RePowerNow - fossil lean solutions
Step 1: Make sure the engine is well tuned

Elsbett recommends to have the engine in faultless condition before you install their system. At the time of conversion our car had done 430,000 kms (~267,000 miles). Checked and adjusted were the injection timing and valve clearances.

The injection pump, although suspected of some wear, only received a visual inspection. Dismantling the pump would have meant being without a car for too long. A few weeks later the injection pump started to leak. The pump will receive a complete overhaul shortly.

Note: Today's low-sulphur diesel can cause damage to the seals of injection pumps. More about the possible effects of SVO in the Experience section.

Step 2: New injector nozzles and glow plugs

Fitting and adjusting new injector nozzles is a job for a specialised diesel workshop. I chose to have the new glow plugs fitted at the same time.

An Elsbett technician confirmed that the car could still be driven on diesel-only after this partial conversion. This meant that I could carry out the remainder of the conversion at a later time.

Note: As suspected, the old injector nozzles and glow plugs were due for replacement. That and the low-sulphur diesel issue were additional reasons for buying the Elsbett kit.

Step 3: Determine location of under-bonnet components

The main components to take up space under the bonnet are the fuel heat exchanger, the SVO fuel filter and the electric filter heater. I found that these components could be fitted on a purpose-made bracket which in turn could be bolted onto the original fuel filter bracket.

This also meant that the heat exchanger and fuel filters would be close together, recommended to minimise heat loss.

Select: photo 1 | photo 2

The ring clamp is where the SVO fuel filter goes. The electric fuel heater fits around the filter.

Step 4: Connect fuel heat exchanger to cooling system

Contrary to instructions the cooling system wasn't drained before connecting the heat exchanger. Instead, when cutting the hoses to the cabin heater, the coolant spilling out was caught and properly disposed off. Afterwards the cooling system was topped up and bled.

Select: photo 1 | photo 2

The temperature switch can be seen fitted to the "in" (hot) side of the system.

Note: When running on diesel-only in warm weather conditions, Elsbett recommends to disengage the fuel heat exchanger. This could be done by installing a valve in the hot coolant hose.