Mk3 golf Upper grill block for under £3($5)
 

I've finally turned my hand to some proper ecomodding!

The 1996 golf TD I have has a tendency to drop engine temp to just about 80 degrees when I'm on the motorway at 60mph. This wasnt great- I'd prefer it to be running 85ish, 90 under heavy load (hills etc).. so I decided to sort it!

managed to make a grillblock for the car today- certainly helps with keeping the temp more constant! Sits at 85 all day long, up to 90 for hills-:Dhappy!

Also easy to remove if the temp rises

Here's some pics to show how I did it for under £3.00:thumbup::

£0.79 worth of Pipe lagging and some scissors:

http://i1197.photobucket.com/albums/...psfc18467d.jpg
http://i1197.photobucket.com/albums/...psffab3ea7.jpg

The bare grill (badge was already missing!)
http://i1197.photobucket.com/albums/...ps322ede94.jpg

Detail of the slats- where I'm going to slot in the pipe lagging
http://i1197.photobucket.com/albums/...ps4c65541b.jpg

First piece cut and trial fitted
http://i1197.photobucket.com/albums/...psdf569199.jpg
http://i1197.photobucket.com/albums/...ps8af65989.jpg

2nd/3rd/4th/5th pieces fitted
http://i1197.photobucket.com/albums/...ps8a2d2651.jpg
http://i1197.photobucket.com/albums/...ps8f161ac4.jpg
http://i1197.photobucket.com/albums/...psc4e56b74.jpg
http://i1197.photobucket.com/albums/...ps66a31982.jpg
http://i1197.photobucket.com/albums/...ps897ff32d.jpg

£1.00 can of primer
http://i1197.photobucket.com/albums/...ps98125255.jpg

£1.00 can of Black Paint
http://i1197.photobucket.com/albums/...ps1427e94f.jpg

The finished article:rolleyes::eek:
http://i1197.photobucket.com/albums/...ps766a3ad4.jpg

Very clever! I wonder if it will impact fuel economy?

The imact on Fuel consumption will tell whether its clever or not;)

I just thought was an opportunity to use some spare stuff!


Initial experience (100 miles) suggests that the car is


1. Running more consistently at temps above 80 degrees (A warmer diesel engine is more efficient, within reason) with much less fluctuation.

2. The higher temp, combined with an increase in % of Veg oil in the fuel seems to have had a positive impact on drivability at higher speed.


so far, so good:turtle:

Improving your fuel economy would be the icing on the cake, but the cleverness comes from solving the overcooling issue with inexpensive materials at hand.

Be sure to let us know if it impacts economy as well.

change your thermostat. Standard one begins to open 87ºC and gets full opened at 102ºC, equilibrium temp on 1.9 Tdi is arund 90.9ºC. (Tested from 0ºC to 45ºC)
Autodata software (maintenance database) says something about 80ºC thermstat in some TDI but I thing it's not true and maybe a mistake, because original parts for engines from 1997 (I/ve seen) to nowadays use 87ºC ones.

Your car is wasting fuel because of your thermostat opens at lower temps and maybe never closes at all.

If you were able to measure the fuel saving with upper grill blocks you will appreciate the big improvement of your thermostat change.

Thanks for that..

My car is not a TDi though, its TD, the AAZ engine- I'm not sure what the thermostat is for that engine?

Termostato, refrigerante para VOLKSWAGEN Golf III 1.9 TD 75cv a bajo precio (spanish or french)

Yours is a 87ºC, and your thermostat needs replacement because is not closing.

VW dsahboard coolant temp indicatro says 90ºC if real temp from coolant temp sensor says 70 to 102ºC, so if yours says 80 fuel sensor is getting maybe 65ºC.
MAybe you need also a replacement for the coolant temps sensor Sensor temp. refrigerante para VOLKSWAGEN Golf III 1.9 TD 75cv a bajo precio

Ask your repair shop to change thermostat and coolant sensor and put VW G12 coolant (G12+ it is a good option). IT's organic, not water with chemical that reacts when you mix different cheap coolants.
I'm using a 12€ per 5L like this:
IADA · Productos
Technical data:
http://www.iada.es/pdf/producto/ft_glycogel_50.pdf
Safety data:
http://www.iada.es/pdf/producto/fds_...o_amarillo.pdf
It should be liquid from -37ºC to 145ºC.

Excellent- many thanks! I shall investigate the thermostat, and getting it replaced. Certainly does sound like its running cold.

A new thermostat appears to be under £10, so not a massive investment. Coolant is simple enough to get too.

:thumbup:

First tank is in with the grill block on. Car was running a 20/80% veg/Diesel mix

670.1 miles for 52.58L of fuel

Giving imp MPG of 57.94:)


thats a 0.37 mpg gain, and I'm happy, bearing in mind the traffic I've had to deal with this week:)

Thermostat now purchased- hopefully get it fitted this weekend, and see how the temp is then.

I'm hoping for a rock steady 90 degrees indicated, with the engine getting there quicker:)

How many weekends we waited for to know fuel economy improvement with new thermostat?
I got +5% mpg in the Seat Leon. And almost +9% in winter when temperatures went from 0º to 10ºC when using climate heat.

I've done 2.75 tanks since fitted (in the fuel log for the car..), I think..

no mpg improvement on first one

back to usual area on 2nd

and the Radiator burst 1/2 way through the current one.

my temper is rising, although my mpg may not be..