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Old 03-22-2013, 04:32 AM   #274 (permalink)
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Originally Posted by Piwoslaw View Post
Since this winter doesn't want to go away (Spring officially started yesterday, but it's still snowing, 25cm expected tonight, and it'll be below freezing for at least another week), I have lots of time to think about engine insulation, cold starts, etc.

I really liked how Brucepick insulated his valve cover with (what I think is) a rubber foam. After reading through his thread I had a long look at my engine and had to frown: The valve cover has plastic on it, plus everything (injectors, glow plugs, cables) is so close together that it would be hard to squeeze any insulation in between. So I looked at the engine block itself, but I can't see it - there are so many things hanging on it, too close to put insulation under them. The only place that has some free surface area is the oil pan, which looks like this:

Over the summer I'll try to insulate the sides to keep more heat from the heating pad in. Also it should keep the oil warmer after killing the engine. I've found rubber foam in all sorts of thicknesses, from 3mm to 25mm, I'll probably settle for ~7mm. I'd like to cover the bottom as well, but the heating pad's instructions warned against that, though I wonder if a thin layer (3-5mm) would do any harm.

Maybe I could insulate the cat converter's housing also, to keep it warm? It is in front of the engine, so it gets hit with cold air coming in through the grille (when open).

Another thought: Since I normally have the intercooler unblocked, the air that goes through it cools the engine bay down. I guess that some fresh, cool air is good in the summer, but what about deflecting that air away from the engine itself - right now it hits the alternator, A/C compressor, and the timing belt cover. This is the end of the engine that needs insulation, I can see this is where most of the heat escapes when preheating.
I've run away from Winter, now I'm in Budapest and going even more to the south on Saturday. But I've heard that there's lots of snow in our country... Anyway I think that oil pan insulation can be a good idea for a hypermiller like you. It's not wise to overheat the oil, but since you don't produce enough waste heat you don't have to worry about that. Or maybe you have an oil heat exchanger oil to coolant. So you'll be on a safe side anyway.

If you want to insulate cat converter you should think of something that can work in a very high temps. Something like this: JEGS Performance Products 32069 JEGS Ultra Hi-Temp Exhaust Wrap

Another thing is tuneling air from IC and radiator. As you may remember Berta has an oem tunnel for air going through IC ant it's very simple to fabricate with a piece of coro.

Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."
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Piwoslaw (03-27-2013)