02 Jetta Tdi Grille block w/ Ram Air?

[COcyclist]

Originally Posted by DIY_GUY

I like where/how you mounted the heater plug, very clean. I also like the extra pitch on the grille block. I do see one thing I need to ask about.The intercooler grille block? Does the aero advantage offset the the IA temp rise? What are you getting for a IA temp? and at what ambient temp? Sorry for all the questions

No problem, I am always happy to see another diesel modder on the forum. I would love to totally Basjoos a TDI to see what they can really do but I am too vain about my VeeDub.

The intercooler grill block is only for extreme cold conditions, i.e. a few sub zero mornings per year and only for the first 40 miles. I do it to speed engine warmup and get more heat into the cabin. Mostly it is left open and I am usually about 10º above ambient unless I am climbing a long pass. Intake temps spike with prolonged boost (up to 180º max in summer IIRC).

I use the black pipe insulation on the upper grill year round. The "winter grill block" is used mostly to keep rock chips off the paint in sloppy weather. They use a lot of grit on the roads in winter here. If it helps with aero, it is so minimal as to be almost impossible to measure a difference in mpg.

[DIY_GUY]

Thanks for the input! I hear you on the "slave to fashion" as my wife puts it. LOL ... I like the way my Jetta looks too. 40°F ambient I'm running 168°F WT which I'm going to look into seems low? and 55°F to 60°F IA temp. I think I'm finally going to get my 700mi to tank! well see tomorrow.

[COcyclist]

Thermostats get weak over time. I would swap yours if you don't hold 195 when warmed up. These diesels do better for mpg when up to full temperature. There is a guy on TDIClub experimenting with a 205 degree thermostat and he feels he has gained several mpg from that alone.

[oil pan 4]

I will tell you what I did.
When I was building up my new engine I took my old thermostat, bought a duralast from autozone and got a carquest thermo.
I put all 3 of them in a pot of water and boiled them together.
My old thermostat only opened a little more than half way, so it was junk.
The duralast opened first and closed last compared to the carquest.
So the carquest became my winter stat and the autozone is my summer thermostat.
Only problem with that is I never put the winter thermostat in.

All 3 were 195'F thermostats.

I would run a 205'F if I could find one.

What I really need to do is build a set of grill shutters. Open them manually automaticly with a 190'F degree shutterstat and have a manual backup.

[UFO]

Originally Posted by oil pan 4

What I really need to do is build a set of grill shutters. Open them manually automaticly with a 190'F degree shutterstat and have a manual backup.

That would be very useful. I would keep it shut until operating temperature, then open it just enough to maintain. The problem with a Beetle is there is not much grille to start with, so it needs most of the opening in any weather warmer than 40F or so.

[oil pan 4]

Have you looked at how the OEMs are making their grill shutters for all these new small cars?
Might give you a few ideas.

[NachtRitter]

Joining this thread late, but wanted to say: Good job!

[DIY_GUY]

Originally Posted by COcyclist

Thermostats get weak over time. I would swap yours if you don't hold 195 when warmed up. These diesels do better for mpg when up to full temperature. There is a guy on TDIClub experimenting with a 205 degree thermostat and he feels he has gained several mpg from that alone.

Yes I agree they do wear out. I've done a few lately on the 06 Cat C8s at work. I just wanted to verify that the sensor was not lying to the computer. I took an infrared gun and shot it yesterday when I got off the highway and yes it is accurately low I will have to look into the higher temp stat and I will modify one to fit if I need to so I get the 205° .Thanks for the input! When I do I'll post the results.

[DIY_GUY]

These readings are when the needle looked dead on the line.
Full-120
7/8-185
3/4-251
5/8-325
1/2-395
3/8-495
1/4-565
1/8-667
Fuel light-683
Just before E-708

It took 15.322Gal to top back off holding the vent button in and purging it like I wanted to drive cross country

[COcyclist]

Originally Posted by DIY_GUY

It took 15.322Gal to top back off holding the vent button in and purging it like I wanted to drive cross country

Search TDIClub for "ventectomy". You can pop that little button out in about 15 seconds and gain almost 2 gallons of fuel capacity (put a clean cloth in the neck first). More important to us is the more accurate fill-ups.