Friday, August 15, 2008

Conversion from Indirect Injection to Direct Injection

This will also work for the 1.6 TD engines.
I have been working to convert an Indirect Injection Engine(IDI) into a Direct Injection Engine (TDI) and fit it in the blue Syncro after the brown one is done.
As I had a few Audi 5 cyl 2.0 TD engines laying around I thought that it would be interesting to convert one of them into a TDI and see if it would run OK and how much improvement there would be in fuel consumption.
I bought a 2.5 TDI cylinder head on Ebay Germany with a set of injectors, injection lines and an TDI Injection pump.
I am using pistons from a Renault 1.5 Clio diesel and modified them to make them fit and compensate for the 6 mm longer stroke of the Audi.
As one of the engines had the last oversize pistons in there, I had a set of sleeves installed in the block and honed out to the 76 mm of the Renault piston.
I have modified the original Audi TD injection pump to accept the 20 mm TDI pump shaft and clearanced the timing advance piston, TDI's need lots of advance.
Also changed the pump internally so that it has four rollers on the camplate instead of the TD's original three.
I will keep you posted on the progress.

Hydrogen generator

As I need to have a few projects going at the same time I have been experimenting with a hydrogen generator.
It consists out of a set of stainless steel plates that are submerged in distilled water with some potassium hydrochloride (KOH) mixed in the water to get the current flowing. Connected to a 12 volt battery it starts to generate Hydrogen gas which then flows into the engines intake.
This will improve the combustion process and save fuel( look on Youtube under HHO generation)or so the story goes.
I have made a few different models but am in the process of testing them to see if indeed it will improve the mileage.