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Old 05-30-2020, 06:18 PM   #1 (permalink)
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Jetta - '01 Volkswagen Jetta TDI
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Hello, I'm a USA Diesel Owner

Finally got the Jetta to something postworthy: Main problems were stuck open thermostat and missing factory bellypan. Also, lots of bad rubber, a few electrical things. It had been used and then sat for a while. Has a Malone Stage 1.5 tune.

The open thermostat was hurting me by 4-5mpg. I finally cobbled enough parts to get the factory bellypan back together. Also removed mudflaps. This gave me inspiration to do a significant grill block. Still testing to see if it is adequate in the hot weather. The cooling happens through the emblem and the ~ 1.5" x 2' opening on the lower bumper (not visible in pics). I believe it will be adequate driving like I stole it in 95F weather. For higher temps I will remove the emblem.

Working hard on the driver mod and looking for some 50+mpg numbers. I broke 55 in a stock (small grill block) Beatle TDI which I am in the process of selling. it is in much better shape than the Jetta haha. These are tank-to-tank numbers.

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Last edited by ssullivan; 05-30-2020 at 06:24 PM..
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Old 05-30-2020, 08:09 PM   #2 (permalink)
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Black and Green - '98 Honda Civic DX Coupe
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Looks good. And with a TDI you will have a high upper maximum MPG as you work on the "driver mod," or the "nut behind the wheel." Is this a manual transmission?

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See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.



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Old 05-31-2020, 12:40 AM   #3 (permalink)
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Jetta - '01 Volkswagen Jetta TDI
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Yep. Auto trans is to be avoided in these years. I understand it injects zero fuel when coasting in gear. I got behind a Model S who was hypermiling on I-80W near Auburn and the engine/regenerative braking were pretty comparable on each short little downhill.
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Old 05-31-2020, 01:08 AM   #4 (permalink)
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Even though a grille block may eventually fool you into believing the thermostat could become somewhat redundant, it's still preferable to have it operating properly.
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Old 05-31-2020, 02:29 AM   #5 (permalink)
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Jetta - '01 Volkswagen Jetta TDI
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Oops I did it again

Haha, love diesel's low heat rejection efficiency. Looking forward to ABA testing with the intercooler and other lower grille blocks. Upper is "temporary." Also have a gap to fill on the driver side one.

Update: I went to measure for a muffler and before I knew it the sawzall was out and the 19lb behemoth was on the ground My hypothesis was: based on its excessive size, it was designed to cancel out low frequency more than make it quieter. It now spools even quicker and has the exact sound I was going for. Total volume still about the same inside so I guess I'm done for now! Planning to make a high velocity tip to get the vapors out safely since they are dumping around the rear axle.

This was inspired by some work where the author measured pressure drop across the MK4 TDI flow path on the air and exhaust sides. The muffler had the most restriction, and it appears the most weight. I'm really stoked about how this car is coming along. Next step I want to pay Malone to work on the low/mid maps to wring as much mpg as possible. It currently has injectors, injection pump, and the stage 1,5 tune. Because of all the fueling mods I believe there is room to improve.

Last edited by ssullivan; 05-31-2020 at 11:33 AM..
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Old 05-31-2020, 01:19 PM   #6 (permalink)
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Black and Green - '98 Honda Civic DX Coupe
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Oh, yeah! Weight reduction, baby!
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See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.



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Old 05-31-2020, 11:24 PM   #7 (permalink)
It's all about Diesel
 
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Quote:
Originally Posted by ssullivan View Post
I went to measure for a muffler and before I knew it the sawzall was out and the 19lb behemoth was on the ground My hypothesis was: based on its excessive size, it was designed to cancel out low frequency more than make it quieter. It now spools even quicker and has the exact sound I was going for.
It's usually pointed out that turbocharged engines don't really require further restrictions after the turbine outlet, so a shorter path for the exhaust might be quite desirable. Plus the turbocharger already provides some reasonable levels of noise suppression too.
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Old 06-07-2020, 01:57 AM   #8 (permalink)
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Jetta - '01 Volkswagen Jetta TDI
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Totally! Glad I didn't buy something before I started cutting. It would have been dead weight.

Another update: The grill block seemed ok testing at 92F. Couldn't get the coolant temp to move. Waiting for the first 100 degree day.
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Old 06-07-2020, 04:53 AM   #9 (permalink)
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GreenTDI - '11 Skoda Fabia Estate R3 1.2 CRTDI
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Diesel
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Nice to welcome another TDI owner on this website! TDI's have enormous potential in terms of consumption figures. With cheap adjustments like grille blocking, weight reduction, overinflating tires and a different driving style, you could easily gain 20%. I recently did a 78 MPG trip where I previously got around 60 MPG And meanwhile I know there is even more to it.
Good luck!
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Old 06-07-2020, 11:34 PM   #10 (permalink)
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Woody - '96 Dodge Ram 2500 SLT
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Welcome from a fellow TDI enthusiast and all diesel family.

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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
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