Simtek BodyLogic



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  • 2010

    Our 2.7 TD V6 Discovery project is now complete and has been a rip roaring success! We have transformed the V8 300 series Discovery into a diesel burning monster!

     

    Our Project Discovery 300 Series V8 Petrol

    Discovery 1 to TDV6 Conversion Project

    Our newly purchased Discovery V8 Petrol conversion vehicle ready to undergo surgery, we chose the V8 petrol as they are readily available at affordable prices and the gearbox is well suited to the TD V6 engine conversion.

     

    Transfer Box and Driveshafts Removed

    Discovery 1 to TDV6 Conversion Project

    The Driveline components removed in order to gain access to the gearbox and remove the V8 engine.

     

    The Old V8 Removed

    Discovery 1 to TDV6 Conversion Project

    The V8 engine removed leaving plenty of space underneath the bonnet for the new powerplant.

     

    V8 Auto Gearbox

    Discovery 1 to TDV6 Conversion Project

    The 4HP22 Gearbox removed from our Discovery, we decided to use the original V8 automatic gearbox and have a adapter manufactured as the auto gearbox were more content with the new TDV6 powerplant than the other gearbox options available.

    The TD V6 Powerplant Arrives

    Discovery 1 to TDV6 Conversion Project

    The TDV6 arrives, freshly removed from a Discovery 3. ready to transplant.

     

    What a Difference a Decade Makes!

    Discovery 1 to TDV6 Conversion Project

    The petrol V8 and TD V6 side by side showing how much smaller the TDV6 is compared to the V8.

     

    The Manufactured Gearbox Conversion Adapters Arrive.

    Discovery 1 to TDV6 Conversion Project

    The bell housing and torque convertor adapters arrive , both the torque convertor adapter and the bell housing adapter are designed and manufactured from aluminium by CNC machining.

    Discovery 1 to TDV6 Conversion Project

    The bell housing adapter fitted to the engine, using Aluminium helps to keep the rotating mass of the driveline components to a minimum. These adapters and more conversion components will be available to purchase to help make the conversion as seamless as possible.

     

    The ECU and Wiring Loom

    Discovery 1 to TDV6 Conversion Project

    The BodyLogic ECU and wiring loom as supplied the only other component we require from you is the engine wiring loom to modify in order to make the wiring system a plug and play affair.

     

    The New Engine Fitted Perfectly

    Discovery 1 to TDV6 Conversion Project

    After a few slight modifications to the engine bay as follows the engine fitted perfectly. We were even able to use the original chassis mounts with new engine mounts manufactured to fit the engine.

    Although we decided to move the steering box a couple of inches forward rather than repositioning the alternator, but all this was achieved in a couple of hours and was a simple retro fit using a slightly longer defender steering shaft. 

    Discovery 1 to TDV6 Conversion Project

    We used the original Discovery 3 thermostat housing but upgraded to a TD5 radiator and intercooler which easily plumbed into the engine. We also located a Discovery 3 fuel filter and purchased a fuel cooler.

    The final fitting of the engine and modification of the exhaust, water and fuel systems complete, it fits so well its like its meant to be.

     

    The Finished Project

     

    Discovery 1 to TDV6 Conversion Project

                      

    Discovery 1 to TDV6 Conversion Project

     

    The First Test Drive

     

     

    Conversion Articles-

    Land Rover Owner International Online Article

    Simtek UK Online Conversion Article

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  •  

    Country Boy's Toy - 1st Full Pull at Whitchurch 29th March

     

     

    Country Boy's Toy - 2nd Full Pull at Whitchurch 29th March

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  • Bad Medicine Common Rail Tractor Puller

     

                   Bad Medicine Tractor Puller

     

    Common Rail Tractor Puller

    Simtek Uk are proud to announce the lauch of the Uk's first common rail tractor puller, exclusively using the Simtek BodyLogic ECU and IDM.

    The use of the BodyLogic ECU enabled the precise control of injection stratergies and engine speeds limits, resulting in this being the only tractor able to run in two different classes during its first event.

    The tractors control maps can be easily re-configured in between runs in order to adapt the tractor to differing conditions, with live data logging coming soon this really will be one to watch.

     

    Technical Specifications-Common Rail Tractor Puller

     

    • 6.7 Litre New Holland Common Rail Inline-6 Engine
    • Single Fixed Vane Aircraft Turbo
    • Enlarged Injectors
    • Standard New Holland Bosch CP3 High Pressure Pump
    • Lowered Compression Ratio (14:1)
    • Electric Radiator Fan
    • Watercooled Intercooler

     

    Further development of the tractor is currently underway, with great things expected in the future, we wish the owner Jim and all his team all the best in the future.

     

    Bad Medicine Tractor Puller First Time in Action (27/08/12)

     

     

    Well done to all the Bad Medicine Team-

    Jim and Jo Greenhalgh

    Leon Attenborough

    Jonathan Yates

    Mark and Sarah Suddle

    Alistair and Lisa Parkinson

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  •  

    Marc Charton wrote:

    "Mercedes OM642 V6 Diesel running with Simtek Body Logic stand alone ECU. I have seen many people try to use the original Bosch ECU by reprogramming it, never to date have I seen one run properly without it going into limp mode. This is because the engine ECU in a Mercedes relies on around 30 other sensors and other ECU, i.e. drive authority, gearbox, ABS, ESP, EGR, catalytic converter, traction control, alternator etc. Although some things can be switched or by passed by reprogramming, too many things are just hard wired.
    Modern common rail diesel engines are complex and depend on precise control of injection timing with upto 5 injection pulses per revolution, injectors are commonly run at 160 Volts and 20 amps dependant upon load conditions and engine speed. Common Rail OEM diesel control units gather information from various ECU''s around the vehicle and are incapable of running the engine without this information or engine function is seriously compromised.
    The Simtek UK BodyLogic diesel control system provides a turn key solution for common rail diesel engines. The BodyLogic system is suitable for a wide range of engine specifications. The system comprises of a ECU and an injector driver module.
    Before installation the engine was tested on a dyno with the Simtek ECU. The power was increased from 225 to 240bhp, torque was increased from 510 to 590Nm. From this point we increased the boost anther 0.5bar and increased the fuel until the exhaust run black, but the engine did not see much further increase in power, may be another 10bhp but did not sound happy.
    This is because the turbo is so closely matched to the engine for emissions and fast pickup that the turbine of the turbo is too restrictive. I have since found a link to another OM642 engine that is using the later 350CDI turbo and produced around 310bhp. Although the turbo configuration is the same it not quite a straight forward swap as the 350CDI turbo is ball raced and water cooled, so some other modifications have to be made.
    As you see from my video the engine runs smooth and clean, the pickup is amazing. The engine in the video sounds noisy but in fact most of the noise is from the Bravo drive caused by gear chatter at idle, apparently this is quite normal. In fact I would go as far as saying it sound more like a petrol engine."

     

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  • QT Services Wildcat 3.0 TDV6

                   Qt Diesel Wildcat

     

    Common Rail Tractor Puller

    Simtek Uk are proud to supply wiring and diesel ECU solutions to QT Services for use in the Qt Wildcat .

    If you need to go everywhere or anywhere at high speed this definately is the vehicle for you! Especially with the new 3.0 twin turbo diesel delivering impressive power and torque figures with improved economy over extreme desert distances.

     

    Technical Specifications-Common Rail Tractor Puller

     

    • JLR 3.0 Litre TDV6 Twin Turbo Engine
    • 245BHP and 600Nm of torque
    • 6 Speed Sequential Gearbox
    • AC and Heating System
    • Desert Jack System
    • Lightweight Spaceframe Chassis
    • 320mm Brake Discs and Alloy Calipers
    • Custom Fully Adjustable Suspension

     

    QT services are at the forefront in off road racing, at Simtek UK we wish them all the best in the future, keep an eye on the podium places for QT Services Wildcats.

     

    QT Wildcat 3.0 TDV6 First Start Up

     

    If you would like more information on the Wildcat or Qt services please visit-

    www.QTwildcat.co.uk

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  •                    P38 to TDV6 Conversion Project

    A newly purchased 4.6 HSE petrol P38 ready to undergo the conversion to diesel power. The Range Rover P38 is an ideal conversion vehicle with a high level of trim and finish.

     

                         P38 Petrol Engine Awaiting Removal

    Although running well the P38''s engine was a little tired, the perfect reason to breathe a new lease of life into the car with a powerful TDV6 engine.

    Engine and Gearbox Removal

    The first task is to remove the Range Rover's old petrol engine to make room for the 2.7 TDV6. The new diesel engine was freshly purchased from a Landrover breakers with all the ancillaries (very important), the engine came from a low mileage Discovery 3 with a guarantee.

     

     Chassis Modifications

    P38 to TDV6 Conversion Project

     

    In order to enhance the silky smooth ride already offered by the Range Rover we decided to use Discovery 3 engine mounts and fitted them to the chassis.

    We also decided to use custom engine mounts to allow the engine to sit as low as possible and slighly further forward within the Range Rover''s chassis.

     

     

     

     Engine Modifications

    P38 to TDV6 Conversion Project

    Unfortunately with the engine sitting as low as possible to clear the bonnet line the TDV6''s steel sump and pickup pipe now required some modification in order to clear the front axle.

    The sump retains the same oil capacity but in a slighly different shape (you may not need the same modiciation if the engine is from a Jaguar model, but please confirm this before purchasing).

     

     

    Gearbox Fitting

      P38 to TDV6 Conversion Project

    With the engine now sitting slightly further forward the gearbox mounting bar required slight modification, this was quickly cut and re-welded to suit the new position and fitting of the engine and gearbox began.

     

     

     

    TDV6 Engine in place

    P38 to TDV6 Conversion ProjectThe engine and gearbox were now fitted in place with the aid of a gearbox adapter plate as used on our Discovery project. As can be seen pleanty of room in front of the engine compared to the old V8.

    The next task was the connection of all the ancillary systems, the aim of the conversion was to increase the P38''s useability without sacrificing the comfort levels offered as such we decided to retain the AC and cruise control systems.

     

    Ancillary Connections

    P38 to TDV6 Conversion ProjectWith the engine now in place the next task was to enable everything to work, the AC and power steering pipework we had professionally modified by a local specialist.

    The remainder of the pipework we manufactured to fit around the engine and we fitted a Discovery 3 water thermostsat within the cooling system to ensure the engine operated within the most efficent temperature range.

    We also used a Discovery 3 fuel filter and modified the P38''s fuel tank in order to accomodate diesel fuel rather than petrol.

    The wiring loom, ECU and injector driver module we then fitted within the original P38''s ECU holder making the installation as OEM as possible.

     

     Finishing Touches

    P38 to TDV6 Conversion Project

     

    The finished conversion with a modified TDV6 engine cover fitted, the engine started first time and has been in daily use without missing a beat since the conversion was completed.

     

    P38 to TDV6 Conversion Project

      

    Range Rover Test Drive

     

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  • Thanks to Andy - please read the article below

    Acknowledgements
     
    Article by Dave Smith Photography by Darren Maybury
    Publication ACM American Classics Magazine
    ACM TDV8 TBIRD (3624kb)

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