I've decided to swap a 1.9 liter VW TDI engine into a Honda Insight.
This project is just getting started since I only have the donor vehicle right now (98 Beetle TDI).
To my knowledge, the TDI swap has only been attempted once before and it was with a 1.2 liter Lupo engine that can't easily be found where I live (America). I'll be using the venerable "ALH" engine which is found in the US Spec Golf, Jetta, and New Beetle from the 98-03 time frame.
I'm currently looking for a 1st gen Insight with a bad battery/IMA/engine that can be used for this swap.
I've started a blog to update as the project moves along. Keep in mind this won't be a quick swap. I'm pretty busy but also pretty anal so progress will be slow. I'll post here with updates as they occur!
Have you read about some of the challenges stuffing a smaller, lighter TDI engine in an Insight? Even their 1.2 l. TDI engine weighs 100 pounds more than the Insight engine, so your 1.9 l. TDI engine will weigh considerably more. Your VW transaxle will weigh considerably more than the very light Insight transaxle. When you remove the IMA electronics and battery pack from the rear of the car, you would have a very front-heavy car that would likely handle very poorly.
The 1.2 l. TDI engine was such a tight fit that there was no room for an A/C compressor. Fitting the turbo of your engine in the Insight engine compartment will likely be very difficult.
It seems to me that you're trying to stuff too much engine in too small an engine compartment. A Honda 4-cylinder non-turbocharged gasoline engine can be made to fit, so maybe you'll find a way.
Good luck and keep us informed of your progress!
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Aloha,
Art Isbell
2000 Insight A/C #559
Genesis One MIMA+FAS and grid charger, OBDIIC&C, Rostra, Fumoto, DEFA engine block heater, Philips LED DRL's, Honda security system
Maybe post your location,..............in case you need moral support.
Willie
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01 MT "Little Red Rocket"
The first "TURBOCHARGED" Hybrid, Insight G1- (01/2003)
MaxIMA Battery (Serial #2), on 8/25/12 @ 301,520 miles
Use: 321,000 mi. @ 57.8 LMPG
Have you read about some of the challenges stuffing a smaller, lighter TDI engine in an Insight? Even their 1.2 l. TDI engine weighs 100 pounds more than the Insight engine, so your 1.9 l. TDI engine will weigh considerably more. Your VW transaxle will weigh considerably more than the very light Insight transaxle. When you remove the IMA electronics and battery pack from the rear of the car, you would have a very front-heavy car that would likely handle very poorly.
The 1.2 l. TDI engine was such a tight fit that there was no room for an A/C compressor. Fitting the turbo of your engine in the Insight engine compartment will likely be very difficult.
It seems to me that you're trying to stuff too much engine in too small an engine compartment. A Honda 4-cylinder non-turbocharged gasoline engine can be made to fit, so maybe you'll find a way.
Good luck and keep us informed of your progress!
Thanks, I'm aware of the change in weight distribution. I have a few ideas to help mitigate this issue. Most Porsche cars are the opposite of what you're correctly suggesting will happen (30/70). The Insight will likely be 70/30 with the VW power train in it so it'll take a creative suspension setup to maintain balance.
Quote:
Originally Posted by Willie Williford
Maybe post your location,..............in case you need moral support.
Willie
I'm in Tucson, Arizona
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2001 Honda Insight 5-speed Monte Carlo Blue
Turbo Diesel engine swap underway! www.hondatdi.com
Did they ever get the IMA working on the Lupo Insight conversion?
If it's the one I'm thinking of, they did. I exchanged a few emails with the guy. Since the diesel had a lot more available torque, he was trying to find a way to get more control over the IMA functions. I suggested he look into MIMA. I haven't heard from him for a year or so.
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Silver '00 MT
90.2 LMPG
80+ psi in RE92's for the past 2 years without incident
Calpod switch
Warm air mod
Grill block
EPS fuse removed
FAS/fuel injector interrupt circuit
grid charger
OBDII C&C gauge
Very interesting project with the bigger more available engine. Best success with it!
fwiw: 70/30 was a ratio sought after by fwd competition cars in ice racing. [and reverse as well for the winningest RX7's]
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__________________
01 MT "Little Red Rocket"
The first "TURBOCHARGED" Hybrid, Insight G1- (01/2003)
MaxIMA Battery (Serial #2), on 8/25/12 @ 301,520 miles
Use: 321,000 mi. @ 57.8 LMPG
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Swapping a TDI engine into a 1st gen Insight
