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Thread: 300TDI WVO Conversion

  1. #1
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    300TDI WVO Conversion

    I decided to document the conversion of my Discovery to use WVO/UCO (Waste Vegetable Oil/ Waste Cooking Oil).


    Project Part 1: Installing Twin tanks. (Diesel/WVO)

    I sourced some lovely sill tanks from a fellow 'Landrover Enthusiest' on Friday, so the first task was installing them.



    I wanted to install a stock sender into the tank, so I could use the original dash gauge to indicate fuel levels, so got angry on the tank with the grinder.




    Shallower tank, and different sizes required some float modification.



    Some pictures inside the tank.




    I had originally intended on using the fuel pickup/return on the sender I was installing, but looking inside the tank convinced me to use the tank pickup instead.



    Filling was originally designed to be via ‘marine hatch’ under the footwell mat, but I intended otherwise.
    The pretty metallic ring is off an old steering wheel I had kept for some reason, probably because it was pretty and too good to throw away, good thing I kept it after all!



  2. #2
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    Weld in the filler.



    Weld on the mounts.



    Some spray paint makes it look a bit prettier




    “Lest we forget”


  3. #3
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    Now the filler. I raided a engine oil filler housing off a motor years ago ‘be handy one day!!’, and so it finally came in handy!

    Machined down a lip for it to adapt to the filler pipe.



    As the material size would allow direct fitment to the filler pipe, had to do it in two stages, fit the filler cap to the sleeve, then the sleeve to the pipe.



    Tight fit, and with a tiny smear of blue, it will never come apart, and never leak! (hope)



    “Together at last, a match made.. IN THE WORKSHOP!!”





    Some more blue, some rubber and a plate to keep them all together.
    Also not having a compatible connector, araldite makes a strong alternative



    Installed nicely.



    Connected nicely.


  4. #4
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    Finished off nicely!!


  5. #5
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    Project Part 2: WVO ‘Conversion’


    The Raw components:

    Pollak Valve: comes with 6 ports, diesel in, diesel return, wvo in, wvo return, and the connections to and from the motor.



    Heat Exchanger: comes in various sizes, this one is a ’30 plate’ unit.



    It has 30 plates between which alternating fluids flow with a copper plate in between for efficient thermal transfer.



    Pollak and heat exchanger installed nicely.
    Also added a vacuum gauge to the fuel supply line to monitor the condition of the filters, not much use in the engine bay, but it was a nice gauge I had raided and saved so I just had to use it! in cabin gauge to come.

    Coolant and Fuel lines connected.



    Coolant lines installed connects the heat exchanger in series with the cabin heater.
    Dual filters, one for each fuel type to save on contamination of the fuels between the tanks.

    I just need to find some banjo fittings and we will be ready to go!



    Diesel goes here.



    Oil goes here.


  6. #6
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    A nice switch in the cabin actuates the pollak valve. Red light for WVO



    And we are now WVO powered


  7. #7
    Join Date
    Sep 2005
    Location
    WA
    Posts
    4,152

    Re: 300TDI WVO Conversion

    Setsuna
    Excellent pictorial of your conversion, Well Done!

    Nice touch with the "WVO Powered" sticker

    Tony
    Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

    Current Vehicles in stable:
    '85 Mercedes Benz W123 300CD Turbodiesel single tank using 95% used cooking oil and 5% to 10% misfuel (where someone had filled diesel vehicle with petrol).
    '06 Musso Sports Crew Cab. Running on used cooking oil with 5% to 10% misfuel.
    Toyota Camry Hybrid - (Wife's Car)

    Previous Vehicles:
    '90 Mazda Capella. (2000 - 2003) My first Fatmobile. Converted to fun on veggie oil with a 2 tank setup. Died when supercharger stuck at max boost for weeks. Stretched head bolts.
    '80 Mercedes 300D. 2 tank conversion [Sold]
    '84 Mercedes 300D. 1 tank, no conversion. Replaced engine with rebuilt OM617A turbodiesel engine. Finally had good power. Donor for current Fatmobile coupe. (body parted out and carcass sold for scrap.)
    '99 Mercedes W202 C250 Turbodiesel (my darling Wife's car)[sold]
    '98 Mercedes W202 C250 Turbodiesel (my car)[sold]
    Parts Car C220 1993 All body panels, headlights, interior engine and ECU available.


    Searching the Biofuels Forum using Google
    Adding images and/or documents to your posts


  8. #8
    Join Date
    Dec 2007
    Location
    South Australia
    Posts
    1,149

    Re: 300TDI WVO Conversion

    Good photos and neat conversion. Are you going to insulate your FPHE? Is the WVO filter between FPHE and IP? Heated filter?
    Your Disco, it's direct injection?
    Johnnojack
    4WD Isuzu Jackaroo 3.1 170,000km on WVO,(2017) 2 tank home built system 6 solenoids. Mk. 9 version. Improvements under investigation

  9. #9
    Join Date
    Sep 2006
    Location
    Perth
    Posts
    48

    Re: 300TDI WVO Conversion

    I don't intend on insulating the FPHE, as the oil gets well hot enough to run nicely.

    I may heat the oil filter later on though, as the filter is after the FPHE and the oil there is dead cold when it is fed to the engine when initially switched over. it runs, and doesn't have a problem (which I was quite surprised about).

    David

  10. #10
    Join Date
    Dec 2007
    Location
    Lake Macquarie (just south of Newcastle) NSW
    Posts
    1,363

    Re: 300TDI WVO Conversion

    Quote Originally Posted by setsuna View Post
    I don't intend on insulating the FPHE, as the oil gets well hot enough to run nicely.

    I may heat the oil filter later on though, as the filter is after the FPHE and the oil there is dead cold when it is fed to the engine when initially switched over. it runs, and doesn't have a problem (which I was quite surprised about).

    David
    I wouldn't be surprised at that, as long as the engine is warm before you switch over. You are in Perth - where it generally does not get too cold.
    I would expect your vehicle to run very well on cold oil - even down around 10oC.
    It is good to heat the oil before the filter to ease its passage through the filter, to avoid fuel starvation and integral lift pump cavitation. What sort of IP is on your vehicle? If it is a Bosch 'clone' then you should have no trouble supplying cold oil to it initially on switch over. If it is a Lucas 'clone' then you should add another HE just before the IP to ensure that it is never fed with oil at less than 40oC to avoid catastrophic failure.

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