VW/AUDI 3.0TDI marinising

Discussion in 'DIY Marinizing' started by MihaS, Nov 2, 2011.

  1. efsta
    Joined: Dec 2011
    Posts: 1
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    Location: vasiliko 34002 Greece

    efsta New Member

    vw -audi marinization

    Hi Mihas
    I have reed carefully your efforts to succed and believe you did a nice job.
    I will contact your friend concerning the electronics but iwould like to phone you
    for some clarifications please email me> eusta100@otenet.gr .
    regards and happy new year
    efsta
     
  2. MihaS
    Joined: Jan 2011
    Posts: 45
    Likes: 2, Points: 8, Legacy Rep: 29
    Location: Adriatic

    MihaS Junior Member

    Hi to all

    Again I start this project. And like i promised you I post new video so you can see it here.

    http://www.youtube.com/watch?v=X5ZYajPLtp4&feature=plcp

    I install new fuel pump and filter. Then i also mount hidraulic pump bottle.

    So here it is in one month will be intalled and tested in boat.


    By
     
  3. gagarin
    Joined: Aug 2012
    Posts: 7
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    Location: Athens

    gagarin Junior Member

    Marinising V6 TDI 2.5l

    Hi Mihas,

    Thanks for sharing with us all your knowledge with this project.
    We are working a similar marinisation with a V6 TDI 2.5 and all your work and suggestions are very useful.
    I was also thinking to replace the DMF with Valeo SMF. The current DMF is in good working condition but I think that the continues heavy load will cause problems soon.
    What your opinion about DMF for boating use. VW (Cummins) marine is using them in all models I think.
    Did you notice any vibration with your machined SMF?
    Here is a video from the first attempts after deimmo the ECU.
    http://www.youtube.com/watch?v=3DUVENIo1jE&feature=player_detailpage#t=230s

    Thank you in advance
    Vasilis
     
  4. MihaS
    Joined: Jan 2011
    Posts: 45
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    Location: Adriatic

    MihaS Junior Member

    Hi

    Gagarin, i check yours video and engine runs smooth.
    About DMF (flywheel) ,my opinion is that in avtiomotive industries is much more money spent on development that in marine. So DMF flywheel is new age piece and some of cars have it instaled 10-15years and many kilometers on engine.But all parts have life age shorter then they can be,because servicing and selling new parts.

    When i was repairing /instaling Mercruiser diesel VM Dtronic 2,8es i was surpised because their version of DMF flywheel,in my opinion is better build and will last longer then usual car DMF,also after their DMF they have bolt on usual mercruiser (rubber) coupler. So they have 2 stage before gets to main shaft.

    I made my own flywheel because i dont have original DMF and new is expensive.On the end off story it would be better to buy new in first place.

    But in every story we learn something new.

    Now i buy DTS control for shifting and throtle + mercruiser shift actuator. Now we have some problems because on CMD mercruiser site there is that those engines are compatible with DTS controls,but when i want to order modul that is compatible with it ,they said CMD support that those engines dont have this module.
    Now im confused,i know that thotle is conecting thru CAN but i dont know what kind of parameters throtle have on output. If anybody have any sugestions, i would be happy to hear it.

    Gagarin ,what kind of heat exchanger,intercooler do you install,did you do it yourself.

    Thanks
     
  5. gagarin
    Joined: Aug 2012
    Posts: 7
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    Location: Athens

    gagarin Junior Member

    Hi again,

    Mihas Thank’s for the extend reply and your suggestion about DMF. I think I will take the risk and stay with the current flywheel. A new solid Valeo comes together with clutch kit and it’s quite expensive ~ 630 €.
    About shifting and throttle in my case i have in my mind to use my old conventional Volvo Penta controls and adapt the accelerator pedal sensor by cutting it small, drilling some holes on it and connect it in the throttle cable.
    For charge air cooler I plan to use a low cost universal water to air aluminum Intercooler and two stages sea water heat exchanger circuit.

    In the aluminum intercooler I will have close circuit coolant and the central sea water heat exchanger will feed both engine and charge air cooler. Complex approach that may become a disaster and in the end I may use two expensive similar to yours sea water heat exchangers.

    Best Regards,
    Vasilis
     
  6. MihaS
    Joined: Jan 2011
    Posts: 45
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    Location: Adriatic

    MihaS Junior Member

    Vasilis

    I was also looking this aluminium intercooler ,but you will have 70C engine coolant temperature.But as you know air from turbine must be cooled.
    Even if you install car intercooler in position that gets fresh air and install el. ventilator would be better,because outside temperature is cca 30-40 deg C, and you will have 70. This is not good at all.

    When i was searching intercoolers,I found one company from USA,that makes ALU intercoolers, but they are painted with some (nasa tech) paint. So inside of intercooler can be saltwater and they can make you intercooler as you wish.

    I have now 3d models for intercooler and heat exchanger,next week we will make fist round of alu castings(heat exchanger,intercooler,exhaust....) for this engine. In one month i think i will have prepared DIY kit for 3.0 tdi engine.

    Best regards

    Miha
     
  7. gagarin
    Joined: Aug 2012
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    Location: Athens

    gagarin Junior Member

    Mihas thanks for the suggestions.
    Can you give me some more details about this USA company as a secondary solution. For the current approach I haven’t explained correct with details the complete circuit. The main saltwater heat exchanger will feed both engine and intercooler but with different circuits. The intercooler will have a separate electric pump that will continuously feed with cold water. The main saltwater heat exchanger will be handmade with double input-output in the closed circuits. I came up in this idea in order to keep the cost as low as possible and less weight but I am not sure that this will be feasible. That’s why I said it’s complex and may became a disaster.
    Do you mean that you will produce your own aftermarket parts? I am really interested for the water cooled exhausts because most probably match also in the 2.5L.

    Thanks again for your help.

    Vasilis
     
  8. MihaS
    Joined: Jan 2011
    Posts: 45
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    Location: Adriatic

    MihaS Junior Member

    Yes I will have my own aftermarket kit for this engine. Exhaust,intercooler,heat exchanger,ECU and all mountigs.

    Best regards
     
  9. gagarin
    Joined: Aug 2012
    Posts: 7
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    Location: Athens

    gagarin Junior Member

    That’s really nice. Will you also produce the mounting and coupler for the water pump?
    I will do some measurements and ask you to see if both engines (3.0 & 2.5) have similar geometry for the mountings and exhaust output. You will save me from a lot of work if parts fits also in 2.5L.
    When pricing will be available I am interested to know.:):)

    Regards,
    Vasilis
     
  10. MihaS
    Joined: Jan 2011
    Posts: 45
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    Location: Adriatic

    MihaS Junior Member

    Vasilis

    I will have in mind for yours request. But I think that 2.5 and 3.0 V6 engine is not so similar.
     
  11. gagarin
    Joined: Aug 2012
    Posts: 7
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    Location: Athens

    gagarin Junior Member

    Hi Mihas,

    Any news about the project? Did you manage to put the engine in the boat?

    Regards
    Vasilis
     
  12. Hukon
    Joined: Jun 2016
    Posts: 2
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    Location: Netherlands

    Hukon New Member

    Hello, I also did marinise his older brother, the 2.5 V6.
    Here a little video how it is doing after more then a decade!
    https://youtu.be/AaZN2nHcMaE

    How is your project going?
     
  13. gagarin
    Joined: Aug 2012
    Posts: 7
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    Location: Athens

    gagarin Junior Member

    Mine almost completed but due to new taxation in Greece for boats above 5m i stopped all activities. Unfortunately i have to pay about 1.5k € per year for this 6m boat and this is not fusible. You have inspired me starting this project and government “inspired” me to pause it :(

    Regards,
    Vasilis
     
  14. MihaS
    Joined: Jan 2011
    Posts: 45
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    Location: Adriatic

    MihaS Junior Member

    Hello Vasilis,Hukon and others,

    engine still work fine, I was very happy with power of the engine and fuel consumption.

    New owner is very happy also, he allredy bought third boat from me which I also produce.

    Hukon did you make new exhaust manifolds or what? I think you are cooling engine with non salt water, is this correct.

    3.0tdi engine never had any problems with electronics.

    Now I have new marinization project in finalization so you can check in new thread.
     

  15. DonziZ33
    Joined: Sep 2017
    Posts: 2
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    Location: Norway

    DonziZ33 New Member

    Hi Mihas,

    After reading the tread of marinisation of Audi/VW 3,0 diesel engine, it seems like you have great experience of this type of project. You mentioned that you will have your own aftermarket kit for this engine. I intend to install to diesel engines in my Donzi Z33 Crossbow. My budget don't allow me to purchase to new VW 3,0 marine engines, so this marinisation project could be a very good solution for me. Please contact me for more information.

    Thank you in advance.

    Best regards
    Andre
    Norway
     
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