 4000 and twice the torque
Will give the man in rotorua a ring when i get a chance


Title: Re: Diesel Transplant
Post by: Paul on January 30, 2020, 08:11:30 AM
LOL monster torque. Based on that graph, I'd be targetting a WOT rpm of 2750-3000 (- just between where the hp & torque lines 'crest over). It'll be a great machine.
Title: Re: Diesel Transplant
Post by: Allen M on January 30, 2020, 21:14:42 PM
With that amount of torque at such low revs I don’t think a 71/2inch unit is going to cut it with any sort of blades  hhh
I’d be considering a larger diameter pump in the near future  once you’ve got the engine sorted.
Interesting project.pop
Title: Re: Diesel Transplant
Post by: mallyxt on January 31, 2020, 07:26:31 AM
Any 212 units out there PM Me
any condition
Title: Re: Diesel Transplant
Post by: mallyxt on February 01, 2020, 11:57:50 AM
Couple videos
Will get some more when there is no wind
Surprisingly quiet
https://www.youtube.com/watch?v=VgWG8g8svME&feature=youtu.be
https://www.youtube.com/watch?v=NFHUP-uRt8g&feature=youtu.be
Title: Re: Diesel Transplant
Post by: mallyxt on February 05, 2020, 18:20:31 PM
Parcel from southern jet
Title: Re: Diesel Transplant
Post by: mallyxt on February 05, 2020, 18:22:57 PM
Nice we impeller to see if we can load the engine up a bit more with the 2 stage
Clayton and his boys have done well
Now for the rivers to come down to a level and colour so i can get some before and after data
Title: Re: Diesel Transplant
Post by: mallyxt on February 08, 2020, 21:44:00 PM
A bit more testing
Getting about 40kph at 3000 up stream so gained 10kph
50kph down at 3000rpm
70kph upstream flat out so 5kph gain
Still about 80kph down
Need to play with the nozzle size to see what effect it has
Off for a longer run up waimack in morning so will see how it performs in the real world



Title: Re: Diesel Transplant
Post by: mallyxt on February 10, 2020, 07:45:07 AM
Did a couple of hours boating up the gorge
Aout 10 or 11 litres per hour fishing and mucking around 
sits on 2800 going up between 28 and 34 kph depending on the water
and about 44kph coming down at same revs
Temp sits at 87 in cruse and the inlet temp at 15-17 degrees in cruse
Beats the commodore motor across the board
couple more mods to do and an annoying whistle to get rid of
May be an air leak in the turbo pipes couple of O ring joints to check at the ramp
Title: Re: Diesel Transplant
Post by: Jimmy Jet on February 10, 2020, 08:48:37 AM
Great results, well done. Something to consider for sure.
Title: Re: Diesel Transplant
Post by: longshot on February 10, 2020, 22:04:26 PM
Have you managed to bypass the eis system or still have that hooked in?
Title: Re: Diesel Transplant
Post by: mallyxt on February 16, 2020, 12:41:53 PM
eis skim system still there got the stripped down bits in the relay box
working on a solution for that at the moment
Title: Re: Diesel Transplant
Post by: mallyxt on March 09, 2020, 07:49:23 AM
Courier arrived early this morning
New Walker everquiet air filter
Hopefully this will shut the induction noise and turbo whistle down
Title: Re: Diesel Transplant
Post by: mallyxt on May 02, 2020, 11:08:11 AM
Finally got around to stripping the inlet manifolds to replace the oil cooler seals and remove the EGR cooler and swirl flaps
Title: Re: Diesel Transplant
Post by: mallyxt on May 02, 2020, 11:14:14 AM
Most of the oil was coming from the PCV valve hose that connects just in front of the turbo
The manifolds didn't have as much carbon in them as I have seen in other engines
But that carbon gets everywhere when you clean it out
Still finding it days later
I removed the swirl flaps and the egr cooler and made up a new pipe for the cooling water
Title: Re: Diesel Transplant
Post by: Warwick Marflitt on May 02, 2020, 12:55:01 PM
Looking good. A clean Diesel/Any clean engine's so much easier to work on and any leaks quick and easy to find.... When the "Gestapo" and Heir Kernel "Juicy Cinders" allows the Prison Population out from containment confinement. You'll be able to get some more test runs. I bet it'll go well without the EGR and PCV.....     
Title: Re: Diesel Transplant
Post by: Paul on May 02, 2020, 17:07:11 PM
I bet it'll go well without the ... PCV

I've seen multiple people remove/disable PCV systems, which I think is kind of daft.  They are there for two reasons:

1, allow excess crankcase pressure (from blowby etc) out of the crankcase;
2, constantly change/refresh the vapours in the crankcase with fresh air, in order to protect your oil from contamination.

Adding a catchcan solves issue 1, but not issue 2.
Title: Re: Diesel Transplant
Post by: mallyxt on August 23, 2020, 21:48:04 PM
A bit of an update
Was looking to build a new hull until the C world arrived
I went and visited paul at flo pro for some bits to turn the 2 stage into a 3 stage
And to get some more impellers
Trying to get the cruise rpm down to 2500
Hull had a we visit to hamilton's to have some therapy for the abuse the hull has had in my care
The unit has had a we tickle up new wear rings tail pipe clean up etc
Started with a 19 24 24 combination
92 96 100mm nozzle tried
2500 37kph up  48kph down
3000 50kph up  58kph down
4100  72kph up  84kph down
Next 19 24 27
Not to much difference speed wise
Next 19-25 SJ bullet 24 27
96 and 100 mm nozzle 92 fond to be noisy and rumbly in th hull
2500 38kph up 53kph down
3000 52kph up 63kp down
4100 75kph up 87 down
Next 19-25 SJ bullet 27 27
similar speed as the above but much quieter
Need to take it for a long run to see how it performs fuel wise and real world boating
planes at about 22kph at 2000rpm
Still gets onto the plane quickly
Would like to get onto a lake to do some better testing
but happy for now

 

 
Title: Re: Diesel Transplant
Post by: mallyxt on September 06, 2020, 19:55:26 PM
Had a week in haast boating the cascade
Did about 8 hours boating for 110l of fuel
3 runs down and up river 50kph
a couple of hours with 5 of us in it exploring the side creaks
So pleased with it so far
Anyone out there running a 3 stage with 2 27 blades in the back
Would like to hear nozzle sizes  as I have gone to 100mm which is my max for my trim nozzle
Has quietined it down without to much loss of performance
And I would like to see how it performs with a bigger nozzle
Next project is a 2 l vw engine to marinise


Title: Re: Diesel Transplant
Post by: Paul on September 06, 2020, 20:40:02 PM
100mm is pretty big for a 3-stage. My 2-stage is down at ~88mm.
Title: Re: Diesel Transplant
Post by: allforham on September 06, 2020, 22:03:40 PM
Hi mally. Have you considered a bmw instead of the vw? That's what im looking at next. Jacketed manifolds are a real pain on the vw and the bmw comes in all alloy 2.0 4cyl or 3.0 6 cyl. Even twin turbo versions capable of big power if you are so inclined
Title: Re: Diesel Transplant
Post by: Jeff B on September 07, 2020, 07:08:57 AM
100mm does sound on the large side for a 3 stage? Normally around 90mm?
What did it do with the tighter nozzle?
Too grumbly?
If you are keen to test some more it might be worth blocking out some of the grill? This sometimes does wonders for shutting up noisy blades/pumps.
Title: Re: Diesel Transplant
Post by: mallyxt on September 07, 2020, 08:10:08 AM
Jeff
The unit is grumbly
problem with the is engine that is quiet you can hear all the other noises
Going to play some more got plenty of time and a boat that goes well
allforham
Looked at the n57 a while ago problem it is a straight 6 so takes up more room
It all comes down to being able to get the engine running on the factory ecu stand alone
The aftermarket ecus are good but dont have all extras the factory ones have and are usually 3-4k to buy and you have to know how to tune them
If I can get a factory ecu and a tune to run stand alone is the preference for me
Download the file send to europe reload test 
There are lots of vw golfs with blown gearboxes so engines cheap and plenty of people have played with the ecus in europe
Paul
What blades are you spinning
Title: Re: Diesel Transplant
Post by: allforham on September 07, 2020, 08:33:04 AM
Hi mally i haven't found a measurement but they're supposedly a very compact inline 6. The 4 cyl versions are still plenty potent too. I've found a guy in portugal putting n57's in patrols who reckons he can delete the immobiliser on the factory ecu in case you're interested. Alternatively the later m57s are all alloy too and have seen plenty of these come up lately
Title: Re: Diesel Transplant
Post by: allforham on September 07, 2020, 08:39:10 AM
Also im in chch and have a vcds in case you go down the vw route you're welcome to borrow it B))T
Title: Re: Diesel Transplant
Post by: Paul on September 07, 2020, 11:41:06 AM
Paul
What blades are you spinning

Two stainless 19-20's.