Project double my VeeDub's mpg

[dremd]

Originally Posted by NachtRitter

I did the hybrid 'stat plus a grill block and it keeps the temps around 210F. I had the same problem with the factory 'stat ... couldn't keep it above 188F. Hard to say how much (or if) the new hybrid 'stat helped with FE since I changed several things at once. Overall the FE has improved since I put it in (FWIW).

Do you have any engine build details (pics, etc)? The text description is interesting but it'd be interesting to see the comparison of old vs new parts if it were available.

I have a few pics that are uploading now (my solar powered remote DSL site took a lightening hit earlier this week, and I'm on cellular at night).
Unfortunately, I don't have old vs new diesel pics because I had to buy basically all of my parts. I could do gasoline vs diesel.

I know, I suck at pics.

[euromodder]

Originally Posted by dremd

Mkiv VW's have a bit of factory ram air.

Quite a few VWs have sort of "ram air".
Not too sure wether I'd want that though.

Friend of mine had a catastrophic engine failure when not air but water was rammed down his VWs throat ...

[dremd]

Originally Posted by euromodder

Quite a few VWs have sort of "ram air".
Not too sure wether I'd want that though.

Friend of mine had a catastrophic engine failure when not air but water was rammed down his VWs throat ...

I didn't realize that was a common VW "feature" neat.

I'd have to go through some pretty deep water for water ingestion, definitely higher than most passenger cars, but yeah, it can totally happen.

[oil pan 4]

Originally Posted by dremd

Mkiv VW's have a bit of factory ram air.

Bigger turbo would only move BSFC curve up, the motor spends most of its time at low- moderate load and 1400-1900 rpm's. Would be fun, but most of the time that I make a boost request, I only want it for 3-7 seconds and a VNT-17 would make me need to downshift (maybe 2x) for the power I normally want.

I do have significantly larger turbo inlet piping (improved spool, tad bit less smoke at WOT). My TIP is from PD150, air box snorkel/ ram air bits are from Euro Dual Clutch R-32.

As far as boost side plumbing, I'm running a stock turbo outlet hose->1.8t pancake pipe (reduces spool a tad with larger volume, but reduces charge temps epically at cruise and allows a tad more high rpm power)-> Ebay stock size, but much higher mass and nicer fined inter cooler-> water / methanol injection (mostly to keep intake clean of EGR geww, but also quiets motor a bit at high power, drastically improves HP when heat soaked, and a tad more high RPM power with not much down side other than using crappy washer fluid up at 1.5x my normal rate) -> 99.5 upper charge pipe which relocates map much nearer intake and after the water/ methanol injection so I can keep a bit more timing from the corectly sensed intake air temp-> PD150 intake manifold (I've never run one before, but everyone loves them and my stocker was sheared off in the wreck.

My buddy runs a 3" straight pipe on his ALH, I'm not 100% sure, but we think he lost a mile or 2 to the gallon with it. Sounds pretty epic, reasonably quiet at idle/ cruise, not terrible at WOT, but sounds like a big single 2jzgte doing 100-150 pulls (except it is actually 30-60 pulls).

This car is for super comfortable highway cruising, so I'm running stock sized exaust with diesel Cat-> glass pack resonator -> factory giant 1.8t muffler. I'm expecting factory noise level, but hoping for lower.

I run my diesel at lower speeds too, 1,200 to 1,600 RPM, its always making some boost above 45mph.
I have experemented with water methanol injection also, its pretty nice.
My W/M system is not installed but I plan to reinstall it this summer.

The thing with diesels on turbos is a lot of the factories seem to have put undersized turbos on them. The OEMs seem to favor smaller turbos because they are cheap, they spool quickly and they like them for the fact that they are small.
A good example of wrong sized turbos is what they used on GM diesels back in the 90s. When you check fuel economy numbers for the last year of the N/A diesel and the first year turbo there is almost no difference.
I picked up over 2mpg when I added a much larger than stock turbo, using 100% non factory parts for everything else.
The problem is the factory turbo on the old GM diesels were too restrictive on the exhaust side.
I went with a turbo that would be more efficient at my normal driving engine speed. It seems to have worked out pretty good.

If you look of your turbo specs and cross that with engine air consumption at certian given speeds you may find the two don't go together very well where you want them to.

I don't see how a free flowing exhaust would hurt a turbo diesel.

Also have you tested an EGR delete?
EGR delete seems to always help trucks get better milage, but cars don't always benifet. I think some cars have a problem getting up to staying at operating temperature with out EGR.

[dremd]

Tonight a very good VeeDub buddy came over and did the majority of the wiring!

front subframe is ready to go in tomorrow.
Intercooler is mostly tweaked, ebay quality isn't as good as the one on my last car.
Removed auto brake pedal, install 5 speed brake pedal tomorrow.
Installed water injection.
fail safe bypass for lift pump parts should be here tomorrow, I'll be able to finish up the fuel system then.
Realized I needed another power steering suction line, ordered that (should be here Tuesday).
Got the exhaust bracket coming, hopefully be here Saturday.


Worked a lot today, but doesn't feel like much got done.

[dremd]

Well, back to real work soon.
Here was today's list with notes on what I need/ haven't done.

Remaining VW
Install ecu. DONE
Air compressor mount.
wire DWA
Swap clusters
Hood switch to CCM
Lift pump wiring
Trailer wiring
Install lift pump DONE
Swap out pre-lube pump (need pump to arrive)
Install ADI solenoid (must locate spare hose first) DONE
Wire ADI just need power now
plug in remaining engine connectors. ERR, SO FRUSTRATING
Plumb vacuum hoses / valvesERR, SO FRUSTRATING
Install coolant orb bottom hose (need hose CLAMPS)
Install coolant (need last hose)
Check heater hose length
Install power steering suction line (need line)
Install power steering fluid (need suction hose installed)
Install AC compressor (waiting until dead last)
Instal front carrier/ lights/ bumper has to be after A/C
Install clutch line (need clip)
Bleed clutch (need line installed)
Bolt in rear of drivers side control arm (need nut)
Bolt in front of dog bone (need bolts)
Mount and balance tires
Install fender liners
Clutch line quick clip needed
Ebrake cable rear trailing arm clip needed
Install/ wire headlight relays for auto headlights need to run wires in to car.
Install relay/ wire for pre-lube pump
Install fuel door DONE
Install fuel cap DONE
Add fuel
E-brake cable FRUSTRATING
E brake clip temporarily solved, need oem clip
Abs sensors DONE
Torque rear suspension
Install last exhaust hanger DONE
Secure vac. Pump near rack DONE
Install battery / battery box (need to complete wiring)
Install air box (need to install battery)

[MetroMPG]

Originally Posted by dremd

SWEET!

I need to upload some better ones, but the ones I have so far are here (follow ups will be in same set). Jetta - a set on Flickr

OK - let me know when you've got one of the whole car.

[dremd]

Major bummer last night.
I forgot that the IMMO 3 system requires 2 SKC's 1) from the cluster (super easy with vac tacho) 2) from the IMMO chip in the ecu which isn't quite so easy.
My cluster guy is on it, it certainly can be obtained, just not sure of how long the delay will be.

Remaining is the IMMO issue, a single power steering hose, the serpentine belt, add fluids, and re-install the front lock carrier and bumper.

[dremd]

Figured I'd update with the following.

ALH Swap into '03 1.8T GLX Wagon - Immobilizer Issues - TDIClub Forums

Not very fun at the moment. For me, just crossed over in to the " I probably should have bought another diesel and swapped goodies in to it".

That said, this is cheaper, and I've gone through everything mechanically already.

[dremd]

IT'S ALIVE! Fired up first time yesterday, I just need a TDI throttle pedal (so I can make it idle) then I can wrap up a lot of odds and ends like securing wire looms, installing covers, and solid mounting the battery.