Efficient Diesel Engine Conversions

 Efficient Diesel Engine Conversions An Appropriate Solution for Light and Heavy Duty Work Trucks Spencer Steelman 2003 Summary Most of us are dependent upon petrol-­‐powered vehicles for everyday commuting, recreation and work use. As concerns arise for global warming, environmental impact, and soaring fuel prices, most of us are left wondering how to address the problems. For the automobile industry hybrid-­‐electric and electric plug-­‐
In technology is advancing and slowly working its way into the market. This is a great approach for combatting these problems but what about the work vehicle? Those who depend or their light duty or heavy duty trucks are stuck paying more at the pump with out any hybrid-­‐electric/plug-­‐in options. There is simply nothing on the market for true work vehicles to help with these problems. My solution is to swap more fuel efficient diesel engines into these older work trucks for greatly improved fuel economy and an over all lower environmental impact. Current State of U.S. Work Vehicles The Problem During the past century, Compact hybrid-­‐electric/plug-­‐
automobiles in the United States have in cars are wonderful for the masses notoriously been known for high fuel but what about rural America or consumption rates. Most of the where heavy work requirements are vehicles in the U.S. are gasoline needed? Those who commute long consumers. Not until recent years distances daily to large metropolitan have we begun to see national areas will benefit from hybrid-­‐
attempts to decrease fuel electric/plug-­‐in technology, however, consumption. However, there were the farmer, contractor, auto some more efficient diesel engine technician, etc. may not. These options manufactured between 1957 individuals on average require the use and 2001. These engines are virtually of a heavier duty, long-­‐range vehicle unknown to the average American, with a truck bed for their everyday thus being lost in the pages of time. task. Not only is a tough and durable Currently, hybrid-­‐
vehicle needed, they usually require a electric/plug-­‐in technology is more powerful engine to haul their sweeping the stage and making heavy payloads. Currently, hybrid-­‐
headlines for its incredible efficiency electric/plug-­‐in technology is unable over traditional options. Hybrid-­‐
to supply the need. Most tradesmen electric technology has vastly are left driving a very fuel inefficient improved since its debut with the six or eight-­‐cylinder engine. Most are Toyota Prius in 1998. Now, in 2013, gasoline consumers and the few diesel there are even several plug-­‐in electric options are very large displacement versions of automobiles available to engines with limited gearing. consumers. This, by far, has proven to Even if there were hybrid-­‐
be the best option for the average auto electric/plug-­‐in options available owner. Tailpipe emissions have been most of these individuals could not drastically reduced while overall afford to purchase the new vehicle. automobile pollution is still There is also the problem of natural staggering. resource depletion. If everyone were to purchase a new vehicle would there These engines are readily available not be a large amount of wasted and can be found in junkyards, embodied energy left in the old internet suppliers, and various other vehicles? Upon purchasing a new auto, places. They all have a vast array of something has to be done with the old parts available both aftermarket and one. According to (Appendix A.) O.E.M. (Original Equipment “What happens to all the millions of Manufacturer). The overall cost to perfectly good used cars? Did it not convert a vehicle would be cheaper take resources to create them as well? than that of a new, slightly more You might say that recycling the old efficient model. All of these engines car is the answer, but not the entire are also biodiesel and waste vegetable car is recyclable and it also takes oil compatible thus improving the energy to redirect the resource.” environmental impact of work trucks. Solution Light Duty Trucks The vast majority of work may be I am proposing the solution of appropriately converting work accomplished with a light duty pickup vehicles into fuel-­‐efficient machines truck like one of these popular models while supplying the work demand listed by manufacturer. needed. I will be using 3, 4, and 5 •
Chevrolet (S-­‐10) cylinder diesel engines because of •
Dodge (Dakota) their efficiency over traditional large •
Ford (Ranger) displacement gasoline and diesel •
Jeep (Comanche and J-­‐
engines. These engines are the ones that were briefly mentioned above, manufactured from 1957 -­‐ 2001. All Series) •
Toyota (Pickup, Tacoma, T-­‐100) conversions will be mechanical In fact, most tradesmen already have injection pump engines, meaning they one of these along with a heavy-­‐duty are non-­‐electronically controlled for truck. It is simply all around cheaper, ease of conversion, maintenance, more environmentally friendly, and simplicity, and longevity. overall more efficient to operate a conversation. The 0M617 5-­‐cylinder light duty truck whenever possible. was introduced to the U.S. in 1978 and Fuel economy may be greatly is among the most reliable diesel increased by utilizing these options engines ever manufactured in the below. world. These engines were not overly The conversion process will powerful but were very economical. basically consist of the same task and My father owns a Mercedes Benz parts requirements for all the vehicles 300D with this engine. He averages mentioned above. I will be showing 32-­‐35 mpg and has over 310,000 the conversion requirements for my miles on the car. This car is Toyota 4x4 Pickup. However, this will give a general idea of conversion cost for other light duty trucks as well. Materials and prices will be listed in the budget section. Light Duty Test Vehicle Specifications •
1986 Toyota Pickup 4x4 •
22r 2.4L 4 cylinder Gasoline Figure 1. Mercedes OM617 Engine what sparked my fascination with Engine diesel engines. •
97 hp & 129 lb.ft. Torque Engine Specifications •
5-­‐Speed Manual Transmission •
17mpg Avg. Fuel Economy •
22r Weight Approximately 350 •
3.0L Inline 5 Cylinder Turbo lbs. •
80hp -­‐125hp & 180 lb.ft. •
Manufactured Between 1978 and 1985 Torque Depending on Year Mercedes Benz OM617 Model When diesel engines are discussed this one almost always emerges somewhere amongst the •
Weight Approximately 600 lbs. •
Rumored Economy in Light Duty Truck 25-­‐30 mpg Pre-­‐1998 Volkswagen TDI claimed an average of 50 mpg with their Volkswagen Diesel. Volkswagen introduced their line of 1.5L and 1.6L diesel engines to Engine Specifications the consumer market in 1970. They •
Manufactured 1993-­‐1997 were a success and later on used the •
1.9L TDI 4 Cylinder (Turbo same engine for industrial Charged Direct Injection) applications in Europe. Many feel that •
90hp & 155 lb.ft. Torque the Volkswagen line of diesel engines •
Weight Approximately 400 lbs. is equal to the Mercedes Bens OM617. •
Rumored Light Duty Pickup They were introduced as a naturally Economy 30-­‐35 mpg Heavy Duty Trucks (1/2 -­‐ 1 ton) For those jobs where a light duty truck is insufficient a heavy-­‐duty truck is used. These include the popular ½ ton – 1 ton trucks listed by manufacturer below. •
Chevrolet (Scottsdale, Cheyenne, 1500, 2500, 3500) •
1500, 2500, 3500) Figure 2. Volkswagen 1.9L TDI aspirated indirect injection and in Dodge (D150, D250, D350, •
Ford (F-­‐100, F-­‐150, F-­‐250, F-­‐
1993 evolved into the 1.9L Turbo that 350, F-­‐Super Duty) lasted through 1997. I will be testing Typical work trucks come with a the 1993-­‐1997 1.9L because the turbo minimum of a V-­‐8 and sometimes a V-­‐
increases its efficiency. These engines 10 gasoline engine. The problem here are smaller than the Mercedes Benz is that a big block gasoline engine is OM617 but tend to be a little more extremely inefficient with fuel expensive to purchase. Many have economy ranging from 5 mpg -­‐ 16 mpg depending on engine and truck size. Most ¾ ton and up trucks are Cummins 4bt & 6bt available with a diesel option. Ford and Chevrolet both offer V-­‐8 Diesels founded in 1919 is the supreme diesel while Dodge offers the Inline 6 engine builder. 1989 Cummins Cummins 5.9L. The diesel options debuted the B-­‐series, which was an with the exception of the Cummins instant success. The inline 4 and 6 rarely ever see more than 16 mpg configuration allowed the B-­‐series to unloaded while the Cummins 5.9L produce more low end torque than may reach 22 mpg unloaded. We any other truck diesel offered for discuss fuel economy in unloaded years to come. Many will argue that Cummins miles since no cargo weighs exactly the same. I will be discussing the conversion requirements for my 1997 Ford F-­‐Super Duty. However, this will give a general idea of conversion cost for other heavy-­‐duty trucks as well. Materials and prices will be listed in the budget section. Heavy Duty Test Vehicle Specifications •
1997 Ford F-­‐Super Duty •
2wd 5-­‐Speed Manual Transmission •
Dually with 12’ Dump Bed •
7.3L Powerstroke Diesel •
250 hp & 520 lb.ft. Torque •
Weight Approximately 950 lbs. •
Fuel Economy Average 10-­‐13 mpg Figure 3. Cummins 3.9L 4bt Low RPM combined with fewer cylinders made the Cummins B-­‐series the most fuel-­‐efficient truck engine money could buy. There are numerous parts available for these motors while most are interchangeable between the 4bt and 6bt. 4bt Engine Specifications •
Manufactured 1989-­‐2002 •
3.9L Inline 4 Cylinder Turbo Direct Injection Detroit 3-­‐53T & 4-­‐53T Detroit Diesel founded by •
105 hp & 265 lb.ft. Torque General Motors in 1937 will forever •
Weight Approximately 750 lbs. be known for their “Screaming •
Rumored Fuel Economy 25-­‐30 Detroit” two-­‐cycle diesel engines. mpg Unloaded They are very unique and millions of Better for ½ -­‐ ¾ Ton them were manufactured. Detroit Conversion than 6bt Diesel manufactured a total of five •
6bt Engine Specifications different two-­‐cycle diesel families •
Manufactured 1989-­‐1998 between 1937 and 1986. We will be •
5.9L Inline 6 Cylinder Turbo focusing on the 53 series engine Direct Injection family that was introduced in 1957. 160 – 215 hp and 400 – 440 All of these engines are considered lb.ft. Torque industrial grade with extremely heavy •
Weight Approximately 975 lbs. engine blocks. Most even include a •
Rumored Fuel Economy 18-­‐22 •
mpg Unloaded factory Jacobsen Engine Brake. They are very durable and are capable of producing enormous amounts of power for their small displacement. The two-­‐cycle design allows combustion with every rotation of the crankshaft unlike it’s four cycle cousin that combusts every two rotations. This allows the power to displacement ratio to be dramatically increased over Figure 4. Cummins 5.9L 6bt •
Better for 1 Ton Applications than 4bt the four-­‐cycle. Detroit Diesel engines are tough when it comes to adapting to transmissions of other vehicles and most swaps require custom transmission bell housing adapters. The shortcut to this problem is to find a junk vehicle and use factory transmission that is already mounted to the Detroit Diesel. Most of these transmissions are industrial 9 and 10-­‐
speeds which is a much better option for towing heavy cargo anyways. Figure 6. Detroit 4-­‐53T 4-­‐53T Engine Specifications •
4 Cylinder – 53 Cubic Inch Per Cylinder -­‐ Turbo •
175 hp & 400 lb.ft. Torque •
Weight Approximately 1300 lbs. Figure 5. Detroit 3-­‐53T •
3-­‐53T Engine Specifications •
20 mpg Unloaded 3 cylinder – 53 Cubic •
Inch per Cylinder -­‐ •
•
•
•
Rumored Fuel Economy Better for 1 Ton Conversions Turbo Budget 131 hp & 229 lb.ft. Torque converting these engines will be Weight Approximately moderately expensive projects but not 950 lbs. anywhere close to that of what a Rumored Fuel Economy hybrid-­‐electric/plug-­‐in electric would 20 mpg Unloaded cost if it were to be available. It would Better for ½ Ton – ¾ also be more cost effective than that of Ton Conversions a new slightly more efficient truck. Overall cost of successfully It will not be an easy task and will conversion cost charts are general require an understanding of ideas of what the total expense would mechanical systems and metal be. I have performed a few fabrication. I will be converting one restorations and engine swaps over light duty truck and one heavy-­‐duty the years and know that it is almost truck with the engines that can be impossible to predict the exact cost purchased for the best price. Trucks to just because every project differs from be converted and tested are the same one another. ones as used above. All of the Table 1. Mercedes Benz OM617 Budget Part Good Used OM617 Adapter Plate Toyota Clutch Fuel Lines/Filters Motor Mounts Misc. Steel/Fasteners Exhaust Work Clutch Cost Quantity Total $1,000.00 1 $1,000.00 $775.00 1 $775.00 $110.00 1 $110.00 $100.00 1 $100.00 $100.00 1 $100.00 $200.00 $300.00 $210.00 1 1 1 Total $200.00 $300.00 $210.00 $2,795.00 Supplier Junk Yard 4x4 Labs Napa Napa Ebay Tractor Supply Co Local Shop ATC Table 2. Pre-­‐1998 Volkswagen TDI Budget Part Good Used '93-­‐'97 TDI Adapter Plate Fuel Lines/Filters Motor Mounts Misc. Steel/Fasteners Exhaust Work Clutch Cost Quantity Total $2,000.00 1 $2,000.00 $475.00 1 $475.00 $100.00 1 $100.00 $100.00 1 $100.00 $200.00 $300.00 $210.00 1 1 1 Total $200.00 $300.00 $210.00 $3,385.00 Supplier Junk Yard Acme Parts Napa Ebay Tractor Supply Co Local Shop ATC Table 3. Cummins 4bt Budget Part Used 4bt In-­‐Frame Rebuild Kit Adapter Plate/Clutch/Starter Fuel Lines/Filters Motor Mounts Misc. Steel/Fasteners Exhaust Work Cost Quantity Total Supplier $2,000.00 1 $2,000.00 Junk Yard $475.00 1 $475.00 Ebay $1,400.00 $100.00 $60.00 $200.00 $300.00 1 $1,400.00 Ebay 1 $100.00 Napa 1 $60.00 Ebay Tractor Supply 1 $200.00 Co 1 $300.00 Local Shop Total $4,535.00 Table 4. Cummins 6bt Budget Part Cost Quantity Total Supplier $1,500.00 1 $1,500.00 Junk Yard $595.00 1 $595.00 Ebay Used 6bt In-­‐frame Rebuild kit Adapter Plate/ Clutch/Starter Fuel Lines/Filters Motor Mounts $1,400.00 $100.00 $60.00 Misc. Steel/Fasteners Exhaust Work $200.00 $300.00 1 $1,400.00 Ebay 1 $100.00 Napa 1 $60.00 Ebay Tractor Supply 1 $200.00 Co 1 $300.00 Local Shop Total $4,155.00 Table 5. Detroit 3-­‐53T Budget Part Used 3-­‐53T with transmission In-­‐frame Rebuild Kit Fuel Lines/Filters Motor Mounts Misc. Steel/Fasteners Exhaust Work Cost $2,000.00 $875.00 $100.00 $100.00 $200.00 $300.00 Quantity Total 1 $2,000.00 1 $875.00 1 $100.00 1 $100.00 Supplier Junk Yard Diesel Specialist Napa Ebay Tractor Supply 1 $200.00 Co 1 $300.00 Local Shop Total $3,575.00 Table 6. Detroit 4-­‐53T Budget Part Used 4-­‐53T with transmission In-­‐frame Rebuild Kit Fuel Lines/Filters Motor Mounts Misc. Steel/Fasteners Exhaust Work Cost $3,000.00 $1,088.00 $100.00 $100.00 $200.00 $300.00 Quantity Total Supplier 1 $3,000.00 1 $1,088.00 1 $100.00 1 $100.00 Junk Yard Diesel Specialist Napa Ebay Tractor Supply 1 $200.00 Co 1 $300.00 Local Shop Total $4,788.00 Conclusion Not everyone is able to purchase a newer more fuel-­‐efficient truck but with this information these conversions listed are not impossible. This would be a wonderful approach for reducing the average work trucks carbon footprint drastically. If implemented this would prevent the mining of millions of tons of natural resources. It may be costly but it not a drop in the bucket when compared to a new truck. When its over you will not have a new truck but you sure will have a unique ride that is capable of operating on biodiesel and vegetable oil. Bibliography http://en.wikipedia.org/wiki/Toyota_R_engine http://en.wikipedia.org/wiki/Mercedes-­‐Benz_OM617 http://www.acmeadapters.com/store_engine.php http://www.hpamotorsport.com/tdiconversions.htm http://www.mercedesdiesel4x4.com/ http://en.wikipedia.org/wiki/Volkswagen_Passat_(B4) http://en.wikipedia.org/wiki/Ford_Power_Stroke_engine http://en.wikipedia.org/wiki/Cummins_B_Series_engine http://www.cumminsdieselspecs.com/4bt.html http://www.cumminsdieselspecs.com/12v.html http://en.wikipedia.org/wiki/Detroit_Diesel http://www.barringtondieselclub.co.za/353DetroitDiesel.html http://www.adieselengine.com/new_page_1.htm http://image.dieselpowermag.com/f/tech/dodge/1204dp_million_mile_cummin
s_rebuild/40502448/1204dp_01%2Bmillion_mile_cummins_rebuild%2Bcummi
ns_6bt_on_engine_stand.jpg http://www.legacypowerwagon.com/assets/images/cummins_4bt_39_literturb
o-­‐diesel.jpg http://www.peachparts.com/shopforum/attachments/diesel-­‐
discussion/20006d1090957897-­‐nekkid-­‐om617-­‐om617.jpg http://deas.com.au/content/engines/detroit/453/udr_spec_3/P1010522.jpg http://www.evwparts.com/images/EngineTDI_ALH.jpg Appendix A. Appropriate Automobile Drive Conversions Automobile fuel economy is unacceptably low for the average owner and we seem to feel that the only way to combat this problem is to purchase a new, more fuel-­‐efficient car. The problem is what happens to all the millions of perfectly good used cars? Did it not take resources to create them as well? You might say that recycling the old car is the answer, but not the entire car is recyclable and it also takes energy to redirect the resource. My solution is to research the conversion of used vehicles into more fuel-­‐
efficient cars while consuming less energy and resources than building new cars. I will be looking into the possibilities of electric vehicle conversions for smaller commuter vehicles. For larger vehicles/work vehicles I will be researching Volkswagen 4 cylinder and Mercedes Benz 5 cylinder diesel engine swaps. These diesels have far greater fuel efficiency than gasoline competitors while offering the option of bio-­‐diesel. I will need to purchase two older vehicles, one smaller commuter and one heavier work vehicle. I will purchase a junkyard diesel engine that I feel is the best value. A bell-­‐housing adapter will be purchased from Advance Adapters. I will be purchasing an EV kit from an online resource and then begin my project. I feel that the project can be completed within 1 – 1.5 years. I will need $15,000 dollars to purchase the materials. I will supply the garage and all tools needed for the projects. I feel that I am qualified for this project. I am a senior in Appropriated Technology and Environmental Design at Appalachian State University. I have been a mechanic all of my life and currently work for Sterling Trucking in Hamptonville, NC as an 18-­‐wheeler mechanic. I am confident in my abilities to complete this project successfully.