Running a D5 engine - without the car...

aland · Sep 26th, 2017, 09:52

I have a spare 163 D5 engine in the garage. I also have it's ECU and most other parts.
I wonder if it would be possible to get the engine running without the car (and all the other systems etc) around it - for a large DIY generator project ?

I suspect the issue would be making the ECU happy without all the other car modules to talk to.
Alternatively, I see there are some aftermarket diesel ECUs about, but they appear to be customized and expensive from what I can see.
Any suggestions? (Other than forget it and just buy a diesel generator!)

cheshired5 · Sep 26th, 2017, 10:00

Getting it running would be easy enough but it wouldn't be running optimally so swings and roundabouts.

aland · Sep 26th, 2017, 10:09

For the proposed use it would be running at a constant 1500rpm (assuming direct-drive to the alternator) - so hardly enough to spin up the turbo. Might be better off without the turbo if I use this engine... or scrap the idea!

cheshired5 · Sep 26th, 2017, 10:23

It's a VNT turbo so would work from low revs but you don't say how many inputs you're keeping.
MAF, MAP, EGR etc..... Also, will you be keeping the original air intake, intercooler, cooling system, alternator.....?

Tannaton · Sep 26th, 2017, 22:46

Given the D5 is fairly compact and light for a diesel, I did have idle thoughts a few years ago about putting one in a Spitfire. Then reality bit me...

You would need to overcome...

Starter/immobiliser systems (could use existing switch, keys, fobs and security unit I guess?)
Lack of integration with the TCM (if doner was auto) and speed sensors
Instrumentation?
Would it all work without say the ABS/DSTC system ECU (from which the ECM takes inputs)?

To get your constant 1500 rpm you could try and use the cruise control but this would really take some trickery....

Volvo did produce a marinised version of the D5 with simpler ECU and modified software for a flatter torque curve, but god knows where you'd get one from....

Dancake · Sep 26th, 2017, 23:27

I can't see why it wouldn't be possible. All you need is a fuel injection management system and a starter system. Whether the existing ECM could be taylored to suit is the question.

Sep 26th, 2017, 09:52	#1
aland Senior Member Last Online: Jan 17th, 2024 15:41 Join Date: Dec 2004 Location: Luton	Running a D5 engine - without the car... I have a spare 163 D5 engine in the garage. I also have it's ECU and most other parts. I wonder if it would be possible to get the engine running without the car (and all the other systems etc) around it - for a large DIY generator project ? I suspect the issue would be making the ECU happy without all the other car modules to talk to. Alternatively, I see there are some aftermarket diesel ECUs about, but they appear to be customized and expensive from what I can see. Any suggestions? (Other than forget it and just buy a diesel generator!)

Sep 26th, 2017, 10:00	#2
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	Getting it running would be easy enough but it wouldn't be running optimally so swings and roundabouts. __________________ 2002 S60 SE D5 Manual 209000 miles

Sep 26th, 2017, 10:23	#4
cheshired5 Premier Member Last Online: Dec 26th, 2021 13:42 Join Date: Dec 2013 Location: Crewe	It's a VNT turbo so would work from low revs but you don't say how many inputs you're keeping. MAF, MAP, EGR etc..... Also, will you be keeping the original air intake, intercooler, cooling system, alternator.....? __________________ 2002 S60 SE D5 Manual 209000 miles

Sep 26th, 2017, 22:46	#5
Tannaton Bungling Amateur Last Online: Today 16:24 Join Date: Aug 2014 Location: Beverley, East Yorks	Given the D5 is fairly compact and light for a diesel, I did have idle thoughts a few years ago about putting one in a Spitfire. Then reality bit me... You would need to overcome... Starter/immobiliser systems (could use existing switch, keys, fobs and security unit I guess?) Lack of integration with the TCM (if doner was auto) and speed sensors Instrumentation? Would it all work without say the ABS/DSTC system ECU (from which the ECM takes inputs)? To get your constant 1500 rpm you could try and use the cruise control but this would really take some trickery.... Volvo did produce a marinised version of the D5 with simpler ECU and modified software for a flatter torque curve, but god knows where you'd get one from.... __________________ 2011 XC90 D5 Executive 2003 C70 T5 GT 2012 Ford Ranger XL SC 1977 Triumph Spitfire 1500 1976 Massey Ferguson 135 Last edited by Tannaton; Sep 26th, 2017 at 22:51.

Sep 26th, 2017, 23:27	#6
Dancake Premier Member Last Online: Today 20:44 Join Date: Apr 2011 Location: Belfast	I can't see why it wouldn't be possible. All you need is a fuel injection management system and a starter system. Whether the existing ECM could be taylored to suit is the question. __________________ 1996 850 T5 - Sold 2003 S40 1.9d - Sold 2004 S60 D5

Sep 26th, 2017, 10:09	#3
aland Senior Member Last Online: Jan 17th, 2024 15:41 Join Date: Dec 2004 Location: Luton	For the proposed use it would be running at a constant 1500rpm (assuming direct-drive to the alternator) - so hardly enough to spin up the turbo. Might be better off without the turbo if I use this engine... or scrap the idea!

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