1.5dci to 1.9tdi pd conversion

[Dr HMS Derv Destroyer]

As above, really getting the itch to do this now, seems as the tuning ability of a 1.9tdi pd engine from a vw is very epic.
race cams
mahooosive VNT turbos
racing injectors...
List goes on.

now I really want to be different and build a powerful diesel clio as apposed to all the petrol boost buses on here.

Iv been looking into the conversion, the engine will fit and so will the 02m/02j gearbox.
the only thing I'm stuck on is engine management, I don't want to start having to make a stripped out clio just so I can use a vw loom to make the engine work aswell as the dash cluster.

More of a sleeper build.
If I'm being honest , this build will be almost a money no object, as bits will have to be made more powerful lol
If anyone has any useful info that could help, fire away

yes I am a mental diesel junky

 

[Chip-mk1]

You can buy aftermarket management for a diesel.

 

[Dr HMS Derv Destroyer]

I tried specialist diesel components after dan ( your mate )
said I could get aftermarket Ecu's. but that company came up short and said they haven't and never will make one for a pd.

if you or anyone can send me in the right direction, I'll be delighted as I'm f**king useless and find stuff

also is anything else going to be a nightmare ?

 

[ThomasBrentnall]

Subscribed. Will be an epic build

 

[Dan@SJM]

I'm finding that width with the 02m is a big ask, the 172 engines must me slightly smaller from fly to cambelt end as it fits fine with an 02m.

 

[Dr HMS Derv Destroyer]

I've measured up the pd lump with the 02m box on and it's a tight fit.
Plus the fact I'd have to throw away the aircon and power steering pump as space up front isn't big enough for rads + fans.

I'm hope'n the dci electric rack will hold up to 470 + torque

 

[Dr HMS Derv Destroyer]

Dan , how much of the chassis can I cut away and remake to clear stuff.
i know the box end sits almost level if not outside the chassis leg

 

[Dan@SJM]

Chassis isn't a problem. It's the extra depth of the o2m that causes the issues with the subframe and the wishbone mounting points.

 

[Dr HMS Derv Destroyer]

Subframe is a pain in the arse, the pd standard sump will foul the subframe so a dark sides development shortened sump will have to be fitted.

How are you getting round the drive shafts? I'm guessing the 02m shafts match the clio hubs?

 

[Spinksy]

Subframe is a pain in the arse, the pd standard sump will foul the subframe so a dark sides development shortened sump will have to be fitted.

How are you getting round the drive shafts? I'm guessing the 02m shafts match the clio hubs?

I keep hearing a lot about the Dark side Developments when talking about getting good power out of Dervs they seem to be building a good rep

If they don't match would custom driveshafts be a possibility?

 

[Dan@SJM]

At the moment I'm going to weld a clio one into the o2m one.

The shallow sump isn't enough. You need to chop the subframe out still. I'm too busy this week to be able to get a few more hour in on mine.

 

[Spinksy]

At the moment I'm going to weld a clio one into the o2m one.

The shallow sump isn't enough. You need to chop the subframe out still. I'm too busy this week to be able to get a few more hour in on mine.

Before or after the CV joint? And will welding be sturdy enough to tolerate bumps etc?

 

[Dr HMS Derv Destroyer]

I keep hearing a lot about the Dark side Developments when talking about getting good power out of Dervs they seem to be building a good rep

If they don't match would custom driveshafts be a possibility?

Yeah I can go custom but if i don't have to, it'll save a load of hassle lol.

Dark side developements are epic, 320bhp 500+ torque from a 1.9/2.0 tdi lump, i think that in a clio shell will keep up with Craig's boosted banana

 

[Spinksy]

Yeah I can go custom but if i don't have to, it'll save a load of hassle lol.

Dark side developements are epic, 320bhp 500+ torque from a 1.9/2.0 tdi lump, i think that in a clio shell will keep up with Craig's boosted banana

Jesus lol, I saw a golf they had worked on in Rotherham tonight at Ship Hill and they had fiddled about with anti-lag or something and the turbo whistle sounded mental and the car itself sounded monstrous!!!

 

[Dr HMS Derv Destroyer]

At the moment I'm going to weld a clio one into the o2m one.

The shallow sump isn't enough. You need to chop the subframe out still. I'm too busy this week to be able to get a few more hour in on mine.

I might aswell make a one off subframe out of box tube'n to suite the engine and suspension pick up points .

I assume you mean welding the inner cv joint of a 02m to the clio shafts ?

Before or after the CV joint? And will welding be sturdy enough to tolerate bumps etc?

Let alone the torque I'm planning on running....

 

[Dr HMS Derv Destroyer]

Jesus lol, I saw a golf they had worked on in Rotherham tonight at Ship Hill and they had fiddled about with anti-lag or something and the turbo whistle sounded mental and the car itself sounded monstrous!!!

Yupp it's on their site. Pop corn mod is what the anti lag you can hear ( the diesel one they built) they also built a 1.8T with silly power.

Pop corn mod is something I'm trying to get to be added to the mapping, once I've found a AF Ecu.

 

[Dan@SJM]

Welding with enough penetration will do fine.

Tbh I have been thinking of replicating the VAG subframes but it just won't overcome the issue as the problem is with where the gearbox fouls the wishbone mounting

 

[Spinksy]

I might aswell make a one off subframe out of box tube'n to suite the engine and suspension pick up points .

I assume you mean welding the inner cv joint of a 02m to the clio shafts ?


Let alone the torque I'm planning on running....

That was also a thought but Shirley the bump would be the bigger worry if they were just a temporary measure until you found some proper ones... (just drive gentle lol)

And would it not be best to do the welding after the CV joint before the end that attaches to the hub as the joint will then take most of the stress and half the shock of a bump instead of it impacting the welding? ( theoretically speaking, and only as a temp-measure)

 

[Dr HMS Derv Destroyer]

Dan, can't you rebuild the mounting points for the wishbones to over come that? Possibly take the design of the golfs setup?

Spinksy , me and dan do do stuff by half if you weld something, weld it properly.

 

[Spinksy]

Yupp it's on their site. Pop corn mod is what the anti lag you can hear ( the diesel one they built) they also built a 1.8T with silly power.

Pop corn mod is something I'm trying to get to be added to the mapping, once I've found a AF Ecu.

Awesome

Welding with enough penetration will do fine.

Tbh I have been thinking of replicating the VAG subframes but it just won't overcome the issue as the problem is with where the gearbox fouls the wishbone mounting

FairPlay with the first point

With the wishbone mounting would you not be able to fabricate your own to better suit the gearbox? (After a lot of time welding and effort mind)

Or mount the engine and box on lifters so it is nowhere near the wishbone mounting point? (Even if it leaves a few mm gap between the engine/box and the wishbone mounting whilst moving)

 

[Dr HMS Derv Destroyer]

Then if you go to high, your fouling other stuff , one being the bonnet

 

[Spinksy]

Dan, can't you rebuild the mounting points for the wishbones to over come that? Possibly take the design of the golfs setup?

Spinksy , me and dan do do stuff by half if you weld something, weld it properly.

Haha I'm not saying you do mate, I have the utmost faith in you and Dan which is why I am going to Dan in August for the belts etc and if I ever came into money would pay you to do a full respray and a decent engine conversion lol

Shirley there will be a mid point where it doesn't foul anything or you relocate smaller items and raise the bonnet if necessary

 

[Dan@SJM]

Problem is doing stuff like that you'll ruin the geometry and it won't handle anywhere near as well as it used to.

 

[Spinksy]

Problem is doing stuff like that you'll ruin the geometry and it won't handle anywhere near as well as it used to.

Drag car ?

 

[Dr HMS Derv Destroyer]

Haha I'm not saying you do mate, I have the utmost faith in you and Dan which is why I am going to Dan in August for the belts etc and if I ever came into money would pay you to do a full respray and a decent engine conversion lol

Lol I had a typo fail there don't do by half !

Haha , dan would probably do better than me at engine conversions, I only mess with diesels tbh.

Either way the logistics of doing this build will be a nightmare BUT there allot to gain from it, with the added smile factor that its the only dci to have a engine swap to something more powerful.

I might just have to struggle putting most of the car together and then trailer it to dan for the rest ( he'll finish his before I even get half way through mine )

 

[Dan@SJM]

Mine won't be, mines going to be a road car with occasional track. Hence retaining air con and PAS

 

[Dr HMS Derv Destroyer]

Problem is doing stuff like that you'll ruin the geometry and it won't handle anywhere near as well as it used to.

Must be a way of getting round it, some hybrid mix of clio and vw parts to make the suspension setup , yet still keep the clio handling characteristics


Mines going to be a road car to, no crappy straight line runner. I can afford to lose PAS asking as the dci EPAS can handle it. Aircon Iv degassed on my dci already , never use it tbh

 

[Spinksy]

Lol I had a typo fail there don't do by half !

Haha , dan would probably do better than me at engine conversions, I only mess with diesels tbh.

Either way the logistics of doing this build will be a nightmare BUT there allot to gain from it, with the added smile factor that its the only dci to have a engine swap to something more powerful.

I might just have to struggle putting most of the car together and then trailer it to dan for the rest ( he'll finish his before I even get half way through mine )

Lol,

By sounds of it Ryan you will find a way mate, you sound determined enough and there will always be a way

What about shoe-horning a Laguna 1.9 TDi lump with box in and getting big figures out of that? (May be slightly bigger but be a different enough shape to limit fouling)... I genuinely don't know as I haven't looked but I thought I would suggest something lol

 

[Dr HMS Derv Destroyer]

Lol,

By sounds of it Ryan you will find a way mate, you sound determined enough and there will always be a way

What about shoe-horning a Laguna 1.9 TDi lump with box in and getting big figures out of that? (May be slightly bigger but be a different enough shape to limit fouling)... I genuinely don't know as I haven't looked but I thought I would suggest something lol

One reason, 1.9 Renault diesel lumps are crap, even more crap with the crappy fuel system they use.

I will make a pd lump fit and work.

Looked into all this renault bigger engines and non really tick the box, meggy 1.9s suffer from stuck piston rings and crappy Delphi fuel systems, 2.0-2.2 dci's are just to big and heavy. Doesn't leave me with any other choices

 

[Spinksy]

One reason, 1.9 Renault diesel lumps are crap, even more crap with the crappy fuel system they use.

I will make a pd lump fit and work.

Looked into all this renault bigger engines and non really tick the box, meggy 1.9s suffer from stuck piston rings and crappy Delphi fuel systems, 2.0-2.2 dci's are just to big and heavy. Doesn't leave me with any other choices

Ah, genuinely wasn't aware of their problems mate, what about an Audi TDi?

 

[Dan@SJM]

That's what he's fitting

 

[Dr HMS Derv Destroyer]

Same engine mate, VAG 1.9/2.0tdi pd lump is fitted in those , golfs/bora's skoda fabia VRS ect.

 

[Dr HMS Derv Destroyer]

That's what he's fitting

Lol

 

[hanby42]

Sounds immense this! Had a vag 130 lump in my last car and that pulled like s**t in a big car! Never mind with mods and in a small car!!!!!

SUBSCRIBED!

 

[Spinksy]

That's what he's fitting

Same engine mate, VAG 1.9/2.0tdi pd lump is fitted in those , golfs/bora's skoda fabia VRS ect.

Tbh I wasn't sure if it was or not *blushes* il stay quiet and just follow the progress lol

 

[Scrooge]

Good plan. Pd engines are awesome. I love mine!

 

[Dr HMS Derv Destroyer]

Few more parts to get and then set a time to start it and we'll be starting it.

Main priority is finding an Ecu first!

 

[Dr HMS Derv Destroyer]

Tbh I wasn't sure if it was or not *blushes* il stay quiet and just follow the progress lol

It's all a learning curve

 

[mikeh]

Forgive me for being a pessimist.

But for the sake of a Diesel shopping car - if you want to tune it, why not just start with a GTTDI or in fact, any PD engined Golf/A3/Fabia?

 

[Chip-mk1]

Forgive me for being a pessimist.

But for the sake of a Diesel shopping car - if you want to tune it, why not just start with a GTTDI or in fact, any PD engined Golf/A3/Fabia?

Must admit Im of the same mindset that putting all that effort in just to end up with a fairly quick diesel clio, seems like a lot of work for not a lot of gain.